You are on page 1of 900

DX420LC

Shop Manual
K1009096E
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.

K1009096E Shop Manual


1Table of Contents
Safety
Track Excavator Safety......................................................................... SP000256

Specifications
Specification for DX420LC.................................................................... SP000257

General Maintenance
General Maintenance Procedures ........................................................ SP000016
Standard Torques ................................................................................. SP000017

Upper Structure
Cabin .................................................................................................... SP000018
Counterweight....................................................................................... SP000265
Fuel Tank.............................................................................................. SP000264
Swing Bearing....................................................................................... SP000262
Swing Reduction Gear.......................................................................... SP000249

Lower Structure and Chassis


Track Assembly .................................................................................... SP000263
Air Conditioner ...................................................................................... SP000025

Engine and Drive Train


Drive Coupling (Main Pump)................................................................. SP000026

Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ............... SP000273
Accumulator.......................................................................................... SP000028
Center Joint (Swivel)............................................................................. SP000181
Cylinders............................................................................................... SP000030

Table of Contents
Page I
Swing Motor.......................................................................................... SP000261
Travel Motor (With Gearbox) ................................................................ SP000266
Main Pump............................................................................................ SP000186
Control Valve (KVMG-400-DA)............................................................. SP000187
Remote Control Valve (Work Lever / Joystick) ..................................... SP000189
Travel Control Valve (With Damper)..................................................... SP000070
Solenoid Valve Assembly ..................................................................... SP000191
Breaker EPPR Valve (Opt) ................................................................... SP000192
Fan Motor (Vane Type)......................................................................... SP000209
Gear Pump (Fan Cooling Drive) ........................................................... SP000208
Fan Cooling Flow In-Out Change Valve ............................................... SP000207
Hydraulic Schematic (DX420LC) .......................................................... SP000274

Electrical System
Electrical System .................................................................................. SP000269
Electrical Schematic (DX420LC) .......................................................... SP000275

Attachments
Boom and Arm...................................................................................... SP000040
Bucket................................................................................................... SP000041

Table of Contents
Page II
1Safety
SP000256
TRACK EXCAVATOR SAFETYSP000256

Track
Excavator
Safety
Edition 1

Track Excavator Safety SP000256


Page 1
MEMO

SP000256 Track Excavator Safety


Page 2
Table of Contents

Track Excavator Safety


Safety Precautions ............................................... 5
Applicable Models ................................................ 5
To the Operator of a DOOSAN Daewoo Excavator
.............................................................................. 6
General Safety Essentials .................................. 10
Location of Safety Labels ................................... 11
Summary of Safety Precautions for Lifting in
Digging Mode ..................................................... 12
Unauthorized Modifications ................................ 13
General Hazard Information ............................... 13
Before Starting Engine ....................................... 22
Machine Operation ............................................. 26
Maintenance ....................................................... 33
Battery ................................................................ 42
Towing ................................................................ 44
Shipping and Transportation .............................. 45
Lifting With Sling ................................................. 45

Track Excavator Safety SP000256


Page 3
MEMO

SP000256 Track Excavator Safety


Page 4
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.

MODEL SERIAL NUMBER RANGE


DX420LC 5001 and Up

SP000256 Track Excavator Safety


Page 5
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.

Please respect the importance of taking responsibility for your


own safety, and that of other people who may be affected by
your actions.
The safety information on the following pages is organized into
the following sections:
1. General Safety Essentials on page 1-10
2. Location of Safety Labels on page 1-11
3. Summary of Safety Precautions for Lifting in Digging
Mode on page 1-12
4. Unauthorized Modifications on page 1-13
5. General Hazard Information on page 1-13
6. Before Starting Engine on page 1-22
7. Machine Operation on page 1-26
8. Maintenance on page 1-33
9. Battery on page 1-42
10. Towing on page 1-44
11. Shipping and Transportation on page 1-45
12. Lifting With Sling on page 1-45

Track Excavator Safety SP000256


Page 6
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.

SP000256 Track Excavator Safety


Page 7
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.

Learn the Signal Words Used with the


Safety Alert Symbol
The words "CAUTION," "WARNING," and "DANGER" used
throughout this manual and on decals on the machine indicate
degree of risk of hazards or unsafe practices. All three degrees
of risk indicate that safety is involved. Observe precautions
indicated whenever you see the Safety Alert "Triangle," no
matter which signal word appears next to the "Exclamation
Point" symbol.

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.

Track Excavator Safety SP000256


Page 8
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.

SP000256 Track Excavator Safety


Page 9
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.

Lifting Capacity Rating Configuration


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

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.

Track Excavator Safety SP000256


Page 10
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.

11 9 11 14 10
3 1 2 6

15

12
2190-3311

13 8 7

16
0

4
FG001823
Figure 1

SP000256 Track Excavator Safety


Page 11
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.

To lift safely while in Digging Mode, the following items must be


evaluated by the operator and the work site crew.
Condition of ground support.
Excavator configuration and attachments.
Weight, lifting height and lifting radius.
Safe rigging of the load.
Proper handling of the suspended load.
Tag lines on opposite sides of the load can be very helpful in
keeping a suspended load secure, if they are anchored safely to
control points on the ground.

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.

Always engage the "Digging Mode" control on the Instrument


Panel before using the excavator for lifting work.

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.

Track Excavator Safety SP000256


Page 12
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.

SP000256 Track Excavator Safety


Page 13
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.

Clothing and Personal Protective Items


Contain long hair, and avoid loose clothing and jewelry. They
can catch on controls or in protruding parts and cause serious
injury or death.
Do not wear oily clothes. They are highly flammable.
Full eye protection, a hard hat, safety shoes and gloves may be
required at the work site.
While working on the machine, never use inadequate tools.
They could break or slip, causing injury, or they may not HAOA020L
adequately perform intended functions. Figure 2

Track Excavator Safety SP000256


Page 14
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
given in the operation mamual.
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 given in the operation
mamual.
Measurement is obtained on a dynamic machine with
the procedures as described in 2000/14/EC.

Vibration Level Information


Hands/Arms: The weighted root mean square acceleration to
which the hands/arms are subjected, is less than 2.5 m/s2.
Whole body: The weighted root mean square acceleration to
which the whole body is subjected, is less than 0.5 m/s2.
Measurements are obtained on a representative machine, using
measuring procedures as described in the following standard:
ISO 2631/1. ISO 5349, and SAE J1166.

Recommendations for Limiting Vibrations


1. Select the right machine, equipment and attachments for a
particular application.
2. Replace any damaged seat by a genuine DOOSAN part.
Keep the seat maintained and adjusted.
Adjust the seat and suspension for the weight and
size of the operator.
Inspect and maintain the suspension and adjustment
mechanisms of the seat regularly.
3. Check that the machine is properly maintained.
Tire pressure, brakes, steering, linkages, etc.
4. Steer, brake, accelerate, shift gears, move the attachments
and load the attachments smoothly.
5. Adjust the machine speed and travel path to reduce the
vibration level.

SP000256 Track Excavator Safety


Page 15
Slow down if it is necessary when passing rough
terrain.
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.

Mounting and Dismounting


Before getting on or off the machine, if there is any oil, grease, or
mud on the handrails, steps, or track shoes, wipe it off
immediately. Always keep these parts clean. Repair any damage
and tighten any loose bolts.
Never jump on or off the machine. In particular, never get on or
off a moving machine. These actions may lead to serious injury.
When getting on or off the machine, always face the machine,
and maintain three-point contact (both feet and one hand or one
foot and both hands) with the handrails, steps, and track shoes
to ensure that you support yourself securely.
Never hold any control levers when getting on or off the
machine.
Apply the door lock securely. If you grip the handrail inside the
door when moving on top of the track shoes, and the door lock is
not applied securely, the door may move and cause you to fall.
Use the points marked by arrows in the diagram when getting on
or off the machine.

FG000355
Figure 3

Track Excavator Safety SP000256


Page 16
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 4
provide a ground.
Keep fuel and other fluid reservoir caps tight and do not start the
engine until caps have been secured.

Precautions When Handling Fluids at High


Temperature
Immediately after operations are stopped, the coolant, engine
oil, and hydraulic oil are at high temperature and the radiator
and hydraulic tank are still under pressure. Attempting to remove
the cap, drain the oil or coolant, or replace the filters may lead to
serious burns. Always wait for the temperature to go down, and
follow the specified procedures when carrying out these
operations.
HAOA050L
Figure 5

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 6

SP000256 Track Excavator Safety


Page 17
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 7
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.

Injury from Work Equipment


Do not enter or put your hand, arm or any other part of your body
between movable parts, such as between the work equipment
and cylinders, or between the machine and work equipment.
If the control levers are operated, the clearance between the
machine and the work equipment will change and this may lead
to serious damage or personal injury.
If going between movable parts is necessary, always position
and secure the work equipment so that it cannot move. HDO1010L
Figure 8

Fire Extinguisher and First Aid Kit


As a precaution if any injury or fire should occur, always do the
following.
Be sure that fire extinguishers have been provided
and read the labels to ensure that you know now to
use them. It is recommended that an appropriately
sized (2.27 kg [5 lb] or larger) multipurpose "A/B/C"
fire extinguisher be mounted in the cabin. Check and
service the fire extinguisher at regular intervals and
make sure that all work site crew members are HDO1009L
adequately trained in its use. Figure 9
Provide a first aid kit in the storage compartment and
keep another at the work site. Check the kit
periodically and make any additions if necessary.
Know what to do in case of injury from fire.
Keep emergency numbers for doctor, ambulance
service, hospital and fire department near your
telephone.

Track Excavator Safety SP000256


Page 18
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.

Protection from Falling or Flying Objects


On work sites where there is danger that falling objects or flying
objects may hit the operator's cabin select a guard to match the
operating conditions to protect the operator.
Working in mines, tunnels, deep pits or on loose or wet surfaces
could produce danger of falling rock or hazardous flying objects.
Additional protection for the operator's cabin could be required in
the form of a FOPS (Falling Object Protective Structure) or
window guards.
HAOA110L
Figure 10

Never attempt to alter or modify any type of protective structure


reinforcement system, by drilling holes, welding, remounting or
relocating fasteners. Any serious impact or damage to the
system requires a complete integrity reevaluation.
Reinstallation, recertification and/or replacement of the system
may be necessary.
Contact your DOOSAN distributor for available safety guards
and/or recommendations if there is any danger of getting hit by
objects that could strike the operator's cabin. Make sure that all
other work site crew members are kept well away from the
excavator and safe from possible hazards. HAOA100L
Figure 11
For breaker operation, install a front guard and apply a
laminated coating sheet to the front glass. Contact your
DOOSAN distributor for recommendations.
When carrying out demolition or cutting operation, install a front
guard and top guard, and apply a laminated coating sheet to the
front glass.
When working in mines or quarries where there is danger of
falling rock, install FOPS (Falling Objects Protective Structure)
and apply a laminated coating sheet to the front glass.
If any glass on the machine is broken, replace it with new glass
immediately.

SP000256 Track Excavator Safety


Page 19
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 12

Track Excavator Safety SP000256


Page 20
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 13

SP000256 Track Excavator Safety


Page 21
BEFORE STARTING ENGINE

Work Site Precautions


Before starting operations, thoroughly check the area for any
unusual conditions that could be dangerous.
Check the terrain and condition of the ground at the work site,
and determine the best and safest method of operation.
Make the ground surface as hard and horizontal as possible
before carrying out operations. If there is a lot of dust and sand
on the work site, spray water before starting operations.
If you need to operate on a street, protect pedestrians and cars
by designating a person for work site traffic duty or by erecting
fences and posting "No Entry" signs around the work site.
Erect fences, post "No Entry" signs, and take other steps to
prevent people from coming close to or entering the work site. If
people come close to a moving machine, they may be hit or
caught by the machine, and this may lead to serious personal
injury or death.
Water lines, gas lines, phone lines and high voltage electrical DANGER
No Entry
lines may be buried under the work site. Contact each utility and FG000400
identify their locations. Be careful not to damage or cut any of
these lines. Figure 14

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 15

Minimum levels of insurance coverage, work permits or


certification, physical barriers around the work site or restricted
hours of operation may be mandated by governing authorities.
There may also be regulations, guidelines, standards or
restrictions on equipment that may have to be followed for local
requirements. There may also be regulations related to
performing certain kinds of work. If there is any question about
whether your machine and work site complies with the
applicable standards and regulations contact your local
authorities and agencies.
Avoid entering soft ground. It will be difficult for the machine to FG000372
escape. Figure 16
Avoid operating your machine to close to the edge of cliffs,
overhangs, and deep ditches. The ground may be weak in such

Track Excavator Safety SP000256


Page 22
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.

Checks Before Starting Engine


Every day before starting the engine for the first time, carry out
the following checks. If these checks are not carried out
properly, there is danger of serious injury.
Completely remove all wood chips, leaves, grass, paper and
other flammable materials accumulated in the engine
compartment and around the battery. They could cause a fire.
Remove any dirt from the window glass, mirrors, handrails, and
steps.
Do not leave tools or spare parts laying around in the operator's
compartment. The vibration of the machine when traveling or
during operations may cause them to fall and damage or break
the control levers or switches. They may also get caught in the
gap of the control levers and cause the work equipment to
malfunction or move dangerously. This may lead to unexpected
accidents.
Check the coolant level, fuel level, and hydraulic tank oil level,
and check for clogged air cleaner and damage to the electrical
wiring.
Adjust the operator's seat to a position where it is easy to
operate the machine, and check the seat belt and mounts for
damage and wear.
Check the operation of the gauges and the angle of the mirrors,
and check that the safety lever is in "LOCKED" position.
If any abnormalities are found in the above checks, carry out
repairs immediately.

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.

SP000256 Track Excavator Safety


Page 23
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.

Before Operating Machine


If checks are not carried out properly after starting the engine, it
may result in a delay in discovering abnormalities in the
machine, and this may lead to personal injury or damage to the
machine.
Carry out the checks in an open area where there are no
obstructions. Do not let anyone near the machine when carrying
out the checks.
Check the operating condition of the equipment, and
the actuation of the bucket, arm, boom, travel, and
swing systems.
Check the machine for any abnormal noise, vibration,
heat, smell, or abnormality with the gauges. Check
also for leakage of air, oil, and fuel.
If any abnormality is found, repair the problem
immediately. If the machine is used without repairing
the problems, it may lead to unexpected injury or
failure.
Clear all personnel from directly around machine and
from the area.
Clear all obstacles from the machine's path. Beware
of hazards.
Be sure that all windows are clean. Secure the doors
and the windows in the open position or in the shut
position.
Adjust the rear view mirrors for best visibility close to
the machine. Make sure that the horn, the travel
alarm (if equipped), and all other warning devices are
working properly.
Fasten the seat belt securely.

Track Excavator Safety SP000256


Page 24
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.

SP000256 Track Excavator Safety


Page 25
MACHINE OPERATION

When Swinging or Changing Direction of


Travel
Before operating the machine or the work equipment, always
observe the following precautions to prevent serious injury or
death.
Start and operate the machine only while seated.
When changing the direction of travel from forward to
reverse or from reverse to forward, reduce speed
early and stop the machine before changing the HAOA190L
direction of travel. Figure 17
Sound the horn to warn people in the area.
Check that there is no one in the area around the
machine. There are blind spots behind the machine,
so if necessary, swing the upper structure to check
that there is no one behind the machine before
traveling in reverse.
When operating in areas that may be hazardous or
have poor visibility, designate a person to direct work
site traffic.
Ensure that no unauthorized person can come within
the turning radius or direction of travel.
Be sure to observe the above precautions even if a travel alarm
or mirrors are installed.

Track Excavator Safety SP000256


Page 26
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.
40 ~ 50 cm (16 ~ 20 in.)
Fold in work equipment so that the outer end of the boom is as
close to the machine as possible, and is 40 - 50 cm (16 - 20 in)
above ground. INCORRECT
Never travel over obstacles or slopes that will cause the
machine 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 FG000349
sudden changes in direction. Figure 18
Always keep to the permissible water depth. Permissible water
depth is to the center line of the upper track rollers.
When traveling over bridges or structures on private land, check
first that the bridge or structure can withstand the weight of the
machine. When traveling on public roads, check with the local
authorities and follow their instructions.

SP000256 Track Excavator Safety


Page 27
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 19

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 20

Track Excavator Safety SP000256


Page 28
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 21

When using the machine, to prevent accidents caused by


damage to the work equipment and overturning because of an
excessive load, do not use the machine in excess of its ability (in
terms of the maximum load and stability determined by the
structure of the machine).
When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death. Investigate the configuration and ground
conditions of the work site beforehand to prevent the machine
from falling and to prevent the ground, stockpiles, or banks from
collapsing. FG000367
Figure 22

Precautions for Operation


Be careful not to go close to the edge of a cliff by mistake.
Use the machine only for its main purpose. Using it for other
purposes will cause failures.
To ensure an ample view, do as follows:
When working in dark areas, attach working lights
and front lights to the machine. If necessary, set up
lighting at the work site.
FG000430
Stop operations when the visibility is poor, such as in
Figure 23
fog, mist, snow, and rain. Wait for the visibility to
improve to a level which causes no problems for the
operation.
To avoid hitting the work equipment, always do the following:
When working in tunnels, on bridges, under electric
wires, or when parking the machine or carrying out
other operations in places with limited height, be
extremely careful not to hit the bucket or other parts.
To prevent collisions, operate the machine at a safe
speed when working in confined spaces, indoors, or
in crowded areas.
Do not pass the bucket over the heads of workers or
over the operator's compartment of dump truck.

SP000256 Track Excavator Safety


Page 29
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.

Voltage Minimum Safe Distance


6.6 kV 3 m (9' 10")
FG000171
33.0 kV 4 m (13' 1")
Figure 24
66.0 kV 5 m (16' 5")
154.0 kV 8 m (26' 3")
275.0 kV 10 m (32' 10")

Use these minimum distances as a guideline only. Depending


upon the voltage in the line and atmospheric conditions, strong
current shocks can occur with the boom or bucket as far away
as 4 - 6 m (13 - 20 ft.) from the power line. Very high voltage and
rainy weather could further decrease that safety margin.
NOTE: Before starting any type of operation near power lines
(either above ground or buried cable type), you
should always contact the power utility directly and
work out a safety plan with them.

Protecting Cabin from Falling Object


(Optional)
In a work site where falling objects or flying objects are
expected, be sure to install adequate protective devices for 1
covering the cabin.
When using a breaker, be sure to install the front window
protection guard (Figure 25).

FG000112
Figure 25

Track Excavator Safety SP000256


Page 30
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 26).
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

Operate Carefully on Snow, Ice and in Very


Cold Temperatures
In icy cold weather avoid sudden travel movements and stay
away from even slight slopes. The machine could skid off to one
side very easily.
Snow accumulation could hide or obscure potential hazards.
Use care while operating or while using the machine to clear FG000113
snow. Figure 26
Warming up the engine for a short period may be necessary, to
avoid operating with sluggish or reduced working capacity. The
jolting shocks and impact loads caused by bumping or bottoming
the boom or attachment are more likely to cause severe stress in
very cold temperatures. Reducing work cycle rate and work load
may be necessary.
When the temperature rises, frozen road surfaces become soft,
so the machine travel becomes unstable.
In cold weather, do not touch metal surfaces with your bare
hands. If you touch a metal surface in extremely cold weather,
your skin may freeze to the metal surface.

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 27
In addition, lower the bucket as far as possible, keep it pulled
into the front, and keep the swing speed as low as possible.

SP000256 Track Excavator Safety


Page 31
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
the "OFF" position, the safety lock lever must be set to the Figure 28
"LOCKED" position. This will disable all pilot circuit control
functions.
Always close the door of the operator's compartment.

Never Let Anyone Ride on Attachment


Never let anyone ride on any work attachment, such as the
bucket, crusher, grapple, or clamshell (grab bucket). There is a
danger of the person falling and suffering serious injury.

ARO1310L
Figure 29

Track Excavator Safety SP000256


Page 32
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
lowered, nonactive position. when performing inspection
or maintenance
Warning tags, for controls are available from DOOSAN
distributors.
190-00695

ARO1320L
Figure 30

Clean Before Inspection or Maintenance


Clean the machine before carrying out inspection and
maintenance. This prevents dirt from getting into the machine
and also ensures safety during maintenance.
If inspection and maintenance are carried out when the machine
is dirty, it will become more difficult to locate the problems, and
also there is danger that you may get dirt or mud in your eyes or
that you may slip and injure yourself.
When washing the machine, do the following:
Wear shoes with nonslip soles to prevent yourself
from slipping and falling on wet places.
Wear safety glasses and protective clothing when
washing the machine with high-pressure steam.
Take action to prevent touching high-pressure water
and cutting your skin or having mud fly into your
eyes. ARO1330L
Figure 31
Do not spray water directly on electrical components
(sensors, connector) (1, Figure 31). If water gets into
the electrical system, there is danger that it will cause
defective operation and malfunction.
Pick up any tools or hammers that are laying in the work place,
wipe up any grease or oil or any other slippery substances, and
clean the area to make it possible to carry out the operation in
safety. If the work place is left untidy, you may trip or slip and
suffer injury.

SP000256 Track Excavator Safety


Page 33
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 32

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 33

Fire Prevention and Explosion Prevention


All fuels, most lubricants and some coolant mixtures are
flammable. Leaking fuel or fuel that is spilled onto hot surfaces
or onto electrical components can cause a fire.
Store all fuels and all lubricants in properly marked containers
and away from all unauthorized persons.
Store oily rags and other flammable material in a protective
container.
Do not smoke while you refuel the machine or while you are in a HDO1015I
refueling area. Figure 34
Do not smoke in battery charging areas or in areas the contain
flammable material.
Clean all electrical connections and tighten all electrical
connections. Check the electrical wires daily for wires that are
loose of frayed. Tighten all lose electrical wires before you
operate the machine. Repair all frayed electrical wires before
you operate the machine.
Remove all flammable materials before they accumulate on the
machine.
Do not weld on pipes or on tubes that contain flammable fluids.
Do not flame cut on pipes or on tubes that contain flammable

Track Excavator Safety SP000256


Page 34
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 35
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.

SP000256 Track Excavator Safety


Page 35
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.

Treatment for Electrical Welding to the Body Structure


To prevent damage to ECU by electrical welding, please
observe the following procedures: +

1. Open the door of the battery cover. -

2. Detach the cover after loosening the bolts on the battery.


+
3. Detach the positive and negative terminal cables from the
battery. -
4. Detach the undercover, and after that detach the connector
(1) from the ECU that are installed at the engine.
5. Proceed with welding.
FG001966
Figure 36

Track Excavator Safety SP000256


Page 36
6. After welding, carefully reassemble the connector. (1,
Figure 37)
7. Connect the battery terminal cables.
8. Reassemble the undercover under the engine.
1
9. Reassemble the cover over the battery.
10. Close the cover of the battery. Sequence is very important.

FG001446
Figure 37

Warning for Counterweight and Front


Attachment Removal

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 38
front attachment has been removed.

Precautions for Removal, Installation, and


Storage of Attachments
Before starting removal and installation of attachments, decide
the team leader.
Do not allow anyone except the authorized workers close to the
machine or attachment.
Place attachments that have been removed from the machine in
a safe place so that they do not fall. Put up a fence around the
attachments and take other measures to prevent unauthorized HDO1041L
persons from entering. Figure 39

SP000256 Track Excavator Safety


Page 37
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 40
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.

Lock Inspection Covers


When carrying out maintenance with the inspection cover open,
lock the cover securely in position with the lock bar.
If maintenance work is carried out with the inspection cover
open but not locked, there is danger that it may suddenly close
and cause injury if there is a gust of wind.

Crushing Prevention and Cutting


Prevention
You should always have at least two people working together if
the engine must be run during service. One person needs to
remain in the operator's seat, ready to work the controls or stop
the machine and shut off the engine.
Unless you are instructed otherwise, never attempt adjustments
while the machine is moving or while the engine is running.
Stay clear of all rotating parts and moving parts.
Keep objects away from moving fan blades. The fan blades will
throw objects and the fan blades can cut objects.
Do not use a wire rope cable that is kinked or flayed. Wear
gloves when you handle a wire rope cable.
When you strike a retainer pin, the retainer pin might fly out. The
loose retainer pin can injure personnel. Make sure that the area
is clear of people when you strike a retainer pin. To avoid injury
to your eyes, wear protective glasses when you strike a retainer
pin.

Track Excavator Safety SP000256


Page 38
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 41

Supports and Blocking for Work


Equipment
Do not allow weight or equipment loads to remain suspended.
Lower everything to the ground before leaving the operator's
seat.
Do not use hollow, cracked or unsteady wobbling supports.
Do not work under any equipment supported only by a lifting
jack.
HDO1042L
Figure 42

Action When Abnormality Is Found During


Inspection
If any abnormality is found during inspection, always carry out
repairs. In particular, if the machine is used when there are still
problems with the brake or work equipment systems, it may lead
to serious injury.
If necessary depending on the type of failure, please contact
your DOOSAN distributor for repairs.

SP000256 Track Excavator Safety


Page 39
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 43
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.

Track Excavator Safety SP000256


Page 40
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 44
Obey appropriate laws and regulations when
disposing of harmful materials such as oil, fuel,
solvent, filters, and batteries.

SP000256 Track Excavator Safety


Page 41
BATTERY

Battery Hazard Prevention


Battery electrolyte contains diluted sulfuric acid and batteries
generate hydrogen gas. Hydrogen gas is highly explosive, and
mistakes in handling them can cause serious injury or fire. To
prevent problems, always do the following:
Do not smoke or bring any flame near the battery.
When working with batteries, ALWAYS wear safety
glasses and rubber gloves.
If you spill battery electrolyte on yourself or your
clothes, immediately flush the area with water.
If battery electrolyte gets into your eyes, flush them
immediately with large quantities of water and see a
doctor at once.
If you accidentally drink battery electrolyte, drink a
large quantity of water or milk, raw egg or vegetable
oil. Call a doctor or poison prevention center
immediately.
When cleaning the top surface of the battery, wipe it
with a clean, damp cloth. Never use gasoline, thinner,
or any other organic solvent or detergent.
Tighten the battery caps securely.
If the battery electrolyte is frozen, do not charge the
battery or start the engine with power from another
source. There is danger that the battery may catch
fire.
When charging the battery or starting with power from Figure 45
another source, let the battery electrolyte melt and
check that there is no leakage of battery electrolyte
before starting the operation.
Always remove the battery from the machine before
charging.

Track Excavator Safety SP000256


Page 42
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 46
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.

SP000256 Track Excavator Safety


Page 43
TOWING

Precautions When Towing


Cloth
If any mistake is made in the method of selecting or inspecting
the towing wire or in the method of towing, it may lead to serious
personal injury. Always do the following:
Always use the method of towing given in this
Operation and Maintenance Manual. Do not use any
other method.
Towing Wire
Use leather gloves when handling the wire rope.
When carrying out the preparation work for towing
with two or more workers, determine the signals to
use and follow these signals correctly.
Always fit the towing rope to the left and right hooks
and secure in position.
Shackle
If the engine on the problem machine will not start or
there is a failure in the brake system. always contact
your DOOSAN distributor.
Towing Wire FG000669
Never go between the towing machine and the towed
machine during the towing operation. Figure 47

It is dangerous to carry out towing on slopes, so


select a place where the slope is gradual. If there is
no place where the slope is gradual, carry out
operations to reduce the angle of the slope before
starting the towing operation.
When towing a problem machine, always use a wire
rope with a sufficient towing capacity.
Do not use a frayed, kinked rope or a rope with any
loss of diameter.
Do not use the lightweight towing hook for towing
another machine.

Track Excavator Safety SP000256


Page 44
SHIPPING AND
TRANSPORTATION

Obey State and Local Over-the-Road


Regulations
Check state and local restrictions regarding weight, width and
length of a load before making any other preparation for
transport.
The hauling vehicle, trailer and load must all be in compliance
with local regulations governing the intended shipping route.
Partial disassembly or teardown of the excavator may be
necessary to meet travel restrictions or particular conditions at
the work site. See the Shop Manual for information on partial
disassembly.
Refer to the Transportation and Shipping section of this
Operation and Maintenance Manual for information on loading,
unloading and towing.

LIFTING WITH SLING

WARNING!
Improper lifting can allow load to shift and cause injury or
damage.

1. Refer to Specification section of Operation and


Maintenance Manual for information on weight and
dimensions.
2. Use properly rated cables and slings for lifting.
3. Position machine for a level lift.
4. Lifting cables should have a long enough length to prevent
contact with the machine. Spreader bars may be required.
If spreader bars are used, be sure that cables are properly
secured to them and that the angle of the cables is factored into Figure 48
the lift strength.

SP000256 Track Excavator Safety


Page 45
Track Excavator Safety SP000256
Page 46
1Specifications
SP000257
SPECIFICATION FOR DX420LCSP000257

Specification
for DX420LC

Edition 1

Specification for DX420LC SP000257


Page 1
MEMO

SP000257 Specification for DX420LC


Page 2
Table of Contents

Specification for DX420LC


Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 7
Component Locations........................................... 8
General Dimensions (DX420LC) ........................ 10
Working Range ................................................... 12
General Specifications........................................ 14
Engine Performance Curves (Per DIN 6270
Standard) ............................................................ 16
Approximate Weight of Workload Materials........ 18
Performance Tests ............................................. 20
Excavator Performance Standards..................... 21
Test Conditions ............................................................. 21
Travel Speed and Travel Motor Balance
(Steering Deviation) Tests............................................. 21
Swing Speed and Deceleration Force Test................... 23
Cylinder Performance Tests.......................................... 25

Specification for DX420LC SP000257


Page 3
MEMO

SP000257 Specification for DX420LC


Page 4
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.

MODEL SERIAL NUMBER RANGE


DX420LC 5001 and Up

SP000257 Specification for DX420LC


Page 5
Specification for DX420LC SP000257
Page 6
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.)

SP000257 Specification for DX420LC


Page 7
COMPONENT LOCATIONS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

40
39
38

37

36

21
35
34

33 22
32
31
30 23
29 27
28

24
25
26

FG001806
Figure 1

Specification for DX420LC SP000257


Page 8
Reference Reference
Description Description
Number Number
1 Counterweight 21 Arm
2 Hood 22 Bucket Cylinder
3 Muffler 23 Guide Link
4 Hydraulic Oil Tank 24 Bucket
5 Engine 25 Push Link
6 Fuel Tank 26 Side Cutter
7 Radiator And Oil Cooler 27 Tooth Point
8 Fuel Tank Fill Cap 28 Idler
9 Control Valves 29 Track Adjuster
10 Swing Motor 30 Track Guard
11 Precleaner 31 Battery
12 Air Cleaner 32 Lower Roller
13 Swing Bearing 33 Center Joint
14 Cabin 34 Upper Roller
15 Seat 35 Sprocket
16 Work Lever (Joystick) Controls 36 Travel Motor
17 Travel Lever 37 Track Link and Shoe
18 Boom Cylinder 38 Suction Filter
19 Arm Cylinder 39 Return Filter
20 Boom 40 Pumps

SP000257 Specification for DX420LC


Page 9
GENERAL DIMENSIONS
(DX420LC)

A
H
I J B C

O G

F
N
M
D
K
L E

FG001798
Figure 2

z
DIMENSION 6.7 M (22 FT) BOOM
2.6 M (8.5 FT) 3.25 M (10.7 FT) 3.95 M (13 FT) 3.25 M (10.7 FT)
ARM ARM ARM HD ARM
2.16 m3 (2.83 yd3) 1.9 m3 (2.49 yd3) 1.44 m3 (1.88 yd3) 1.51 m3 (1.98 yd3)
BUCKET BUCKET BUCKET BUCKET
A 11,770 mm (38' 7") 11,660 mm (38' 3")
B 3,660 mm (12')
C 8,110 mm (26' 7") 8,000 mm (26' 3")
D 4,250 mm (13' 11")
E 5,200 mm (17' 1") * 5,205 mm (17' 1")
F 1,265 mm (4' 2") * 1,275 mm (4' 2")
G 3,680 mm (12' 1") 3,480 mm (11' 5") 3,500 mm (11' 6") * 3,480 mm (11' 5")
H 2,990 mm (9' 10")
I 1,500 mm (4' 11")
J 1,490 mm (4' 11")
K 2,750 mm (9' 0")
L 3,550 mm (11' 8")
M 800 mm (2' 7")
N 540 mm (1' 9") * 555 mm (1' 10")
O 3,154 mm (10' 4") * 3,270 mm (10' 9")

* Indicates double grouser shoes installed dimension.

Specification for DX420LC SP000257


Page 10
SP000257 Specification for DX420LC
Page 11
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

6
C
5

4 D

0
0 1 2 3 4 5 6 7 8 9 10 11 12
-1

-2

-3

-4 B

-5

-6

-7

-8

A
FG001799

Specification for DX420LC SP000257


Page 12
BOOM TYPE ONE PIECE 6.7 m (22 ft)
ARM TYPE 2.6 m (8.5 ft) 3.25 m (10.7 ft) 3.95 m (13.0 ft) 3.25 m (10.7 ft)
DIM. 3 3 3
BUCKET TYPE 2.16 m 1.9 m 1.44 m 1.51 m3
(PCSA) (2.83 yd3) (2.49 yd3) (1.88 yd3) (1.98 yd3)
10,880 mm 11,495 mm 12,170 mm * 11,540 mm
A Max. digging radius
(35' 8") (37' 9") (40' 0") (37' 10")
7,080 mm 7,730 mm 8,430 mm * 7,770 mm
B Max. digging depth
(23' 3") (25' 4") (27' 8") (25' 6")
10,560 mm 10,920 mm 11,350 mm * 10,800 mm
C Max. digging height
(34' 8") (35' 10") (37' 3") (35' 5")
7,460 mm 7,795 mm 8,200 mm * 7,755 mm
D Max. loading height
(24' 6") (25' 7") (26' 11") (25' 5")
4,385 mm 4,380 mm 4,445 mm * 4,380 mm
E Min. swing radius
(14' 5") (14' 4") (14' 7") (14' 4")

* Indicates double grouser shoes installed dimension.

SP000257 Specification for DX420LC


Page 13
GENERAL SPECIFICATIONS
Shipping Weight 40.5 metric tons (89,290 lb), includes fuel 100, boom,
3,250mm (10' 8"), arm, standard bucket and standard
shoes
Operating Weight 40.9 metric tons (90,170 lb) includes weight of full fuel tank.
Shipping Weights With Optional Track Shoes Add 720 kg (1,590 lb) for 750 mm (30") shoes
Add 970 kg (2,140 lb) for 800 mm (32") shoes
Add 1,460 kg (3,220 lb) for 900 mm (35") shoes
Major Component Weights Standard Boom 6,700mm (22ft) 2,820kg (6,220 lb)
2,600 mm (8' 6") Arm 1,300kg (2,870 lb)
3,250 mm (10' 8") Arm 1,400 kg (3,090 lb)
3,950 mm (13' 0") Arm 1,630 kg (3,590 lb)
Boom Cylinders 370 kg (812 lb) each
Arm Cylinder 530 kg (1,168 lb)
Bucket Cylinder 340 kg (750 lb)
Counterweight 8,000 kg (17,640 lb)
Upper Turntable 10,130 kg (22,300 lb) (Excluding
Counterweight and Front)
Lower - 15,000 kg (33,070 lb) (Including Swing Bearing)
Digging Forces (at Power Boost) :
Bucket Cylinder 24,200 kg (53,350 lb) with 3,250 mm (10' 8") arm
Arm Cylinder 23,800 kg (52,470 lb) with 2,600 mm (8' 6") arm
19,260 kg (42,460 lb) with 3,250 mm (10' 8") arm
16,660 kg (36,600 lb) with 3,950 mm (13' 0") arm
Fuel Tank Capacity 550 liters (145 U.S. gal)
Hydraulic System Capacity 420 liters (111 U.S. gal)
Hydraulic Reservoir Capacity 265 liters (70 U.S. gal)
Bucket Heaped Capacity Range PCSA 1.44 - 2.16 m3 (1.88 - 2.83 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 (24") - standard
750 mm (30") - optional
800 mm (32") - optional
900 mm (35") - optional
Ground Pressure Ratings:
Standard 600 mm (24.0") shoe - 0.74 kg/cm2 (10.5 psi)
Optional 750 mm (30.0")shoe- 0.61kg/cm2 (8.7 psi)
Optional 800 mm (32.0") shoe - 0.57 kg/cm2 (8.1 psi)
Optional 900 mm (35.0")shoe- 0.50 kg/cm2 (7.1 psi)
Transport Dimensions

Specification for DX420LC SP000257


Page 14
Overall Shipping Length 11,660 mm (38' 3")
(standard boom and arm)
Overall Shipping Width 3,350 mm (11' 0")
(standard shoes)
Overall Shipping Height 3,480 mm (11' 5")
(to top of cylinder hose)
Track Shipping Length 5,200 mm (17' 1")
Transport Trailer Capacity 41.0 metric tons (45.2 tons) minimum load capacity
Transport Loading Ramp 15 angle CAUTION: Refer to Transport Maximum
Allowable Slope Procedure for Safe Shipping Instructions.

SP000257 Specification for DX420LC


Page 15
ENGINE PERFORMANCE
CURVES (PER DIN 6270
STANDARD)

Figure 3

Specification for DX420LC SP000257


Page 16
Condition Specification
Engine Model DV11
Barometric Pressure 760 mmHg (20C (68F))
Alternator 24V x 50A
Air Cleaner Installed
Muffler Installed

Performance Standard DIN 6270


297 ps @ 1,800 rpm
Power
(293 hp @ 1,800 rpm)
140 kgm @ 1,300 rpm
Max. Torque
(1013 ft lb @ 1,300 rpm)
160 g/psh
Fuel Consumption (MIn. Rated)
(5.64 oz/hph)

SP000257 Specification for DX420LC


Page 17
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)

Specification for DX420LC SP000257


Page 18
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)

SP000257 Specification for DX420LC


Page 19
PERFORMANCE TESTS
1. Main Relief Pressure

normal operation: 320 kg/cm3 (4,641 psi)

with "Pressure Up": 350 kg/cm3 (4,970 psi)


2. Actuator Speeds

Operation Unit Standard Mode Power Mode


Up sec 4.2 0.4 3.8 0.4
Boom
Down sec 2.4 0.3 2.4 0.3
Dump sec 3.3 0.3 3.1 0.3
Arm
Crowd sec 4.3 0.4 4.2 0.4
Dump sec 3.1 0.3 3.0 0.3
Bucket
Crowd sec 3.3 0.4 3.2 0.4
Swing (3 Revolutions) sec 21.0 1.5 19.6 1.5
High sec 22.9 1.5 21.4 1.5
Jack-up Speed (3 Turns)
Low sec 39.1 2.0 36.4 2.0
High sec 15.3 1.0 14.3 1.0
Travel Speed 20 m (65.62 ft)
Low sec 26.1 1.5 24.3 1.5
High mm (in) 150 (5.91) 150 (5.91
Travel Deviation 20 m (65.62ft)
Low mm (in) 150 (5.91) 150 (5.91)

Specification for DX420LC SP000257


Page 20
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 - 55C (112 - 135F).
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.

Travel Speed and Travel Motor Balance


(Steering Deviation) Tests

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.

SP000257 Specification for DX420LC


Page 21
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 15.3 1.0 sec 14.3 1.0 sec
Low Speed 26.1 1.5 sec 24.3 1.5 sec

Rotate the turntable 180. Both tests should be repeated three


times. Average all results to obtain a final value.

3M - 5M
3M - 5M 20M
(10' - 15')
(10' - 15') (65' 7-1/2'')
FG000467
Figure 5

Specification for DX420LC SP000257


Page 22
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.

Rate of Travel Max. Distance


High Speed 150 mm (5.91 in)
Low Speed 150 mm (5.91 in)

Swing Speed and Deceleration Force Test

Swing Speed Test

1.0M

FG004993
Figure 6

Extend the bucket cylinder completely and retract the arm


cylinder, as shown in Figure 6, to test swing speed. The lowest
point of the bucket will be approximately 1 m (3.3') off the
ground.
Use paint marks at the same point on the turntable and
undercarriage, or select alternate measuring locations and use a
stopwatch to time 3 full 360 rotations. The time required for 3
revolutions should be between 19.5 and 22.5 seconds in
Standard Mode, 18.1 and 21.1 seconds in Power Mode.

SP000257 Specification for DX420LC


Page 23
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 3
the turntable and undercarriage with paint at the 90 point. 4

Make several attempts to rotate the turntable exactly 90,


starting from the boom straight ahead position. Engage the
swing lever and brake at the 90 point, shown as "swing stop" in
Figure 7. 2

Record how far the turntable drifts past the stop point,
measuring the distance between paint marks. Maximum
distance should be less than 1000 mm (39.4"), in both Power
Mode and Standard Mode.

Reference
Description
Number
1 Start Swing
1
2 90 Swing
FG005122
3 Swing Force
Figure 7
4 Swing Stop

Maximum Less than 1,000 mm


Distance (39.4 in)

Specification for DX420LC SP000257


Page 24
Cylinder Performance Tests
NOTE: All tests are performed with standard boom, arm and
bucket configuration. The bucket should be empty.

Boom Cylinders Test


The starting points for the test are with the boom and arm
extended away from the excavator, and the bucket curled
inward. The arm cylinder should be fully retracted; boom and
bucket cylinders must be extended. Test movement in both
directions, several times, and average results for both Standard
Mode and Power Mode.

Arm Cylinder Test


Start with the boom up and the arm cylinder fully retracted. Test
movement in both directions several times, between the "crowd"
and "dump" positions, and average the results of both tests, in
both standard and extra-duty power modes.

Bucket Cylinder Test


Start with the boom up and the teeth of the bucket hanging
vertically, 500 mm (1-1/2' - 2') above the ground. Dump and
crowd the bucket several times, and average results, for both
standard and extra-duty power modes.

Operation Standard Mode Power Mode


Boom Up 3.8 - 4.6 sec 3.4 - 4.2 sec
Boom Down 2.1 - 2.7 sec 2.1 - 2.7 sec
Arm Dump 3.0 - 3.6 sec 2.8 - 3.4 sec
Arm Crowd 3.9 - 4.7 sec 3.8 - 4.6 sec
Bucket Dump 2.8 - 3.4 sec 2.7 - 3.3 sec
Bucket Crowd 2.9 - 3.7 sec 2.8 - 3.6 sec

Hydraulic Cylinder Natural Drop Test


To check boom and arm cylinder tightness against the specified
performance standard for new cylinders, put a full load of dirt in
the bucket and move the attachment cylinders so that the arm
cylinder is extended 20 - 50 mm (1" - 2") and boom cylinders are
retracted the same amount, 20 - 50 mm (1" - 2"). The top of the
bucket should be approximately 2 m (6' - 7') off the ground.
Shut down engine and measure cylinder drop after 5 minutes.
Bucket cylinder should not show more than 40 mm (1.57")
change, while the arm and boom cylinders should not fall more
than 10 mm (0.39").

Cylinder Location Maximum Drop


Boom Cylinder Less Than 5 mm (0.20 in)
Arm Cylinder Less Than 5 mm (0.20 in)
Bucket Cylinder Less Than 20 mm (0.79 in)

SP000257 Specification for DX420LC


Page 25
Travel Motor Jack-up Test
Test travel motor operation on each side by painting or chalking
a mark on one crawler shoe, with a corresponding mark on the
travel frame. Use the attachment to jack up one side of the
machine and operate the raised travel motor. Record the
number of seconds it takes the crawler shoe to make 3 full
rotations, during both high speed and low speed operation.

Operation Standard Mode Power Mode


High Speed seconds 22.91.5 21.41.5
Low Speed seconds 39.12.0 36.42.0

Specification for DX420LC SP000257


Page 26
1General Maintenance
SP000016
GENERAL MAINTENANCE PROCEDURES
SP000016

General
Maintenance
Procedures
Edition 1

General Maintenance Procedures SP000016


Page 1
MEMO

SP000016 General Maintenance Procedures


Page 2
Table of Contents

General Maintenance Procedures


Safety Precautions ............................................... 5
Applicable Models ................................................ 5
Welding Precautions and Guidelines.................... 6
Hydraulic System - General Precautions.............. 7
Maintenance Service and Repair Procedure ........ 9
General Precautions........................................................ 9
Hydraulic System Cleanliness and Oil Leaks ..... 10
Maintenance Precautions for Hydraulic System Service10
Oil Leakage Precautions ............................................... 11
Cleaning and Inspection ..................................... 12
General Guidelines........................................................ 12
Bearing inspection......................................................... 13

General Maintenance Procedures SP000016


Page 3
MEMO

SP000016 General Maintenance Procedures


Page 4
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.

MODEL SERIAL NUMBER RANGE


ALL MODELS ALL RANGES

SP000016 General Maintenance Procedures


Page 5
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.

General Maintenance Procedures SP000016


Page 6
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

SP000016 General Maintenance Procedures


Page 7
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.

General Maintenance Procedures SP000016


Page 8
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.

SP000016 General Maintenance Procedures


Page 9
HYDRAULIC SYSTEM
CLEANLINESS AND OIL LEAKS

Maintenance Precautions for Hydraulic


System Service
Whenever maintenance, repairs or any other type of
troubleshooting or service is being performed, it's important to
remember that the hydraulic system - including both the interior
and exterior surfaces of assemblies, and every drop of operating
fluid - must be protected from contamination.
Dust and other foreign contaminants are major contributors to
premature wear in hydraulic circuits. The narrow tolerances,
rapidly moving parts and high operating pressures of the system
require that fluid be kept as clean as possible. The performance
and dependability of the machine (and the service lift of
individual components) can be noticeably reduced if proper
precautions are not observed:
Use a safe, noncombustible, evaporative type, low-
residue solvent and thoroughly clean exterior
surfaces of assemblies before any part of the circuit is
opened up or disassembled.
NOTE: It's just as important to clean the cap and
reservoir top before routine fluid changes
or quick checks as it is before major
repairs. (Accumulated dirt attracts
moisture, oil and other fluids - and more
dirt.)
Keep dismantled parts covered during disassembly.
Use clean caps, plugs or tape to protect the
disconnected openings of flanges, manifolds and
piping.
Do not allow cleaning solvents or other fluids to mix
with the oil in the system. Use clean oil to flush any
traces of solvent or other residue before reassembly.
If metal or rubber fragments are found in the system,
flush and replace all fluid in the system and
troubleshoot the circuit to identify the source of
contamination.

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.

General Maintenance Procedures SP000016


Page 10
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

SP000016 General Maintenance Procedures


Page 11
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.

1. Clean all metal parts thoroughly using a suitable cleaning


fluid. It is recommended that parts be immersed in
cleaning fluid and moved up and down slowly until all oils,
lubricants, and/or foreign materials are dissolved and parts
are thoroughly clean.
2. For bearings that can be removed, soak them in a suitable
cleaning fluid for a minute or two, then remove bearings
from cleaning fluid and strike flat against a block of wood to
dislodge solidified particles of lubricant. Immerse again in
cleaning fluid to flush out particles. Repeat above
operation until bearings are thoroughly clean. To dry
bearings, use moisture-free compressed air. Be careful to
direct air stream across bearing to avoid spinning bearings
that are not lubricated. DO NOT SPIN BEARINGS WHEN
DRYING; bearings may be rotated slowly by hand to
facilitate drying process.
3. Carefully inspect all bearing rollers, cages and cups for
wear, chipping or nicks to determine condition. Do not
replace a bearing cone or cup individually without
replacing mating cup or cone at the same time. After
inspection, dip bearings in light weight oil and wrap in clean
lintless cloth or paper to protect them until installation.
For those bearings that are to be inspected in place;
inspect bearings for roughness of rotation, scoring, pitting,
cracked or chipped races. If any of these defects are found,
replace bearings. Also, inspect defective bearing housing
and/or shaft for grooved, galled or burred conditions that
indicate bearing has been turning in its housing or on its
shaft.
4. It is more economical to replace oil seals, O-rings, sealing
rings, gaskets and retaining rings when unit is
disassembled than waiting for premature failures; refer to
latest Micro Fiche and/or Parts Book for replacement
items. Be extremely careful when installing sealing
members, to avoid cutting or scratching. Curling under of

General Maintenance Procedures SP000016


Page 12
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.

SP000016 General Maintenance Procedures


Page 13
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

General Maintenance Procedures SP000016


Page 14
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

Abrasive Step Wear


Pattern on roller ends caused by fine abrasives.
Clean all parts and housings, check all parts and housings,
check seals and bearings and replace if leaking, rough or noisy.

Figure 6

SP000016 General Maintenance Procedures


Page 15
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

General Maintenance Procedures SP000016


Page 16
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

SP000016 General Maintenance Procedures


Page 17
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

Cracked Inner Race


Race cracked due to improper fit, cocking or poor bearing seat.
Replace all parts and housings, check seals and bearings and
replace if leaking.

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

General Maintenance Procedures SP000016


Page 18
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

SP000016 General Maintenance Procedures


Page 19
General Maintenance Procedures SP000016
Page 20
SP000017
STANDARD TORQUESSP000017

Standard
Torques

Edition 1

Standard Torques SP000017


Page 1
MEMO

SP000017 Standard Torques


Page 2
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

Standard Torques SP000017


Page 3
MEMO

SP000017 Standard Torques


Page 4
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.

MODEL SERIAL NUMBER RANGE


ALL MODELS ALL RANGES

SP000017 Standard Torques


Page 5
TORQUE VALUES FOR
STANDARD METRIC
FASTENERS
NOTE: The units for the torque values are kgm (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)

Standard Torques SP000017


Page 6
TORQUE VALUES FOR
STANDARD U.S. FASTENERS
S.A.E. Bolt Head
Type Description
Grade Marking

WILL HAVE NO MARKINGS IN THE CENTER OF THE


HEAD.
1 1 OR 2

Low or Medium Carbon Steel Not Heat Treated.

WILL HAVE THREE RADIAL LINES.


5 5
Quenched and Tempered Medium Carbon Steel.

WILL HAVE 6 RADIAL LINES.


8 8
Quenched and Tempered Special Carbon or Alloy Steel.

Recommended torque, in foot pounds, for all Standard


Application Nuts and Bolts, provided:
1. All thread surfaces are clean and lubricated with SAE-30
engine oil. (See Note.)
2. Joints are rigid, that is, no gaskets or compressible
materials are used.
3. When reusing nuts or bolts, use minimum torque values.
NOTE: Multiply the standard torque by:
0.65 When finished jam nuts are used.
0.70 When Molykote, white lead or similar
mixtures are used as lubricants.
0.75 When Parkerized bolts or nuts are used.
0.85 When cadmium plated bolts or nuts and
zinc bolts w/waxed zinc nuts are used.
0.90 When hardened surfaces are used under
the nut or bolt head.
NOTE: When reusing bolts and nuts in service, use
minimum torque values.

SP000017 Standard Torques


Page 7
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.

Standard Torques SP000017


Page 8
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.

Standard Torque 10%


Nominal Thread Diameter Kilogram Meter Foot Pounds
(kgm) (ft lb)
1/4" 1.1 8
5/16" 2.2 16
3/8" 3.9 28
7/16" 6.2 45
1/2" 9.7 70
9/16" 13.8 100
5/8" 19.4 140
3/4" 33.2 240
7/8" 53.9 390
1" 80.2 580
1 - 1/8" 113.4 820
1 - 1/4" 160.4 1160
1 - 3/8" 210.2 1520
1 - 1/2" 279.4 2020
1 - 3/4" 347.1 2510
2 522.8 3780

SP000017 Standard Torques


Page 9
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
(kgm) (in lb) (kgm) (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"

Standard Torques SP000017


Page 10
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
(kgm) (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

(*) - Inside diameter of flange on end of hydraulic tube or hose


fitting.
NOTE: Values stated in chart are for Standard Pressure
Series (Code 61) Split Flanges.

SP000017 Standard Torques


Page 11
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

A = Length of the torque wrench (between the center of the nut


or bolt and the center of the handle).
B = Length of the extension.
As an example, if a 12" extension is added to a 12" torque
wrench, and the indicated torque on the dial reads "150 ft lb,"
the real force applied to the bolt is 300 ft lb:

AxT 12 x 300 3600


I= = = = 150
A+B 12 + 12 24

NOTE:The formula assumes that there is no added


deflection or "give" in the joint between the

Standard Torques SP000017


Page 12
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.

Other Uses for Torque Wrench Extension


Tools
Torque wrench extensions are sometimes made up for reasons
other than increasing leverage on a fastener.
For example, a torque wrench and extension can be used to
measure adjustment "tightness" of a linkage or assembly.
Specially fabricated extensions can be used to make very
precise checks of the force required to engage or disengage a
clutch mechanism, release a spring-applied brake assembly, or
"take up" free play in most any movable linkage.
Once the value of the adjustment force is established, repeated
checks at regular intervals can help to monitor and maintain
peak operating efficiency. These types of adjustment checks are
especially useful if physical measurements of linkage travel are
difficult to make or will not provide the needed degree of
precision and accuracy.
To allow the assembly or mechanism to accept a torque wrench,
welding a nut or other adapter on the end of a linkage shaft or
other leverage point will allow turning the shaft or assembly
manually.

Tightening Torque Specifications (Metric)


(For coated threads, prelubricated assemblies.)

SP000017 Standard Torques


Page 13
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.

Standard Torques SP000017


Page 14
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/260C (500F)
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/260C (500F)
271 Red 160
fasteners up to 25 mm (1") diameter. Remove HOT
High temperature/high strength for
Heat/316C (600F)
272 hostile environments to 232C Red 180
Remove HOT
(450F).
Extra high strength for coarse thread
Heat/260C (500F)
277 fasteners 25 mm (1") diameter and Red 210
Remove HOT
larger.

II. "Loctite" Pipe Thread Sealant

Product Application Color Removal Required Setup


"No-filler/nonclog" formula for high-
4 Hours (or 1/2
pressure hydraulic systems. Over
545 Purple Hand tools hour with Locquic
application will not restrict or foul
"T" Primer)
system components.
4 Hours (or 1/2
Solvent resistant, higher viscosity
656 White Hand tools hour with Locquic
tapered thread sealer.
"T" Primer)

III. "Loctite" gasket/flange sealer

Product Application Color Notes


Gasket eliminator specifically made
for aluminum flanges/surfaces. For Use Locquic "N" primer for fast (1/2 - 4
518 Red
hydraulic systems to 34,475 kPa hours) setup. Unprimed setup 4 - 24 hours.
(5,000 psi).
Low-pressure/wide-gap gasket
eliminator compound. Fills gaps to Use Locquic "N" primer for faster (1/2 - 4
504 Orange
0.0012 mm (0.030"), cures to rigid hours) setup. Unprimed setup 4 - 24 hours.
seal.
General purpose, fast setup, flexible-
cure gasket eliminator. For nonrigid Use Locquic "N" primer for faster (1/4 - 2
515 Purple
assemblies subject to shock, vibration hours) setup. Unprimed setup 1 - 12 hours.
or deflection.

SP000017 Standard Torques


Page 15
IV. "Loctite" retaining compounds

Product Application Color Notes


For bushings, sleeves, press fit
Use Locquic "N" primer for increased bond
bearings, splines and collars. For
609 Green strength and all cold temperature
gaps to 0.0002 mm (0.005"),
applications.
temperatures to 121C (250F).
For high temperatures to 232C
620 Green Same as 609, above.
(450F).
For high strength bonds and tight
680 clearance gaps, to 0.00008 mm Green Same as 609, above.
(0.002").

V. "Loctite" Adhesives

Product Application Color Notes


Black Max instant adhesive for shock May take 120 hours to reach full cure
380 Black
and vibration-resistant bonds. strength.
454 Adhesive for porous surfaces. Clear Full strength in 24 hours.
Increased strength (+50%), shock and
480 Black Full strength in 24 hours.
vibration-resistant.

Standard Torques SP000017


Page 16
1Upper Structure
SP000018
CABIN SP000018

Cabin

Edition 1

Cabin SP000018
Page 1
MEMO

SP000018 Cabin
Page 2
Table of Contents

Cabin
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
Removal ............................................................... 6
Installation ............................................................ 8

Cabin SP000018
Page 3
MEMO

SP000018 Cabin
Page 4
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.

MODEL SERIAL NUMBER RANGE


DX300LC 5001 and Up
DX340LC 5001 and Up
DX420LC 5001 and Up
DX480LC 5001 and Up
DX520LC 5001 and Up

SP000018 Cabin
Page 5
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.

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!
DON'T TOUCH WHEN
PERFORMING INSPECTION
OR MAINTENANCE

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.

6. Fully stroke work levers (joysticks) in all directions to


relieve pressure from accumulators.
7. Set safety lever on "LOCK" position.
8. Turn key to "O" (OFF) position and remove from starter
switch.
9. Hang maintenance warning tag on controls.
10. Disconnect the battery cable from the negative (-) battery
terminal.
11. Prepare cabin shell for removal by disconnecting wiring
connectors for:
A. Cabin interior lighting.
B. External light wiring.
C. Radio antenna and connections.
D. Wiper/washer connections.
NOTE: Control console wiring harnesses and hydraulic
piping lines that pass through the floor of the
cabin do not need to be disassembled.
NOTE: If unit is equipped with a cabin protective
structure (for forestry, or hazardous working
conditions), it must be removed.

Cabin SP000018
Page 6
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 6
removing cover (2) disconnect hour meter connector and
7
cigar lighter 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

16. Remove air duct (1, 2 and 3, Figure 3) at right side of


cabin. Disconnect duct wiring connector before removing
duct (2). 3

17. Disconnect washer hose at floor plate bottom. 1

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

right dash covers. Remove left side cover (3). 4


5
20. Lift right side dash cover (4, Figure 4) and disconnect
speaker wire. Remove cover.

ARS1530L
Figure 4

21. Remove three bolts (2, Figure 5) after disconnecting the


speaker and antenna wires. Remove stereo assembly.
22. Disconnect cabin light wiring connector.
2
23. Disconnect cabin ground cable (7, Figure 2).

ARS1540L
Figure 5

SP000018 Cabin
Page 7
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
3 10 mm x 1.5 mm hex head bolts, 2 on
HAOF270L
the right side of the cabin and 1 under
the front window. Figure 6

27. 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).
28. Lift cabin approximately 25 - 50 mm (1" - 2") above deck.
Check that all electrical connections have been
disconnected and all other items unbolted.
29. Continue lifting with the assist crane to remove the cabin
shell. Lower the shell to a prepared safe blocking support.

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
3. Install four mounting nuts on four corners of cabin floor (2,
Figure 9). 1
NOTE: Mounting nut torque 20.2 kgm (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 3
of the cabin. HAOF270L
3 10 mm x 1.5 mm hex head bolts, 2 on Figure 9
the right side of the cabin and 1 under
the front window.

6. Once cabin is mounted to floor, unhook lifting device.


7. Connect cabin ground cable (7, Figure 2).
8. Connect cabin light wiring connector.
9. Install stereo assembly with bolts (2, Figure 10) after
connecting speaker and antenna wires.

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,
1
Figure 10). Install two rubber stops (2, Figure 11). 2 2

12. Install cover (5, Figure 11) on left side dash cover (3). 3

NOTE: Connect speaker wire before installing cover. 4


5

13. Connect washer hose at floor plate bottom.

ARS1530L
Figure 11

SP000018 Cabin
Page 9
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
SP000265
COUNTERWEIGHT SP000265

Counterweight

Edition 1

Counterweight SP000265
Page 1
MEMO

SP000265 Counterweight
Page 2
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 SP000265
Page 3
MEMO

SP000265 Counterweight
Page 4
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.

MODEL SERIAL NUMBER RANGE


DX420LC 5001 and Up

SP000265 Counterweight
Page 5
GENERAL

Warning for Counterweight and Front


Attachment Removal

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.

Before any attempt is made to begin removal or installation of


the counterweight, the excavator must be parked on a firm and
level supporting surface, with no sloping surfaces or soft or
muddy ground in the area where the assist lift crane will be
working. Position all accessories in the overnight storage
position.

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.

Model Weight of Counterweight


8,000 kg (17,640 lb)
DX420LC
10,000 kg (22,050 lb) (Optional)

Responsibility should be assigned to one person to be in charge


of the lifting crew, and to verify that required safe lifting
precautions have been taken before each part of this procedure
has been started.
All members of the working crew should know and understand
the signals that will be used between the lifting leader, the assist
crane operator and the remainder of the work crew.

Counterweight SP000265
Page 6
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.

To maintain stability the counterweight should be removed


whenever the front attachment is taken off the machine.

90 ~ 110

15 FG000325
Figure 1

When loading an excavator (either track or wheeled type) on a


trailer for transport after the front attachment has been removed,
always go backwards up the loading ramp. The counterweight
end of the deck has to get on the trailer first, while the cabin is
still going up the ramp (Figure 1).

15

FG000326
Figure 2

SP000265 Counterweight
Page 7
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

WARNING!
DON'T TOUCH WHEN
PERFORMING INSPECTION
OR MAINTENANCE

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.

6. Fully stroke work levers (joysticks) in all directions to


relieve any pressure from accumulators.
7. Set safety lever on "LOCK" position.
8. Turn key to "O" (OFF) position and remove from starter
switch.
9. Hang maintenance warning tag on controls.
10. Disconnect the battery cable from the negative (-) battery
terminal.
11. Remove engine compartment cover.

Counterweight SP000265
Page 8
12. Remove two caps (1, Figure 4) from counterweight (2).
13. Install two lifting eyes in lifting holes (3, Figure 4).

Model Lifting Eye Size


DX420LC M48x5.0 3 1
2

14. Using a suitable lifting device capable of handling a heavy 3

load, partially support counterweight (2, Figure 4) before


loosening four bolts (4). Stop lifting with assist crane as
soon as lifting slings are taut.
15. Remove four bolts (4, Figure 4) and washers (5) from
counterweight (2).
NOTE: Heat bolts if necessary, to free them.
16. When bolts (4, Figure 4) and washers (5) have been
removed, lift counterweight (2) a very short distance above
support frame (6) and stop. Check slings and make sure
counterweight is being supported evenly. 6

FG005138
Figure 4

SP000265 Counterweight
Page 9
INSTALLATION
1. Using suitable lifting device capable of handling a heavy
load, raise counterweight (2, Figure 5) into position just
above support frame (6) leaving counterweight suspended.
Verify that counterweight is level and even.
NOTE: Leave counterweight (2, Figure 5) suspended 3 1
3 mm (0.125") above support frame (6) until all 2

four mounting bolts (4) are started in 3

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.
6

Model Bolt Torque


DX420LC 250 kgm (1,807 ft lb)
5

4. Remove lifting device and lifting eyes from counterweight 4

lifting holes (3, Figure 5).


5. Install two caps (1, Figure 5) in lifting holes (3).
FG005138
6. Install engine compartment cover. Figure 5
7. Connect negative (-) battery cable to battery.

Counterweight SP000265
Page 10
SP000264
FUEL TANK SP000264

Fuel Tank

Edition 1

Fuel Tank SP000264


Page 1
MEMO

SP000264 Fuel Tank


Page 2
Table of Contents

Fuel Tank
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 6
Parts List ......................................................................... 8
Specifications .................................................................. 9
Removal ............................................................. 10
Installation .......................................................... 14
Start-up Procedures ........................................... 16

Fuel Tank SP000264


Page 3
MEMO

SP000264 Fuel Tank


Page 4
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.

MODEL SERIAL NUMBER RANGE


DX420LC 5001 and Up

SP000264 Fuel Tank


Page 5
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.

Fuel Tank SP000264


Page 6
SP000264 Fuel Tank
Page 7
Parts List

12
FR
ON
T

11

22
1
23
22
21 23
16 20
15 19
2

51

18 52
17

18
17

14

9
13

8 10
3
13
4
8

5 7
25

24
Figure 1

Fuel Tank SP000264


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

Specifications
Fuel tank capacity is 550 liters (145 U.S. gal).

SP000264 Fuel Tank


Page 9
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

2. Park on firm and level ground and swing turntable to


approximately a 90 with respect to tracks. See Figure 3.

FG000471
Figure 3

3. Lower front attachment (bucket) to ground. O I


4. Shut down engine.
5. Set safety lever on "RELEASED" position.
6. Turn starter switch to "I" (ON) position.

WARNING! WARNING

DON'T TOUCH WHEN


PERFORMING INSPECTION
OR MAINTENANCE

If engine must be run while performing maintenance,


FG003015
use extreme care. Always have one person in the
Figure 4
cabin at all times. Never leave the cabin with the
engine running.

7. Fully stroke work levers (joysticks) in all directions to


relieve any pressure from accumulators.
8. Set safety lever on "LOCK" position.
9. Turn key to "O" (OFF) position and remove from starter
switch.
10. Hang maintenance warning tag on controls.
11. Disconnect negative (-) battery cable leading to frame from
battery.

Fuel Tank SP000264


Page 10
12. Clean area around fuel tank fill cap (12, Figure 5). Open 12
fuel cap.

FG005137
Figure 5

13. Place a large enough container under fuel tank to collect


remaining fuel. Open drain cock (7, Figure 6) at bottom of
tank and drain.
NOTE: Fuel tank capacity is 550 liters (145 U.S. gal).

FG005130
Figure 6

14. Tag and disconnect fuel supply line (26, Figure 7) and fuel
1
return line (27) from fuel tank (1) and carefully drain
remaining fuel from lines.
15. Remove clamp (28, Figure 7) holding fuel return line (27) to 27
tank (1).

28

26
FG005131
Figure 7

16. Remove components from fuel filler pump port (29, Figure 29 1
8) on side of fuel tank (1).

FG005132
Figure 8

SP000264 Fuel Tank


Page 11
17. Remove eight bolts (30, Figure 9) and cover (31) from fuel
30
tank. 31

FG005134
Figure 9

18. Remove eight bolts (32 and 33, Figure 10) and stay (34)
from fuel tank and frame.
Remove four bolts (35 and 36) and fuel tank cover (37)
from fuel tank. 35
33
Remove two bolts (38) and bracket (39) from tank. 34

Remove four bolts (40) and battery cover (41) from frame.
36 40

39
38
37

32

41

FG005133
Figure 10

19. Tag and disconnect wires leading to fuel sender (2, Figure
11) on side of fuel tank (1).
1

FG005135
Figure 11

Fuel Tank SP000264


Page 12
20. Install two 12 mm eyebolts in threaded holes (42 and 43,
1
Figure 12). Using a suitable lifting device, sling eyebolts. 43
42

21. Remove six bolts and spacers (8 and 13, Figure 12)
holding tank (1) to frame. Lift tank 25 mm (1") and make
sure it is balanced. Make sure that there are no other
electrical wires or hoses connected to tank. Completely
remove tank after inspection.
NOTE: The clear level gauge on the side of the tank is 10
easily damaged. Be careful of obstacles and 13
wind gusts. 8

22. Remove shims (10, Figure 12). FG005136

Figure 12
NOTE: If tank is to be reused note position and amount
of shims used for each mounting bolt location.

SP000264 Fuel Tank


Page 13
INSTALLATION
1. Install two 12 mm eyebolts in threaded holes (42 and 43,
1
Figure 13). Using a suitable lifting device, sling eyebolts. 43
42

2. Set fuel tank (1, Figure 13) into position. Install six bolts
and spacers (8 and 13, Figure 13) finger tight, to secure
tank to frame.
NOTE: The clear level gauge on the side of the tank is
easily damaged. Be careful of obstacles and
wind gusts. 10

3. Install shims (10, Figure 13) as needed to prevent tank (1) 13

from rocking or stress from mounting bolts (8). 8

FG005136
4. Tighten mounting bolts (8, Figure 13) after shims are
Figure 13
installed.
NOTE: Bolt torque is 27 kgm (200 ft lb).
5. Connect wires as tagged to fuel sender (2, Figure 14) on
side of fuel tank (1).
1

FG005135
Figure 14

6. Install four bolts (40, Figure 15) and battery cover (41) on
frame.
Install two bolts (38) and bracket (39) on fuel tank.
Install four bolts (35 and 36) and fuel tank cover on fuel 33
35

tank. 34

Install eight bolts (32 and 33) and stay (34) on fuel tank and
frame. 36 40

39
38
37

32

41

FG005133
Figure 15

Fuel Tank SP000264


Page 14
7. Install eight bolts (30, Figure 16) and cover (31) on fuel
30
tank. 31

FG005134
Figure 16

8. Connect components to fuel filler pump port (29, Figure 17)


29 1
on side of fuel tank (1).

FG005132
Figure 17

9. Connect as tagged, fuel supply line (26, Figure 18) and fuel
1
return line (27) to fuel tank (1).
10. Install clamp (28, Figure 18) to hold fuel return line (27) to
tank (1). 27

28

26
FG005131
Figure 18

11. Make sure fuel tank drain valve (7, Figure 19) on bottom of
tank is closed.
12. Fill fuel tank and check for signs of leaks. Correct any
problems found.
13. Connect negative (-) battery cable to battery.
7

FG005130
Figure 19

SP000264 Fuel Tank


Page 15
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.

FG004960
Figure 20

3. Loosen plug (1, Figure 21) on top of fuel filter head.


1
4. Pump hand operated primer pump (2, Figure 21) by the
fuel injection pump. Pump primer until fuel is present at 2
plug hole in fuel filter head.
5. Tighten plug in fuel filter head.
6. Continue to pump primer pump until a strong resistance is
felt.
7. Start engine and look for signs of leaks.
Repeat procedure if necessary. FG000431
Figure 21

Fuel Tank SP000264


Page 16
SP000262
SWING BEARING SP000262

Swing Bearing

Edition 1

Swing Bearing SP000262


Page 1
MEMO

SP000262 Swing Bearing


Page 2
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
Disassembly .................................................................... 7
Assembly......................................................................... 9

Swing Bearing SP000262


Page 3
MEMO

SP000262 Swing Bearing


Page 4
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.

MODEL SERIAL NUMBER RANGE


DX420LC 5001 and Up

SP000262 Swing Bearing


Page 5
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.

Measuring Swing Bearing Axial Play


Periodic, regular checks of bearing displacement should be
made at least twice a year. Use a dial indicator. Push the 1
attachment against the ground to lift the excavator off the ground
and take measurements at 4 points, 90 apart, around the
circumference of the bearing (Figure 1).
2
Record and keep all measurements. Play in the bearing should
increase minimally from one inspection to the next. Eventually,
however, as the bearing begins to approach the limit of its
service life, clearance increases become much more
pronounced and the actual measured play in the bearing could
exceed twice the value that was measured when the machine
was new.

Measuring Bearing Lateral Play


When vertical checks are made, the side to side play in the
bearing can be checked by fully retracting the arm and bucket
cylinders and extending the tip of the bucket as far forward as it
will go. With the excavator parked on a flat, level surface and the FG000533
bucket tip just off the ground, push against the bucket sideways
Figure 1
to take up all of the lateral clearance in the bearing. (Less than
100 lb of force should be required to move the bucket over all
the way.) Check lateral play in both directions and record the
values. When the bearing is beginning to approach the end of its
service life, measured lateral clearance should start to show
larger and larger increases.

Swing Bearing SP000262


Page 6
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

Disassembly

1. Remove tip of tapered pin (3, Figure 3) using grinder and


tap lightly to remove debris.

Figure 3

2. Remove plug (4, Figure 4) using a M10 x 1.5 bolt.

Figure 4

SP000262 Swing Bearing


Page 7
3. Turn inner ring and use magnet bar (C, Figure 5) to
remove steel balls (5).

Figure 5

4. Turn inner ring and use wire (D, Figure 6) to remove


retainers (6).

Figure 6

Swing Bearing SP000262


Page 8
Assembly
1. Clean (degrease) the seal groove for the outer and inner
seals (7).
Apply instant glue to seal (7).
Install both seals respectively into position.

Figure 7

2. Hoist the outer race by crane horizontally and match it with


the inner race coaxially.
Rotating the outer race, insert balls (5), support (6) into the
plug (4) hole one by one with a round bar.

Figure 8

Figure 9

3. Top plug (4) into outer race (1) and then, drive pin (3) into
the pin hole.
Caulk the head of pin (3) with a punch.
Fill grease through the grease fitting.

Figure 10

SP000262 Swing Bearing


Page 9
Swing Bearing SP000262
Page 10
SP000249
SWING REDUCTION GEARSP000249

Swing
Reduction Gear

Edition 1

Swing Reduction Gear SP000249


Page 1
MEMO

SP000249 Swing Reduction Gear


Page 2
Table of Contents

Swing Reduction Gear


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

Swing Reduction Gear SP000249


Page 3
MEMO

SP000249 Swing Reduction Gear


Page 4
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.

MODEL SERIAL NUMBER RANGE


DX340LC 5001 and Up
DX420LC 5001 and Up

SP000249 Swing Reduction Gear


Page 5
Swing Reduction Gear SP000249
Page 6
GENERAL DESCRIPTION

Theory of Operation
The swing reduction gearbox is a two-step planetary gearbox
with three planet gears, one sun gear and 2-step output
reduction. The planetary gear engages with the ring gear. The
pinion gear is connected with the output shaft and spline.
The gearbox reduces swing motor rpm to increase swing motor
output torque. The available maximum swing speed provides a
fast turning rate for efficient, rapid work cycling with more than
adequate power for good acceleration.

SP000249 Swing Reduction Gear


Page 7
Parts List

Figure 1

Swing Reduction Gear SP000249


Page 8
Reference Reference
Description Description
Number Number
1 Drive Shaft 20 Plate
2 Gear Case 21 Lock Ring
3 Carrier No. 2 22 Spherical Roller Bearing
4 Sun Gear No. 2 23 Spherical Roller Bearing
5 Planetary Gear No. 2 24 Oil Seal
6 Side Plate No. 2 25 Spring Pin
7 No. 2 Shaft for Pin 26 Plug
8 No. 2 Bush 27 Plug
9 Carrier No. 1 28 Oil inlet
10 Sun Gear No. 1 29 Bolt Socket
11 Planetary Gear No. 1 30 Pipe
12 Side Plate No. 1 31 Level Bar
13 Pin Assembly No. 1 32 Bolt Socket
14 Ring Gear 33 Side Plate No. 3
15 Thrust Plate 34 Snap Ring
16 Case Cover 35 Pinion
17 Lock Pin 36 Cover
18 Spacer 37 Bolt Socket
19 Collar 38 Wire

SP000249 Swing Reduction Gear


Page 9
Specifications
DX340LC DX420LC
Swing Reduction Gearbox
Drive Type Two Stage Planetary Gear
Reduction Ratio 19.565 21.968
Maximum Output Speed 57.3 rpm 59.9 rpm
2,100 kgm 2,360 kgm
Maximum Output Torque
(15,189 ft lb) (17,070 ft lb)
275 kg
Weight
(606 lb)
Pinion Gear
Type Spur Gear
196 mm
Gear P.C.D
(7.72 in)
No. of Teeth 14
Module 14

Swing Reduction Gear SP000249


Page 10
TROUBLESHOOTING, TESTING
AND ADJUSTMENT

Symptoms Possible Causes Remedies


1. No rotation and
a. Pressure at swing motor inlet Swing brake not releasing Check brake engagement
increases and disengagement,
check release pressure
Internal damage to gearbox Replace broken gears,
drive train drive train assemblies
Overload Reduce load weight
b. Pressure at swing motor inlet Swing motor drive shaft damage Replace swing motor
shows no increase, and the swing
motor is making irregular noises Internal damage to gearbox Repair/replace broken or
drive train faulty assemblies
c. Pressure at swing motor inlet shows Hydraulic pump or valve broken Troubleshoot hydraulic
no increase, but without irregular system
noises from the swing motor
2. Oil leakage
a. From drive shaft Oil seal damaged Replace oil seal
b. From bolted connections or other Assembly compound (joint sealer) Disassemble and check
assembled surfaces old and not sealing, bolt not tight mating surfaces. Reapply
or flange warped Loctite, torque bolts to
specifications
3. Excess heat
Gearbox casing becomes excessively Low oil level Replace oil, refill to
hot, with or without irregular noise(s) specified level
during operation
Bearings or gear worn but not Repair or replace
completely inoperative gearbox
HAOE960L

SP000249 Swing Reduction Gear


Page 11
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!
DON'T TOUCH WHEN
PERFORMING INSPECTION
OR MAINTENANCE

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.

6. Fully stroke work levers (joysticks) in all directions to


relieve any pressure from accumulators.
7. Set safety lever on "LOCK" position.
8. Turn key to "O" (OFF) position and remove from starter
switch.
9. Hang a maintenance warning tag on controls.
10. Disconnect negative (-) battery cable leading to frame from
battery.
11. Tag and disconnect hoses from swing motor (1, Figure 3).
Plug and cap hoses and ports to prevent contamination
from entering hydraulic system or component.
12. Disconnect tube (2) from drain cock (3) and hose fitting (7)
from fill hole.
13. Remove twelve bolts and washers (4, Figure 3) holding
swing reduction gearbox (5) to frame.
14. Using a suitable lifting device, sling swing motor (1, Figure
3) and remove swing motor and reduction gearbox (5) as
an assembly from unit.
NOTE: A drain cock (3, Figure 3) and tube are on side
of gearbox. Be careful not to damage valve or
tube.
NOTE: There are two alignment pins (6, Figure 3), one
on each side of reduction gearbox flange.

Figure 3

Swing Reduction Gear SP000249


Page 12
DISASSEMBLY
NOTE: Clean all exterior surfaces of the gearbox before
beginning disassembly.
1. Remove the drain plugs and allow all oil to drain from the
gearbox.

IMPORTANT
Use a clean, dry container (with at least 11 liters, or 2.9
gallons capacity) to catch gear oil. A clean container
allows an evaluation to be made of the used oil. The
presence or relative lack of metal wear shavings in the
used oil or obvious deterioration or contamination of
the oil can provide a useful indicator of the motors Figure 4
general condition.

2. Remove the socket cap screws that hold the cover to the
gearbox housing. Remove the cover from the housing.
3. Remove the sun gear.
4. Thread an eye bolt into each of the three shafts that
support the 1st level planetary gears. Loop lifting straps
through the eye bolts and lift the planetary gears and the
first planetary mounting plate out of the gearbox.
5. Slide sun gear off the shaft and out of the gearbox.

Figure 5

6. Thread an eye bolt into each of the three shafts that


support the planetary gears. Loop lifting straps through the
eye bolts and lift the gear housing assembly out of the
gearbox.

Figure 6

SP000249 Swing Reduction Gear


Page 13
7. Use a flat tipped punch to drive the spring pin back into the
shaft, so that the shaft can be pulled out of the gear
housing. Drive back the spring pins on the other two shafts.

Figure 7

8. Hold the planetary gear and thrust plate with one hand and
slide the gear shaft out of the housing. Use this method to
remove the two remaining gear shafts, gears, and thrust
plates.
Use the punch to drive the spring pins out of the shafts.
Use new spring pins when assembling the gearbox.

Figure 8

9. Sealant has been applied to the joint where the ring gear
and the gear case meet. It will be necessary to pry the ring
gear from the gear case, to separate the two parts.

Figure 9

10. Use a screwdriver to pry the snap ring from the output side
of the gear case.

Figure 10

Swing Reduction Gear SP000249


Page 14
11. Insert the gear case into a hydraulic press. Position the
gear case so that the input end of the shaft is facing up.
Insert a metal spacer into the bore of the shaft. Press down
on the shaft until the shaft, with the spacer, plate, and roller
bearing attached, is pressed out of the gear case.

Figure 11

12. Reach into the gear case and remove the roller bearing.

Figure 12

13. Use a hammer and a screwdriver to drive the seal out of


the gear case.
NOTE: It is only necessary to disassemble the shaft
when one of the shaft components is damaged
(bearing, spacer, etc.) and needs replacement.

Figure 13

SP000249 Swing Reduction Gear


Page 15
14. Set the shaft down into a metal pipe that has an inside
diameter of 145 mm. The pipe should contact the bearing
inner race only. Place a metal spacer on top of the shaft.
Use a hydraulic press to press down on the spacer until the
bearing is free of the shaft. Slide the shaft spacer, plate,
bearing and bearing spacer off the shaft.
15. Use a nonflammable, nontoxic solvent to clean all gearbox
parts. Dry the parts with compressed air. Inspect all parts
before assembly. Replace any parts that show damage or
obvious signs of wear.

Figure 14

Swing Reduction Gear SP000249


Page 16
ASSEMBLY

Shaft and S/R Bearing Shrinkage Fitting


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

Figure 15

Figure 16

SP000249 Swing Reduction Gear


Page 17
Figure 17

3. Lift the bearing when the temperature of the heater


reaches 90 - 100C (194 - 212F) and put it into the shaft
with both hands holding it horizontally. To do so, insert it
slowly about 4 to 5 mm that the bearing takes its seat by
itself and then push it with force that it sticks to the spacer
assembled into the shaft.

Figure 18

Swing Reduction Gear SP000249


Page 18
Figure 19

4. After completing the assembly of the bearing, allow the


bearing to air dry for one to two hours.

Figure 20

Assembly of the Carrier Subassembly

Washing of the Carrier


Use a dipping washer to wash the carrier which was got rid of
burr through a corner end finishing (shaping) process, check
again if foreign substance is removed completely, and put it on
the assembly die.

Washing of Planet Gears


Check if planet gears are washed well and have any dent and
put them on the assembly die.

SP000249 Swing Reduction Gear


Page 19
Assembly of the Carrier Subassembly 1
1. Put the carrier No.1 on the assembly jig as shown in the
figure below.

Figure 21

2. Put the pin assembly No.1 on the pin hole correctly and
insert it with a press.

Figure 22

Figure 23

Swing Reduction Gear SP000249


Page 20
3. After its pressure insert, check its state visually.

Figure 24

4. Insert the pin assembly 1 in the 3 remaining parts with a


pressure in the same way.

Figure 25

5. Turn over the carrier in which the pin is inserted and put the
thrust washer No.1 on 4 pins as shown in the figure below.

Figure 26

SP000249 Swing Reduction Gear


Page 21
Figure 27

6. Assemble the planetary gear No.1.

Figure 28

7. Put thrust washer No.3 as shown in the figure below.

Figure 29

Swing Reduction Gear SP000249


Page 22
8. Engage the snap ring (for 40 axis) to each thread of the
pin 1 and turn the gear to check if it rotates smooth.

Figure 30

Figure 31

Assembly of the Carrier Subassembly 2


1. Put the carrier No.2 on the assembly die as shown in the
figure below.

Figure 32

SP000249 Swing Reduction Gear


Page 23
2. Insert the bush No.2 in the planetary gear No.2 and put the
thrust washer No.2 on it.

Figure 33

Figure 34

3. Hold the gear with both hands and the thrust washer facing
downward, insert it in the carrier, and arrange both gauges
of the carrier and the bush.

Figure 35

Figure 36

Swing Reduction Gear SP000249


Page 24
4. Erect the pin 2 above the pin hole (10) of the gear
inserted carrier that the pin and the spring pin hole of the
carrier are in the line, and push it with a hand or tap it with
a hammer.

Figure 37

Figure 38

5. Assemble the remaining 3 parts in the same way.

Figure 39

6. After the completion of assembling pins, erect the spring


pin (10x25L) above the hole 10 of the carrier, and push
it inside with a hammer and then a caulking punch.

Figure 40

SP000249 Swing Reduction Gear


Page 25
Figure 41

7. Use a caulking punch to tap three areas around the spring


pin hole.

Figure 42

Figure 43

8. Assemble the 3 remaining parts in the same way and turn


the gear to check if it rotates smooth.

Figure 44

Swing Reduction Gear SP000249


Page 26
Assembly of Main Case

Washing of the Casing and Other Components


Use supersonic waves to wash out foreign substance remaining
on the casing and other components mentioned in the Parts List
after casting and processes.
Cleaning fluid: PK6540 (alkali)
Liquid density: 3 - 5%
Liquid temperature: 60 - 70C (140 - 158F)

Assembly of the Shaft and the Pinion


1. Press fitting of the shaft subassembly
Pun the washed casing as shown in the figure below and
use a hoist to put shaft subassembly in the area to be
inserted. Bearing kept horizontal, put the specific jig to
insert it into the press table, and use a press to fit it into the
casing.

Figure 45

Figure 46

Figure 47

SP000249 Swing Reduction Gear


Page 27
Figure 48

2. Remove the bearing press fitting jig and assemble the


plate with its stepped part facing downward.

Figure 49

Figure 50

3. Insert the lock ring into the groove in the casing.

CAUTION!
Care should be taken not to have drive shaft drop to
floor when it is pressed out of case.

Figure 51

Swing Reduction Gear SP000249


Page 28
Figure 52

4. Insert the collar in the shaft, keep it horizontal, put the


piston on it, put the press fitting jig on it, and use a press to
insert it.

Figure 53

Figure 54

5. Put the lock plate on it, engage the bolt applied Loctite
#262 (M16x40, torque: 2,700 kgfcm), and complete the
procedure by tying it with wire as shown in the figure below.

Figure 55

SP000249 Swing Reduction Gear


Page 29
Figure 56

Figure 57

Figure 58

Figure 59

Swing Reduction Gear SP000249


Page 30
Figure 60

Figure 61

Figure 62

SP000249 Swing Reduction Gear


Page 31
Assembly of the Seal and the Bearing
1. Put the assembled casing in the turnover machine and turn
it over.

Figure 63

Figure 64

2. Check if there is any foreign substance on the seal


assembly, apply grease and Loctite #609 to the seal and
the outside of the oil seal (TC5001300), respectively, push
it into the case while keeping it horizontal, put the seal
press fitting jig, and use a press to insert it.

CAUTION!
Take care to prevent contamination by foreign substance
or damage to the lip area, and check the press fitting of the
seal visually. Figure 65

Figure 66

Swing Reduction Gear SP000249


Page 32
Figure 67

Figure 68

Figure 69

Figure 70

SP000249 Swing Reduction Gear


Page 33
Figure 71

Figure 72

3. Put out the inner part of the prepared bearing (23024CD)


and assemble them again that its trade mark is visible,
insert it in the shaft as shown in the figure below, put the
bearing press fitting jig on it, and use a press to insert it.

Figure 73

Figure 74

Swing Reduction Gear SP000249


Page 34
Figure 75

Figure 76

4. Hold the pinion with both hands and turn it to check if it


rotates smooth.

Figure 77

5. Insert plugs in the PT3/8 and PT1/8 taps of the drain port.

Figure 78

SP000249 Swing Reduction Gear


Page 35
Figure 79

Figure 80

Assembly of the Ring Gear


1. Press fitting of the lock pin
Insert lock pins (13 x 31.5) in 4 reamer holes of the
casing and use a hammer to tap them.

FG000936
Figure 81

FG000937
Figure 82

Swing Reduction Gear SP000249


Page 36
2. Apply liquid gasket (Three Bond 1104) to the area where
the ring gear of the casing is assembled.

FG000938
Figure 83

3. Use a hoist to lift the prepared ring gear, wipe the


Aim at holes.
assembled part with a cloth, put it on the hole considering
its assembly direction, tighten specific bolts (M16 x 160), to
which Loctite is not applied, in the symmetrical order, and
be sure that the assembled parts are pressed each other
completely.

FG001353
Figure 84

Figure 85

SP000249 Swing Reduction Gear


Page 37
Assembly of the Carrier
1. Use a hoist to lift the prepared No.2 carrier assembly and
turn it clockwise or anticlockwise lightly for it to engage with
the spline of the ring gear and the shaft naturally. Use a
rubber hammer to tap the top of the carrier that it sticks to
the bearing during the assembly.

Figure 86

FG000942
Figure 87

Figure 88

2. Insert the sun gear No.2 in the middle of the carrier No.2 as
shown in the figure below and put the thrust plate on it.

Figure 89

Swing Reduction Gear SP000249


Page 38
Figure 90

3. Put the prepared carrier assembly No.1 on the assembling


part and turn it clockwise or anticlockwise lightly for it to
engage with the low toothed shaft end of the ring gear and
the sun gear No.2.

Figure 91

Figure 92

4. Insert the sun gear No.1 in the middle of the carrier No.1.

Figure 93

SP000249 Swing Reduction Gear


Page 39
Figure 94

5. Loosen the retaining bolt and apply liquid gasket to the


assembling part.

Figure 95

FG000950
Figure 96

Swing Reduction Gear SP000249


Page 40
Figure 97

6. Lift the cover and check if there remains any foreign


substance, put the level pipe on the hole of the case 11,
and use an impact wrench to tighten bolts (M16x180)
applied Loctite by pulling it to your breast slowly, which
should be repeated once more to ensure its torque after
the first torque engagement is heard. Use a paint marker to
mark the torqued bolts.

FG000954
Figure 98

Figure 99

SP000249 Swing Reduction Gear


Page 41
Figure 100

7. Assemble the plug with caution to prevent the inflow of


foreign substance into the tap (PT1/4) used for the
assembly of the level pipe of the cover during the test.

Figure 101

Swing Reduction Gear SP000249


Page 42
Test

Pneumatic Test
1. After the completion of the cover assembly, engage the
pneumatic test jig as shown in the figure below.

Figure 102

Figure 103

2. Supply air when the pressure gauge indicates 2 kgfcm2


and check if the gauge indicates any change of pressure
for 3 minutes.
3. Finishing the test, release and remove the jig.

Figure 104

SP000249 Swing Reduction Gear


Page 43
Noise and Abnormal Sound Test
1. Upon the completion of the pneumatic test, pour gear oil of
5 into the reduction gear and engage the test motor.

Figure 105

Figure 106

2. Start the motor up to 1400 RPM and use a noise


measuring machine to carefully measure its noise level
which should be below 90 dB and not include abnormal
sound.

Figure 107

Swing Reduction Gear SP000249


Page 44
Figure 108

Assembly of the Motor

Supply of Gear Oil


Upon the completion of the noise test, remove the test motor
and pour gear oil of 2.5 more.

Figure 109

Figure 110

SP000249 Swing Reduction Gear


Page 45
Assembly of the Motor
1. Apply liquid gasket to the assembling part of the cover.

Figure 111

2. Use a hoist to lift the motor, wipe its assembling part with a
clean cloth, check the O-ring of the motor shaft, and
assemble it at the tap of the PT3/4 of the cover with the
brake valve of the motor facing to the left.

Figure 112

Figure 113

Swing Reduction Gear SP000249


Page 46
3. Engage bolts (M16x40, torque: 2,700 kgfcm) applied
Loctite using a L wrench, check the standard torque using
a torque wrench, and mark using a paint marker.

FG000973
Figure 114

Figure 115

Figure 116

SP000249 Swing Reduction Gear


Page 47
4. Engage the plug at the PT3/4 tap.

Figure 117

5. Remove the plug, engage the level pipe sealed with Teflon
tape, and check the oil level.

Figure 118

Figure 119

Swing Reduction Gear SP000249


Page 48
Figure 120

6. Supply of Grease
A. Assemble the caulk in the grease inlet, and put the
nipple to supply grease until it flows out of the
opposite hole.

FG000978
Figure 121

FG000979
Figure 122

SP000249 Swing Reduction Gear


Page 49
B. After the completion of supplying grease, release and
remove the caulk, assemble the plug sealed with
Teflon tape, tighten it with a torque wrench, and finish
the procedure by wiping out grease and other foreign
substance remaining on the surface.

FG000980
Figure 123

FG000981
Figure 124

Figure 125

Swing Reduction Gear SP000249


Page 50
INSTALLATION
1. Coat pinion gear with grease. Refer to operation manual for
specifications.
2. Make sure two alignment pins (6) are installed in flange of
swing reduction gearbox (5).
3. Using a suitable lifting device, sling swing motor (1, Figure
3) and position swing motor and reduction gearbox (5) as
an assembly on unit.
4. Install twelve bolts and washers (4, Figure 3) to secure
swing reduction gearbox (5) to frame.
NOTE: Apply Loctite #262 to bolt threads.
5. Connect tube (2) to drain cock (3) and hose fitting (7) to fill
hole.
6. Connect hoses as tagged during removal to swing motor
(1, Figure 3).
7. Fill swing reduction gearbox with oil. Refer to operation
manual for specifications. Figure 126

SP000249 Swing Reduction Gear


Page 51
Swing Reduction Gear SP000249
Page 52
1Lower Structure and
Chassis
SP000263
TRACK ASSEMBLY SP000263

1Track
Assembly

Edition 1

Track Assembly SP000263


Page 1
MEMO

SP000263 Track Assembly


Page 2
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 ............................................. 30
Track Spring and Track Adjusting Cylinder ........ 32
Under Carrige Track Spring................................ 33
Track Spring Assembly Diagram .................................. 33

Track Assembly SP000263


Page 3
Track Spring Disassembly Diagram .............................. 34
Disassembly of the Track Spring Assembly .................. 35
Assembly of the Track Spring ....................................... 37

SP000263 Track Assembly


Page 4
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.

MODEL SERIAL NUMBER RANGE


DX420LC 5001 and Up

SP000263 Track Assembly


Page 5
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

Track Assembly SP000263


Page 6
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
DX420LC
Normal "B" 380 - 430 mm
(14.96 - 16.93 in)
Minimum "C" 380 mm
(14.96 in)
Muddy "D" 430 - 460 mm
(16.93 - 18.11 in)
Gravel, Rocky, Sand or 460 mm
Snow "E" (18.11 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.

SP000263 Track Assembly


Page 7
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

Track Assembly SP000263


Page 8
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.

The tables that follow provide factory specified dimensional


limits (as new condition, recommended service and replacement
limit) for lower travel frame components.
Recommended maintenance to renew most listed components
requires welding on additional material and grinding off excess.
Some components must be replaced before the service limit is
exceeded. No maintenance or renewal is possible.
Compare the values in the tables with dimensions and profiles
shown in the adjacent figures.

SP000263 Track Assembly


Page 9
Track Shoe

8 10

7
2 11
9

1
3
6

4 5
FG004347
Figure 4

Track Assembly SP000263


Page 10
Limit for Use
Recommended Limit for
No. Check Item Standard Dimension (Repair - P or
Maintenance
Replace - R)
215.9 mm
1 Link Pitch
(8.50")
Bushing Outside 71.0 mm 68.0 mm 66.0 mm [R]
2
Diameter (2.80") (2.68") (2.60")
129 mm 126 mm 122 mm [P]
3 Link Height
(5.08") (4.96") (4.80")
24 mm
4 Length at Tip
(0.94")
18 mm
5 Length at Tip
(0.71")
36 mm 32 mm 30 mm
6 Height
(1.42") (1.26") (1.18")
Standard Tolerance Standard Repair
Interference between Dimension Shaft Hole Interference Limit
7
bushing and link 71.0 mm +0.344 +0.074
0.23 - 0.344
(2.80") +0.304 0.0
Standard Tolerance Standard Repair
Interference between Dimension Shaft Hole Interference Limit
8
regular pin and link 47.0 mm +0.235 -0.138
0.303 - 0.435
(1.85") +0.165 -0.20
Standard Tolerance Standard Repair
Clearance between Dimension Shaft Hole Interference Limit
9
regular pin and bushing 47.0 mm +0.235 +1.0
0.165 - 0.835
(1.85") +0.165 +0.4
Standard Tolerance Standard Repair
Interference between Dimension Shaft Hole Interference Limit
10
master pin and bushing 47.0 mm +0.235 +1.0
0.165 - 0.835
(1.85") +0.165 +0.4
Standard Tolerance Standard Repair
Clearance between Dimension Shaft Hole Interference Limit
11
master pin and bushing 47.0 mm +0.11 +1.0
0.29 - 0.92
(1.85") +0.08 +0.4

*Check and record the pitch of at least 5 links. Use average of all
measruements to assess requried service ar action. Master links
must be replaced, they cannot be renewed or rebuilt.

SP000263 Track Assembly


Page 11
Lower Roller

3 4

1
FG004351
Figure 5

Limit for Use


Recommended Limit for
No. Check Item Standard Dimension (Repair - P or
Maintenance
Replace - R)
Outside Diameter of 250 mm
1
flange (9.84")
Outside Diameter of 200 mm 194 mm 190 mm [P]
2
Tread (7.87") (7.64") (7.48")
54.6 mm 64 mm 71 mm [P]
3 Width of Tread
(2.15") (2.52") (2.80")
34.4 mm
4 Width of Flange
(1.35")
Standard Tolerance Standard Repair
Clearance between Dimension Shaft Hole Interference Limit
5
shaft and bushing 85 mm 0 +0.370 1.8 mm [R]
0.300 - 0.405
(3.35") -0.035 +0.300 (0.07")
Standard Tolerance Standard Repair
Interference between Dimension Shaft Hole Interference Limit
6
roller and bushing 92 mm +0.132 +0.035
0.067 - 0.132
(3.62") +0.102 0

Track Assembly SP000263


Page 12
Upper Roller

4 3

1
FG004352
Figure 6

Limit for Use


Recommended Limit for
No. Check Item Standard Dimension (Repair - P or
Maintenance
Replace - R)
Outside Diameter of 210 mm
1
flange (8.27")
Outside Diameter of 180 mm 171 mm 162.5 mm [P]
2
Tread (7.09") (6.73") (6.40")
47.5 mm
3 Width of Tread
(1.87")
17.5 mm 11.5 mm
4 Width of Flange
(0.69") (0.45")
Standard Tolerance Standard Repair
Clearance between Dimension Shaft Hole Interference Limit
5
shaft and bushing 60 mm 0 +0.45
0.40 - 0.50
(2.36") -0.05 +0.40
Standard Tolerance Standard Repair
Interference between Dimension Shaft Hole Interference Limit
6
roller and bushing 68 mm +0.132 +0.035
0.067 - 0.132
(2.68") +0.102 0.

SP000263 Track Assembly


Page 13
Front Idler

4
3 5

1
2

FG000510
Figure 7

Limit for Use


Recommended Limit for
No. Check Item Standard Dimension (Repair - P or
Maintenance
Replace - R)
Outside Diameter of 640 mm
1
flange (25.2")
Outside Diameter of 590 mm 578 mm
2
Tread (23.23") (22.76")
102 mm
3 Width of Protrusion
(4.02")
203 mm
4 Total Width
(7.99")
50.5 mm 56 mm
5 Width of Tread
(1.99") (2.20")
Standard Tolerance Standard Repair
Clearance between Dimension Shaft Hole Interference Limit
6
shaft and bushing 94 mm 0 +0.515 +0.461
(3.74") -0.035 +0.415 +0.256
Standard Tolerance Standard Repair
Interference between Dimension Shaft Hole Interference Limit
7
roller and bushing 105 mm +0.159 +0.035
0.089 - 0.159
(4.13") +0.124 0

Track Assembly SP000263


Page 14
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 FG003982
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

8. Rotate upper structure to 90 from track. Use bucket and


boom to raise track frame off track.
9. Position blocking under frame.

90 ~ 110

FG000345
Figure 10

SP000263 Track Assembly


Page 15
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

4. Move unit forward while feeding track up over drive


sprocket. Continue to pull track back until it engages front
idle roller.

FG003912
Figure 12

5. Align master links and install master pin.


6. Insert new lock pin in master pin. Bend end of pin over so it
is pointing in opposite direction of other end as shown.
7. Apply track tension. Refer to "Track Tension" in this 4
section for procedure. 3
1
2

FG003982
Figure 13

Track Assembly SP000263


Page 16
SP000263 Track Assembly
Page 17
FRONT IDLER ROLLER

Parts List

2
8
7
5

3
4

6 5
8 7

FG004357
Figure 14

Track Assembly SP000263


Page 18
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

Front Idler Roller Disassembly


1. Remove plug (9, Figure 15) from roller assembly (3), and
drain into a suitable container.

9
3
FG004358
Figure 15

2. Separate the pin (6, Figure 16) from the bearing (3).

3
FG004359
Figure 16

3. Use a press to remove the bearing from the axle (4).


Separate the O-ring (8, Figure 17) from the axle.
1 8
4

FG004360
Figure 17

SP000263 Track Assembly


Page 19
4. Detach the floating seal (7, Figure 18) from the idler (2)
and bearing (3). 3
7
2

3
FG004361
Figure 18

5. Use a press to separate the axle (4, Figure 19), O-ring (8)
and bearing (3).
8
3

FG004362
Figure 19

6. Remove bushing (5, Figure 20) with the press and special
tool.
10 5 2

FG004363
Figure 20

Front Idler Roller Reassembly 4


3
1. Degrease, clean and dry all parts before reassembly. Insert 8
bushing (5, Figure 20) into the idler (2). 6
2. Grease O-ring (8, Figure 21) and insert it into the axle.
3. Align the bearing (3, Figure 21) and axle (4) holes and pin
(6) them together.

8
FG004364
Figure 21

Track Assembly SP000263


Page 20
4. Install floating seal (7, Figure 22) inside the idler (2) and
bearing (3). 3
7
NOTE: Apply clean engine oil to the joint side of the 2
floating seal. Apply grease to the floating seal
O-ring.

3
FG004361
Figure 22

5. Install idler (2, Figure 23) on the axle.


6. Install bearing (3, Figure 23) and pin (6) to the axle.
NOTE: Fill the idler assembly with new engine oil with 9
approximately 450 cc (15.2 oz). 2

7. Install plug (9, Figure 23) on the idler.


6

FG004365
Figure 23

SP000263 Track Assembly


Page 21
LOWER ROLLER

Parts List

5
2 8

7
6

8 7

2 FG004392
Figure 24

Track Assembly SP000263


Page 22
Reference Reference
Description Description
Number Number
1 Roller 5 Pin
2 Collar 6 Floating Seal
3 Shaft 7 O-ring
4 Bushing 8 Plug

Lower Roller Removal


1. Relieve track tension. Refer to "Track Tension" in this
section for procedure.
2. Swing upper structure at 90 to frame. 90 ~ 110
3. Using bucket raise track off ground and place blocking
under frame.
4. Remove four bolts and lower roller assembly from track
frame.
FG000345
NOTE: To gain access to some rollers the link guard
Figure 25
may have to be removed. Remove four spring
washers and bolts to remove guard.
NOTE: If additional track clearance is required, remove
upper rollers before raising track.

Lower Roller Disassembly


1. Remove plug from the collar and drain oil.
2. Pull the pin (5, Figure 26) from the collar. 5

2 FG004366
Figure 26

SP000263 Track Assembly


Page 23
3. Separate the collar (2, Figure 27) from the axle, using
press.
2

'(
Figure 27

4. Detach O-rings (7, Figure 28) from the axle.


1
5. Separate floating seals (6, Figure 28) from the collar and
roller (1). 6
6. Detach collar (2, Figure 28) and O-rings (7) from the axle, 2
using press.

2
6

7 FG004393
Figure 28

Lower Roller Reassembly


1. Degrease, clean and dry all parts before reassembly. Insert
bushing (4, Figure 29) into roller.
4

FG004396
Figure 29

2. Apply grease to the O-rings (7, Figure 30) and insert into
axle. 5

3. Align collar (2, Figure 30) and axle (3) pin holes and pin (5) 7
the collar. 3 2

FG004397
Figure 30

Track Assembly SP000263


Page 24
4. Insert floating seals (6, Figure 31) into the roller (1) and
1
collar (2).
NOTE: Apply clean engine oil to the joint side of the 6
floating seal. Apply grease to the floating seal
O-ring. 2

5. Slide the axle inside the roller.

2
6

7 FG004393
Figure 31

6. Install the collar (2, Figure 32), O-ring (7, Figure 31), and
pin (5) on the remaining side.
7. Fill with new engine oil with approximately 450cc (15.2 oz).
5
8. Install plug (8, Figure 32) on the collar.

2 FG004366
Figure 32

Lower Roller Installation


1. Install four bolts to hold lower roller assembly to track
frame.
NOTE: To gain access to some rollers a link guard may 90 ~ 110
have to be removed. Remove four spring
washers and bolts to remove guard.

FG000345
Figure 33

SP000263 Track Assembly


Page 25
UPPER ROLLER

Parts List

8
3

1
7

5
11

12

10

13

14

'(
Figure 34

Track Assembly SP000263


Page 26
Reference Reference
Description Description
Number Number
1 Roller 8 O-ring
2 Shaft 9 Plug
3 Thrust Ring 10 Cover
4 Bushing 11 Washer
5 Bushing 12 Bolt
6 Floating Seal 13 Blot
7 O-ring 14 O-ring

Upper Roller Removal


1. Relieve track tension. This will allow track to be raised so
that links clear top of roller.
2. Position a bottle jack on top of track frame and apply
pressure to track shoe.
3. Remove mounting hardware holding upper roller assembly
to track frame.

FG005127

Figure 35

Upper Roller Disassembly


1. Remove the plug (9, Figure 36) from the cover and drain
oil.

FG004400
Figure 36

SP000263 Track Assembly


Page 27
2. Remove the bolts (13, Figure 37) and cover (10). Detach o-
ring (14), bolts (12) and washer (11).

11
12
10

13

14
FG004404
Figure 37

3. Separate the roller (1, Figure 38) from the axle (2).
2
1

FG004406
Figure 38

4. Separate the floating seal (6, Figure 39) from the roller and
coller(1). 6
1

FG004409
Figure 39

5. Separate the O-ring (8) and thrust ring (3) from the axle(2).

3 8

FG004411
Figure 40

Track Assembly SP000263


Page 28
6. Separate the bushing (4 and 5, Figure 41) from the roller
with a press.
ST-1919

FG001502
Figure 41

SP000263 Track Assembly


Page 29
Upper Roller Reassembly
1. Degrease, clean and dry all parts before reassembly. Insert
1
bushing (4 and 5, Figure 42) into the roller (1).

5
4

FG004419
Figure 42

2. Insert floating seal (6, Figure 43) into the roller (1) and
coller. 6
NOTE: Apply clean engine oil to the joint side of the 1
floating seal. Apply grease to the floating seal
O-ring.

FG004409
Figure 43

3. Install the axle, washer (11, Figure 44) and bolt (12).
4. Insert the O-ring (8, Figure 44) to the cover.
Attach cover (10) and bolt (13) to the roller. 11
5. Fill with new engine oil with 600cc (20.3 oz). 14 12
6. Tighten plug (9, Figure 44). 10

13

9 FG004427
Figure 44

Track Assembly SP000263


Page 30
SP000263 Track Assembly
Page 31
TRACK SPRING AND TRACK
ADJUSTING CYLINDER

FR
11 ON
12 T
10
6

13

14

15

7
8
9

FG004444
Figure 45

Track Assembly SP000263


Page 32
Reference Reference
Description Description
Number Number
1 Body 9 Dust Seal
2 Bracket 10 Plate
3 Rod 11 Bolt
4 Spring 12 Spring Washer
5 Tie Bar 13 Stopper
6 Nut 14 Spring Pin
7 Rod Packing 15 Body Assembly
8 Backup Ring

UNDER CARRIGE TRACK


SPRING

Track Spring Assembly Diagram

Figure 46

SP000263 Track Assembly


Page 33
Track Spring Disassembly Diagram

Figure 47

Reference Reference
Description Description
Number Number
1 Bolt 8 Spring Pin
2 Lock Plate 9 Body
3 Lock Nut 10 Rod Packing
4 Bracket 11 Back up Rinf
5 Spring 12 Dust Seal
6 Sotpper 13 Rod
7 Tie Bar

Track Assembly SP000263


Page 34
Disassembly of the Track Spring
Assembly

CAUTION!
The track spring assembly is assembled with strong force
that more care should be taken for its disassembly.

1. Use a 27 mm spanner to remove the grease valve from the


rod (13).

CAUTION!
When supplying air, the operator should stand beside,
not behind, the rod for it may be sprung forth suddenly
with a blasting sound.

Figure 48

2. Use a flat driver to remove from the body (9) the dust seal
(12), the back up ring (11), and the rod packing (10), which
should be replaced with new ones because they cannot be
reused.

Figure 49

SP000263 Track Assembly


Page 35
CAUTION!
Remember that spring has a very high elasticity that it
might be sprung forth during assembly or
disassembly.

3. Recommended load of press is higher than 28 ton.


4. Compress the track spring slowly until the lock nut (3) has
clearance of more than 10 mm from the bracket (4)

CAUTION!
The lock nut (3) can be removed easily by means of
heating, as it is attached with a special adhesive.

5. After removing the bolt (1), the lock plate (2), and the lock
nut (3), release the load of the press to separate the
bracket (4), the spring (5), the stopper (6), and the body
assemblies (7, 8, 9).

Figure 50

CAUTION!
When using a spanner, nuts should be tightened in a
zigzag pattern that force can be spread evenly.

Track Assembly SP000263


Page 36
CAUTION!
Take care not to damage the inside of the body and
screw threads after the disassembly of the tie bar.

Figure 51

6. Use a 10 drill to remove the spring pin (8) retaining the tie
bar (7) and the body (9).
7. Disassemble the tie bar (7) and the body (9) after oxygen
heating them, as they are attached with a special
adhesive.
8. Check and remove rust or damage in the body (9).

Assembly of the Track Spring

CAUTION!
Take care not to damage the inside of the body and screw
threads after the disassembly of the tie bar.

Figure 52

SP000263 Track Assembly


Page 37
1. Erect the body and engage the tie bar by 390 mm after
checking the presence of any foreign substance in screw
threads of the tie bar (7) and the body (9).
2. It may not be used unless there is a special adhesive
(Loctite 277 threadlocker) available.
3. Use a drill a hole, 10 and 60 mm deep, in the tie bar (7)
and the body (9) and insert the spring pin (8) in it.
4. Seat the bracket (4) in the press.
5. Insert the spring (5) and the stopper (6) in the body
assembly, which shall be seated in the press.
6. Apply pressure to the press slowly.

CAUTION!
When applying pressure, make sure that the tie bar is
set to the hole of the bracket properly, or its screw
thread may be damaged.

7. Continue pressure until the clearance between the bottom


of the bracket and the end of the body is 965 mm.
8. Apply the adhesive (Loctite 277 threadlocker) to the lock
nut and bolt it on the lock plate.

CAUTION!
When tightening the bolt, it should be torqued at
within 18.0 2.0 kg m.

Figure 53

CAUTION!
Remember that spring has a very high elasticity that it
might be sprung forth during assembly or
disassembly.

Track Assembly SP000263


Page 38
Figure 54

CAUTION!
Remember that spring has a very high elasticity that it
might be sprung forth during assembly or
disassembly.

9. Make sure that, after the assembly, the range of the right
angle made by the bracket floor and the external side of
the body should be within 3 mm.

CAUTION!
If the range is poor, eccentric driving and/or earlier
wear of the idler may occur.

CAUTION!
Safety precaution should be followed, as the track
spring ass'y is the system assembled with strong
force.

10. Wash out the inside of the body and apply grease in the
body evenly.
11. Insert the back up ring (3) and press outward.
12. Bend the rod packing and insert it into the back up ring.

SP000263 Track Assembly


Page 39
13. Seat the dust seal (3) on the body and use a hammer to
tap it to stick it.
14. Apply grease in the body and carefully push the rod
completely.
15. Use a 27 mm spanner to install the grease valve and
supply grease.
16. Release the grease valve a little, push the rod with full
force to remove air completely, and tighten it again.

CAUTION!
If air is not removed completely, air explosion due to
load may damage the rod packing.

Track Assembly SP000263


Page 40
SP000025
AIR CONDITIONER SP000025

Air Conditioner

Edition 1

Air Conditioner SP000025


Page 1
MEMO

SP000025 Air Conditioner


Page 2
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
Relay - Blower ............................................................... 15
Relay - A/C .................................................................... 15
Duct Sensor................................................................... 15
Water Temp Sensor ...................................................... 16
Internal Air Temp Sensor .............................................. 16
Ambient Air Temperature Sensor.................................. 16
Sun Sensor.................................................................... 17
Control Panel................................................................. 17
Compressor................................................................... 25
Receiver Dryer .............................................................. 25
Troubleshooting .................................................. 26
Weight of R134a Gas Used In Machines ........... 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

Air Conditioner SP000025


Page 3
MEMO

SP000025 Air Conditioner


Page 4
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.

MODEL SERIAL NUMBER RANGE


DX300LC 5001 and Up
DX340LC 5001 and Up
DX420LC 5001 and Up
DX480LC 5001 and Up
DX520LC 5001 and Up

SP000025 Air Conditioner


Page 5
AIR CONDITIONER SYSTEM

Outline

A
C

FG000784
Figure 1

Solid-type heater and air conditioner are installed in the cover


behind the driver's seat.
Temperature of the driver's room is adjusted automatically to the
temperature set by operator.

Air Conditioner SP000025


Page 6
(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

Internal and External Filters


Internal and external air purification filters are installed for the
driver's room.
Filters should be cleaned every 500 hours.
If machine operates in an excessively contaminated
environment, filters should be cleaned more frequently and if
necessary, replaced with new ones.

How to check Indoor air filter


1. Press both levers on the left and right side at the top of the
filter installed at the rear of the driver's seat.

FG000422
Figure 2

How to check outdoor air filter


1. Open the front door at the left side of machine and loosen
four marked bolts to remove the cover (1, Figure 3).
1
TOP

Donaldson.

FG000440
Figure 3

SP000025 Air Conditioner


Page 7
2. Turn marked knobs (1, Figure 4) at the rear side of the
cabin to open the cover.

FG000441
Figure 4

3. Remove the filter attached to the cover and clean the


contaminated filter using compressed air.
4. Close the cover, replace the knobs, and secure the cover
to the support with butterfly bolts.

FG000342
Figure 5

Air Conditioner SP000025


Page 8
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

SP000025 Air Conditioner


Page 9
Air Conditioner/Heater Circuit Diagram

0.5RW

FUSIBLE LINK
LAMP SWITCH

20A STARTER SWITCH


BATTERY RELAY

A/C CONTROL PANEL AIRCON UNIT BATT.


1.25LR CN11-2 42C 24V
LED 1~12 130C CN9-6
0.85LR CN10-8 42D
54E CN9-11 0.5WR
CN10-18 46B
ILL 42B CN9-5 1.25LR
0.85BW
0.85LR
RECEIVER DRIER
BLOWER A/C
42E 46A
RELAY RELAY
COMPRESSOR
168B CN8-10 0.5LG CN10-16 168A

A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A CN11-4 0.85LW 47C

106B CN8-11 CN10-6 106A 47A 47B


0.5LY
FET

DIODE 4
1.25B CN11-1 99 - +
M
107B CN8-12 0.5LW CN10-1 107A 0.85B 0.85B
BLOWER

108A CN9-13 0.5GrG CN10-2 108B FRE (P1)


INTAKE
109A CN9-12 0.5GrY CN10-20 109B REC (P2) ACTUATOR
M

110A CN9-15 0.5OrR CN10-12 110B DEF (P1)


111A CN9-14 0.5OrW CN10-13 111B VENT (P2)
M
MODE
43A CN9-16 0.5YB CN10-11 43B Vref MODE
ACTUATOR
44A CN9-17 0.5YW CN10-10 44B MODE F/BACK

99 CN9-10 1.25B

112A CN9-1 0.5LgW CN10-19 112B WARM (P1)


113A CN9-18 0.5LgB CN10-3 113B COOL (P2)
M
114A CN9-3 0.5YR CN10-7 114B Vref MIX Temp. Control
115A CN9-4 0.5YW CN10-9 115B MIX F/BACK ACTUATOR
167C CN9-2 1.25BL CN10-4 167A GND

116A CN8-2 0.5OrB CN10-15 116B


DUCT
SENSOR

45A CN8-1 0.5LgR CN10-14 45B


WATER
SENSOR
2
48A CN8-5 0.5LY CN10-17 48B 1 INCAR
SENSOR
SUN LOAD SENSOR

0.5Lg 2 - + 1 CN10 AMP 20P CN11 KET 4P


142A CN8-3
142B 0.5YR
114C 0.85BL 167B 2
49A CN8-4 0.85YG 0.85YG 49B 1 AMBIENT TEMP
SENSOR
CN8 CN9
AMP 18P + 12P

AMP 040-III 20P


KET 4P AMP 070 18P AMP 070 12P
2 1 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 5 4 3 2 1

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

(CN11) (CN10) (CN9) (CN8)

FG000781
Figure 7

Air Conditioner SP000025


Page 10
Air Conditioner/Heater Unit

Air Flow Diagram

External Air Inlet

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

Heater Evaporator Fan


Core
FOOT
FG001359
Figure 8

SP000025 Air Conditioner


Page 11
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

Air Flow Actuator


Duct Blower Blower
Control - Internal/external
Actuator A/C Sensor Relay Motor
Module Air Exchanger
- Temp Relay
Control

Internal
Internal Air Sensor
Air Filter
Actuator Water Temp Evaporator
-Wind Direction Sensor FG001360
Control
Figure 9

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.
Actuator - Temp control: Change of discharged air temperature
by controlling the position of temp control door.

Air Conditioner SP000025


Page 12
FG001361
Figure 10

Actuator - Wind direction control

Wind Direction Mode Output Terminal Voltage


Vent 0.5 0.2V
Bi-level 1.3 0.2V
c(+): CN10-10
Foot 2.45 0.2V
b(-): CN10-4
Foot/def 3.5 0.2V
Def 4.5 0.2V

Actuator - Temp control

Set Temp Output Terminal Voltage


Max cooling c(+): CN10-9 Below 0.4V
Max heating b(-): CN10-4 Above 4.5V

SP000025 Air Conditioner


Page 13
Actuator - Internal/external air exchange

CN10-20 CN10-2

FG001055
Figure 11

Sel mode Output Terminal Output


Internal Air Moving of exchange door
P1(+), P2(-)
by selecting external air
External Air Moving of exchange door
P1(-), P2(+)
by selecting internal air

Air Flow Control Module


Air flow is controlled through the control of voltage between
GATE and SOURCE.

DRAIN
(CN10-1)

SOURCE GATE
(CN11-1) (CN10-6)

FG001056
Figure 12

Air flow Output Terminal Output


1st 10 0.5V
2nd 12.5 0.5V
3rd 15 0.5V
4th CN11-2 CN10-1 17.5 0.5V
5th 20.0 0.5V
6th 22.0 0.5V
7th More than 25V

Applied voltage: Standard voltage is 27.5V.

Air Conditioner SP000025


Page 14
Basically, air flow is set manually.
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) Resistance (K)


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

SP000025 Air Conditioner


Page 15
Water Temp Sensor
It senses the temperature of coolant water in the heater core.

Temp (C) Resistance (K)


-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

Internal Air Temp Sensor


Built in the internal air filter, it senses the internal temperature.

Temp (C) Resistance (K)


-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

Ambient Air Temperature Sensor


Built at the bottom of the cockpit, it senses the temperature of
external air.

Temp (C) Resistance (K)


-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

Air Conditioner SP000025


Page 16
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

1.0 2.0 3.0 4.0 5.0 6.0 7.0


LUX(x10,000)
FG001062
Figure 19

Control Panel

Appearance and Terminal Arrangement

A/C OUTSIDE
AUTO A/C
AUTO MAX

TEMP

OFF
SEL MODE

AMP 070 18P AMP 070 12P


8 7 6 5 4 3 2 1 5 4 3 2 1

18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6

(CN9) (CN8) FG001063


Figure 20

Refer to "Air Conditioner and Heater" of operation manual.

SP000025 Air Conditioner


Page 17
Terminal Terms

CN Term No. Terms CN Term No. Terms


1 Temp control (warm) 1 Water temp sensor
2 Sensor earth 2 Duct sensor
3 Temp control Power 3 Sun sensor
(5V)
4 Mix feedback 4 Ambient air temp sensor
5 Power (KEY ON) 5 Internal air temp sensor
6 Back-up 6 -
CN8
7 - 7 -
8 A/C output (LOW) 8 -
9 - 9 -
10 Earth 10 D.P.S CHECK
CN9 11 Light 11 Air flow module (gate)
12 External/internal air 12 Blower motor (feedback)
(Ex.)
13 External/internal air (In.)
14 Wind direction control
(VENT)
15 Wind direction control
(DEF.)
16 Wind direction control
Power (5V)
17 Wind direction control
(feedback)
18 Temp control (cool)

Control Logic

Categories Inputs System Operation


AUTO Set Temp 1. Automatically adjust room temp as set and then next items.
Internal air temp sensor Temp/wind direction/internal, external air/air flow/
compressor.
Ambient air temp sensor
2. Auto mode is released when manually setting any switch
Water temp sensor
except.
Sun sensor
Temp Control switch in Auto mode.
3. Upon the releasing of Auto mode, all of functions except
selected switch are controlled automatically.

Air Conditioner SP000025


Page 18
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: 25C Ambient air temperature
sensor: 25C, Duct sensor: -2C.
Ambient air temp sensor
Temp control actuator:
Water temp sensor
- Set Temp 17 - 24.5C: Max cooling, Set Temp 25 - 32C:
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 32C: Max heating
heating
Auto Setting 2. Set Temp 17C: Max cooling
control

Max Cooling (17 C) Max Heating (32 C)

Temp Control
FULL COOL FULL HOT
Actuator

Air Flow MAX HI AUTO HI

Compressor Forced ON OFF

Intake/Recircle Recircle Intake

Wind Direction Mode VENT FOOT

* Max cooling/heating control is possible only in Auto mode.

SP000025 Air Conditioner


Page 19
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 30C
(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.

Air Conditioner SP000025


Page 20
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 <
73C
(3) Air flow: Auto mode
(4) Set temp > Internal air temp + 3C
* 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 4. Air flow is controlled only when the wind direction is in the
heater (1) Auto mode
manual mode and BI-LEVEL, FOOT, or FOOT/DEF is set.
Set Temp
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 (17C) is selected.
(4) Water temp sensor > 73C

SP000025 Air Conditioner


Page 21
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 < 5C and difference between external
Internal air temp sensor and internal air temp 5C
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>15C
(4) When Max Cooling (17C) 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

*Only for Auto mode.

Air Conditioner SP000025


Page 22
Self Diagnosis
How to start self diagnosis

Starter Switch ON

Set temp to 25 C Set temp to 77 F

Press the SEL switch more than 3 times in


5 secs while pressing the A/C switch

Auto diagnosis starts after every graphic


in LCD displays twice every 0.5 sec.

A code concerned blinks in the cycle of 0.5-sec ON


and 0.5-sec OFF. In case of two or more errors, codes
concerned blink twice at a time.

For normal, E0 lights; for error, the first


error code is indicated.

For 2 or more error, error codes are indicated


upstreams/downstreams if the temp control switch is
set to up/down. (For normal condition, only EO lights.)

Press the SEL switch more than 3 times in


5 secs while pressing the A/C switch. Return to default status if no switch
operated for 30 secs in diagnosis mode.

Return to position before auto diagnosis


starts.
FG001367
Figure 21

SP000025 Air Conditioner


Page 23
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.

NOTE: Position error means that it fails to move to


designated place in 40 seconds.
Sun sensor displays E8 in case of no sunlight. E1 E1 E2 E2 E3

2 and more fails: Codes concerned blinks twice at a


time.

0.5 0.5

FG001067
Figure 22

Ambient Temp Display


Selection of both the SEL and MODE switch for more than 3
seconds indicates the ambient temp in the set temp display
department.
- Range of temp display: -40 - +60C
NOTE: Display of ambient temp may be released in the
same way for its entry way.
It returns automatically to default mode 5 seconds
after entering the ambient air temp display mode.

Air Conditioner SP000025


Page 24
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)

Compressor sucks in refrigerant which evaporates completely in


the evaporator and discharges it to the condenser.
Refrigerant undergoes repeated status change in the order of
liquid, gas, and liquid in the freezing cycle, and the compressor
makes evaporated refrigerant a high temperatures and high-
pressured gas to freeze it in the condenser.

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

Volume of refrigerant by model FG003921


Figure 25
Model Volume of refrigerant (g)
DX300LC 80050
DX140W 80050

SP000025 Air Conditioner


Page 25
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.

High-pressure: 8.0 - 10.0 kg/cm2 (114 - 142 psi)


1
Low-pressure: Approximately 1.0 kg/cm2 (14 psi)
Possible Cause: Low Refrigerant Level
Step Inspection Item Remedy
Reassemble using correct tightening
Yes
1 Check for traces of refrigerant oil. torque.
No Go to next step.
Using a leak detection device or soapy water Yes Repair leaking component.
2 check for refrigerant leakage at all major No Recharge system to correct
components and joints. pressure.

High-pressure: Over 23 kg/cm2 (327 psi)


2
Low-pressure: Approximately 2.5 - 3.0 kg/cm2 (36 - 43 psi)
Possible Cause: Overcharge, Frost on condenser
Step Inspection Item Remedy
Check for condenser pin damage or Yes Clean, repair or replace condenser.
1
contamination. No Refrigerant overcharge.

Air Conditioner SP000025


Page 26
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.

High-pressure: Over 6 kg/cm2 (85 psi)


4
Low-pressure: Approximately 760 mmHg (Negative Pressure)
Possible Cause: Refrigerant does not circulate
Step Inspection Item Remedy
1. Connect manifold gauge and start engine.
2. Turn on air conditioner. Moisture in system, replace receiver
Yes
dryer.
3. Set blower switch to HIGH position.
4. Turn air conditioner OFF and wait 10
1 minutes.
5. Recheck high / low-pressure readings. Contaminated system, replace
No expansion valve.
High-pressure: 13.0 - 19.0 kg/cm2 (185 - 270 psi) (Replace evaporator core assembly.)
2
Low-pressure: 1.5 - 3.3 kg/cm (21.3 - 46.9 psi)

High-pressure: Over 6 - 18 kg/cm2 (85 - 256 psi)


5
Low-pressure: 500 mmHg (Negative Pressure) - Dial indicator needle unstable.
Possible Cause: Moisture in system has iced up the expansion valve.
NOTE: When the absorbed moisture freezes the pressure readings may look normal. Careful readings
should be made to determine whether pressure is in normal range.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long period of time, replace the receiver dryer.

High-pressure: Over 22.0 - 23 kg/cm2 (313 - 327 psi)


6
Low-pressure: 2.5 kg/cm2 (36 psi)
Possible Cause: Refrigerant pressure problem due to defective expansion valve or temperature sensor.
Step Inspection Item Remedy
Inspect whether the temperature sensor is Yes Replace expansion valve.
1
installed properly. No Exchange duct sensor.

High-pressure: Over 7.0 - 11.0 kg/cm2 (100 - 156 psi)


7
Low-pressure: 4.0 - 6.0 kg/cm2 (57 - 85 psi)
Possible Cause: Low refrigerant pressure due to poor compressor compression.

SP000025 Air Conditioner


Page 27
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.

Air Conditioner SP000025


Page 28
WEIGHT OF R134a GAS USED IN
MACHINES

Model Weight of Gas


DX420LC 800 20 grams (28 0.7 oz)

SP000025 Air Conditioner


Page 29
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 40C (104F). 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.

Refrigerant Safe Handling Procedures

UNION NUT

TORQUE WRENCH

CORRECT WRONG
WRONG

WRONG

CORRECT

O - RING POSITION

CAP & PLUG CORRECT WRONG WRONG

HDA6066L
Figure 27

The following procedures should be observed for safe handling


of refrigerant during vacuum and charging process.
1. Use an approved recovery / charging device which can
safely perform vacuum and charge work simultaneously.
2. The new refrigerant has improved cooling characteristics
than the old type and care should be used not to
overcharge the system.

Air Conditioner SP000025


Page 30
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.

Repair and Replacement Procedure


1. Work Procedure
A. Before repairing or replacing any refrigerant
components first, return all refrigerant oil to the
compressor and perform recovery procedures.
2. Operating Condition
A. Run engine at maximum engine speed.
B. Select 'HI' blower fan speed and select A/C switch to
'ON'.
C. Set the temperature control switch for maximum
cooling and leave running for approximately 20
minutes.
NOTE: The manifold gauge dial pointer can vary
depending on the outdoor temperatures.

SP000025 Air Conditioner


Page 31
INSTALL REPAIR TOOL

RECOVER REFRIGERANT

REPAIR / REPLACE DEFECTIVE PARTS

VACUUM SYSTEM (OVER 5 MINUTES)

CHECK SYSTEM FOR AIR LEAKAGE REPAIR

VACUUM SYSTEM (OVER 20 MINUTES)

CHARGE SYSTEM (APPROXIMATELY 100 g)

CHECK SYSTEM FOR REFRIGERANT LEAKAGE

CHARGE SYSTEM TO PROPER LEVEL


(Standard Capacity less Initial Charge)

CHECK SYSTEM FOR REFRIGERANT LEAKAGE

CHECK FOR PROPER REFRIGERANT LEVEL

RUN SYSTEM

RECOVER REFRIGERANT IN CHARGING HOSE

REMOVE REPAIR TOOLS


HDA6067L
Figure 28

Air Conditioner SP000025


Page 32
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

1. Attach the manifold gauges and the refrigerant recovery 5


unit to the refrigerant lines as shown. HDA6067L
Figure 29
NOTE: Be careful not to switch the connections for the
low and high-pressure valves.
2. Open the high-pressure valve slowly to release the
refrigerant to the recovery unit.
NOTE: Open the valve slowly, while checking to see
that refrigerant is not leaking out.

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).

Vacuuming Refrigerant System


2 3
Reference
Description 1 4
Number
1 To Compressor
2 Low-pressure Side
3 High-pressure Side
4 From Receiver
5 Vacuum Pump 5
HDA6068L
1. Vacuuming Procedure Figure 30
NOTE: When the A/C system has been exposed to the
air, it must be vacuumed out. Perform vacuum
process for 30 minutes for complete moisture
and air evacuation.
A. Attach the manifold gauges and vacuum pump to the
refrigerant system as shown.
B. Turn on the vacuum pump and open both valves.
C. When the low-pressure gauge shows approximately
710 mmHg, close both valves and turn off vacuum
pump.

SP000025 Air Conditioner


Page 33
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.

Air Conditioner SP000025


Page 34
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

4. If a leak is detected, check for O-ring damage or correct


tightening torque and replace or repair as necessary.
5. If no leaks are detected, proceed with the charging
process. HDA6071L
Figure 33

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

2. Charge the system by opening the manifold gauge low 5


side valve. HDA6072L
Figure 34
Initial charge amount: 100 g (3.5 ounces).
3. If refrigerant does not flow freely into system, try starting
engine first before operating air conditioner.
Temperature control switch setting: Maximum
Cooling
Blower Speed Setting: Hi (3 step)
Engine Speed: 1,300 - 1,500 rpm

SP000025 Air Conditioner


Page 35
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.

4. Open the manifold gauge low side valve and charge


system to standard capacity.

Gauge Dial Standard Reading

High Side Gauge 13 - 20 kg/cm2


(185 - 285 psi)

Low Side Gauge 1.5 - 3.5 kg/cm2


(22 - 50 psi)

NOTE: These standards are for outside temperatures


between 30 - 35C (86 - 95F). The gauge
readings may vary for extreme temperature
conditions.

WARNING!
When outside temperature is low, warm the
refrigerant supply container with warm
water not exceeding 40C (104F). 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.

5. Close low-pressure side valve.


6. Shut off engine and close refrigerant supply container
adapter valve. Disconnect manifold gauge hoses from
vehicle.

Air Conditioner SP000025


Page 36
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 will result in 3
a accurate test.

Reference 4
HDA6073L
Description
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.

SP000025 Air Conditioner


Page 37
Air Conditioner SP000025
Page 38
1Engine and Drive Train
SP000026
DRIVE COUPLING (MAIN PUMP)SP000026

1Drive Coupling
(Main Pump)

Edition 1

Drive Coupling (Main Pump) SP000026


Page 1
MEMO

SP000026 Drive Coupling (Main Pump)


Page 2
Table of Contents

Drive Coupling (Main Pump)


Safety Precautions ............................................... 5
Applicable Models ................................................ 5
Drive Coupling ...................................................... 6
Installation of Drive Coupling ................................ 7
Installation Procedure...................................................... 7

Drive Coupling (Main Pump) SP000026


Page 3
MEMO

SP000026 Drive Coupling (Main Pump)


Page 4
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.

MODEL SERIAL NUMBER RANGE


DX300LC 5001 and Up
DX340LC 5001 and Up
DX420LC 5001 and Up
DX480LC 5001 and Up
DX520LC 5001 and Up

SP000026 Drive Coupling (Main Pump)


Page 5
DRIVE COUPLING
Figure 1 thru Figure 2, show typical drive coupling installations.

FG000656
Figure 1

FG000657
Figure 2

Drive Coupling (Main Pump) SP000026


Page 6
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

2. Assemble it until it is put to the end of pump axle of the 4


clamping hub (3, Figure 3). 3
3. Tighten the socket bolt (4, Figure 3).
NOTE: Tightening torque = 21.4kgm FG000658
Figure 3
4. Assemble the pump cover to the fly wheel housing.
5. Assemble the pump.

SP000026 Drive Coupling (Main Pump)


Page 7
Drive Coupling (Main Pump) SP000026
Page 8
1Hydraulics
SP000273
HYDRAULIC SYSTEM TROUBLESHOOTING,
TESTING AND ADJUSTMENTSP000273

Hydraulic System
Troubleshooting,
Testing and
Adjustment
Edition 1

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment Page 1
MEMO

SP000273 Hydraulic System Troubleshooting, Testing and


Page 2 Adjustment
Table of Contents

Hydraulic System Troubleshooting,


Testing and Adjustment
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
Hydraulic System - General Notes ....................... 6
Hydraulic Schematic ............................................. 8
General Notes ................................................................. 8
Operation of Working Components .................... 10
Boom Operating Circuit ................................................. 10
Boom Up Circuit ............................................................ 10
Boom Down Circuit........................................................ 11
Arm Operating Circuit.................................................... 11
Arm Crowd Circuit ......................................................... 12
Arm Dump Circuit .......................................................... 12
Bucket Operating Circuit ............................................... 13
Bucket Crowd Circuit..................................................... 13
Bucket Dump Circuit...................................................... 13
Swing Operating Circuit................................................. 13
Right Swing Operating Circuit ....................................... 14
Left Swing Operating Circuit.......................................... 14
Swing Relief Valve and Makeup Valve.......................... 14
Travel Operating Circuit ................................................ 14
Forward Travel Circuit ................................................... 15
Reverse Travel Circuit................................................... 15
Procedural Troubleshooting Baseline
Recommendations.............................................. 16
Initial Checks and Tests to Establish Operating
Condition of the Excavator ........................................... 16
Pilot Pressure ..................................................... 18
Adjustment and Testing................................................. 18
Power Mode Valve ............................................. 19
Current Signal and Hydraulic Pressure Adjustments .... 19
Boom/Front Priority Valve................................... 21

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment Page 3
Control Valve Pressure and Current Adjustments......... 21
Pressure Up Valve.............................................. 22
Checks and Adjustments............................................... 22
Pump Input Power Control ................................. 24
Pump Regulator Adjustment ......................................... 24
Flow Meter and Flow Meter Kit Installation and
Testing ............................................................... 27
Swing System Troubleshooting .......................... 29
Precautions/Initial Checks ............................................. 29
Swing Relief Valve Checking and Adjustment .............. 29
Troubleshooting Swing Gearbox ..................... 32
Troubleshooting Hydraulic Problems............... 33
Troubleshooting Control Valve ........................ 34
Troubleshooting Travel Control Valve ............. 36
Troubleshooting Joystick Control Valve........... 36

SP000273 Hydraulic System Troubleshooting, Testing and


Page 4 Adjustment
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.

MODEL SERIAL NUMBER RANGE


DX420LC 5001 and Up

SP000273 Hydraulic System Troubleshooting, Testing and


Adjustment
Page 5
HYDRAULIC SYSTEM -
GENERAL NOTES

CENTER JOINT
20

14 FR
ON
16
T
20 14 16 20
16 14

18 19
10
16 11
14

20

1 5
2

1
1
4

1 6
21 13

15
17

7
9 12
13
12 8

21
15
17
FG004981
Figure 1

The hydraulic system has several improvements over


conventional hydraulic systems - including cross-sensing total
horsepower control - to maximize output efficiency.
The system features an electronically controlled output
optimization system, which allows the operator to choose
between two, distinctly different power modes: high-output/rapid
cycling maximum speed power mode, and a standard power
mode for most types of general operation.

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment
Page 6
Electronic management of hydraulic control valves assists in
optimizing the application speed and overall operator control of
hydraulic actuators and functions.

SP000273 Hydraulic System Troubleshooting, Testing and


Adjustment
Page 7
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.

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment
Page 8
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
50C (122F).
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.

SP000273 Hydraulic System Troubleshooting, Testing and


Adjustment
Page 9
OPERATION OF WORKING
COMPONENTS

Boom Operating Circuit


The boom operating circuit includes the right and left main
hydraulic pumps (both halves of the main pump assembly), both
sides of the control valve and the boom cylinder. The circuit
operates in boom down mode through the first shift position and
through the second shift position in boom up mode. Overload
relief valves set at 360 kg/cm2. (5,112 psi) protect the hydraulic
system from damage as a result of overloads or shocks to the
boom. Additional protection - to prevent cavitation of the cylinder
- is provided by a make-up valve and reservoir return circuit,
which ensures that the volume of oil going to the cylinder will not
exceed the volume of oil coming out

Boom Up Circuit
When you pull the boom control lever backward, the right side
pilot valve generates secondary boom up pilot 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
oil from both pumps goes to the boom cylinder.
BOOM1 BOOM2
BOOM UP
PILOT

PUMP(L) PUMP(R)
ATS0750L
Figure 2

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment
Page 10
Boom Down Circuit
When the boom control lever is pushed forward, the right side
pilot valve generates secondary boom down pilot pressure that BOOM
CYLINDER
is transmitted only to the BOOM1 spool of the control valve.
When secondary pilot pressure reaches 7 - 9 kg/cm2 (100 - 130
psi), the BOOM1 spool on the left side of the control valve opens
so that oil from only one pump (PUMP (L)) assembly goes to the
boom cylinder for boom lowering. BOOM1 BOOM2
BOOM DOWN
PILOT

PUMP(L) PUMP(R)
ATS0760L
Figure 3

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.

SP000273 Hydraulic System Troubleshooting, Testing and


Adjustment
Page 11
Arm Crowd Circuit
When the arm control lever is put in the crowd mode, the left
side pilot valve generates secondary pressure that is transmitted ARM
to the AM1 and AM2 spools of the control valve simultaneously. CYLINDER

When secondary pilot pressure reaches 7 - 9 kg/cm2 (100 - 130


psi), the arm control valve spools AM1 and AM2 open. Output
flow from both halves of the pump assembly is directed to the
arm cylinder. ARM2 ARM CROWD ARM1
PILOT
When working in the arm crowd mode, under certain conditions,
oil in the arm cylinder could suddenly be forced out by the weight
of the arm and bucket. Insufficient oil flow to the cylinder could REGEN V/V
lead to cavitation in the cylinder and/or surging or irregular
movement. This is prevented by a regeneration valve attached
to the control valve which maintains the balance between oil
flowing into the cylinder and oil flowing out. PUMP(L) PUMP(R)
ATS0770L
Figure 4

Arm Dump Circuit


When the arm control lever is put in "dump" mode, the left side
pilot valve generates secondary pilot pressure that goes to both ARM
CYLINDER
spools AM1 and AM2 of the control valve simultaneously.

When pilot pressure reaches 7 - 9 kg/cm2 (100 - 130 psi), the


control spools open, allowing oil from PUMP (L) and PUMP (R)
to flow to the arm cylinder.

ARM DUMP
ARM2 ARM1
PILOT

PUMP(L) PUMP(R)
ATS0780L
Figure 5

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment
Page 12
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.

Bucket Crowd Circuit


When the bucket control lever is placed in the crowd position,
BUCKET
the bucket control valve spool on the left side of the control valve
CYLINDER
opens and oil from left main pump flows to the bucket cylinder.

BUCKET
BUCKET
CROWD BC
PILOT

PUMP(L) PUMP(R)
ATS0790L
Figure 6

Bucket Dump Circuit


When the bucket control lever is put in the dump mode, the
BUCKET
bucket control valve spool in the left half of the control valve
CYLINDER
opens to supply oil from the left main pump to the cylinder.

Swing Operating Circuit


BUCKET BUCKET
The swing operating circuit consists of the right main pump in DUMP
the pump assembly, the right half of the control valve and the PILOT
swing motor. To keep the upper works from coasting when the
swing control is in neutral, an electrical sensor in the control
circuit activates a valve to automatically engage a mechanical
brake.
PUMP(L) PUMP(R)
ATS0800L
Figure 7

SP000273 Hydraulic System Troubleshooting, Testing and


Adjustment
Page 13
Right Swing Operating Circuit
SWING MOTOR
When the swing control lever is pushed to the right swing
position, pilot pressure from the left side pilot valve is directed to
the right side pump regulator and right half of the control valve.
Output flow from the right pump is then directed through the PR
and SWR ports of the control valve to the swing motor. SWING
SWING
RIGHT
PILOT

PUMP(L) PUMP(R)
ATS0810L
Figure 8

Left Swing Operating Circuit SWING MOTOR


When the swing control lever is pushed to the left swing position,
the control valve spool at the right side of the control valve
moves in the opposite direction and output flow from the right
pump is directed through the PR and SWL ports of the control
SWING SWING
valve to the swing motor.
LEFT
PILOT

Swing Relief Valve and Makeup Valve


Whenever the spool is shifted to the neutral mode during swing
operation, the possibility exists that surge pressure in the circuit
- caused by inertial momentum of the upper works and PUMP(L) PUMP(R)
correspondingly reduced pressure at the opposite motor port - ATS0820L
could produce cavitation in the circuit. To keep that from Figure 9
happening, a 285 kg/cm2 (4,052 psi) relief valve is installed in
the swing motor and a large capacity makeup valve is connected
to the entrance port of the hydraulic reservoir, helping maintain
acceptable pressures on both sides of the circuit.

Travel Operating Circuit


Output flow from both halves of the pump assembly is directed
to the right and left travel motors through the right and left sides
of the control valve, and the upper works center joint.

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment
Page 14
Forward Travel Circuit TRAVEL TRAVEL
MOTOR(L) MOTOR(R)
When the right and left travel control levers are pushed forward,
output from both of the main pumps is directed through the PR,
PL, TRRF, and TRLF ports on the control valve, through the
upper works center joint, to the travel motors on each side of the CENTER JOINT
machine.

TRAVEL(L) TRAVEL(R)
L.TRAVEL R.TRAVEL
FORWARD FORWARD
PILOT PILOT

PUMP(L) PUMP(R)
ATS0830L
Figure 10

Reverse Travel Circuit


TRAVEL TRAVEL
When the right and left travel control levers are pushed MOTOR(L) MOTOR(R)
backward, output from both main pumps is directed through the
PR, PL, TRRR, and TRLR ports on the control valve, through the
upper works center joint, to the travel motors.
CENTER JOINT

TRAVEL(L) TRAVEL(R)
L.TRAVEL R.TRAVEL
BACKWARD BACKWARD
PILOT PILOT

PUMP(L) PUMP(R)
ATS0840L
Figure 11

SP000273 Hydraulic System Troubleshooting, Testing and


Adjustment
Page 15
PROCEDURAL
TROUBLESHOOTING BASELINE
RECOMMENDATIONS

Initial Checks and Tests to Establish


Operating Condition of the Excavator

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 1,880 rpm with no load.
at 1,800 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

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment
Page 16
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.

SP000273 Hydraulic System Troubleshooting, Testing and


Adjustment
Page 17
PILOT PRESSURE

Adjustment and Testing

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.

Vent hydraulic pressure from the reservoir before breaking the


seal on fittings to install two in-line "T-style" adapters and test
gauges (60 bar/1,000 psi) at the gear pump outlet port, and at
the joystick control valve pilot line.
Start the engine and turn the engine speed control dial to the
maximum setting. After the excavator has been operated long
enough to reach normal operating temperature, back off the
engine control dial to minimum rated rpm speed. With all
controls in neutral, make sure the left console control stand is
locked in the down (operating) position and check pressure at
the gear pump outlet port and at the joystick.
If gear pump pressure is outside the tolerance specified in the
table, adjust gear pump relief pressure by loosening the lock nut
and turning the set screw in (clockwise) to increase pressure, or
turning it out to decrease it.
NOTE: Be aware that serial number changes and variation in
the joystick assemblies used on different excavators
could produce slight change in actual performance
characteristics. Comparison of part numbers to serial
numbers stamped on your assembly may be
required, if questions or doubt exists.

IMPORTANT
Top off the hydraulic fluid reservoir if there is any
measurable loss of hydraulic oil during test gauge and
adapter fitting installation.

Engine RPM Pilot Pressure @ Pump Pilot Pressure - Joystick


Minimum Speed Setting (full left) 40 5 bar 40 5 bar
on Speed Control Dial (580 73 psi) (580 73 psi)

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment
Page 18
POWER MODE VALVE

Current Signal and Hydraulic Pressure


Adjustments

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.

The electromagnetic pressure proportioning control (EPPR)


"power mode" valve is on the underside of the pumps (not visible
in the harness connections drawing, because it is underneath
the assembly), near the engine/pump flexible coupling, adjacent
to the pump return line. To test and adjust power shift current
and pressure through the power mode valve a multilead jumper
harness is required. The jumper harness (which is available
through DOOSAN After Sales Service, or could be spliced
together from commonly available, purchased parts) has extra
leads so that a VOM meter can be connected to the circuit.
To set up the testing equipment, shut down engine and
disconnect the single electrical lead from the power mode valve.
Attach the jumper harness to the terminal on the valve, connect
the test leads of the multimeter to the extra leads on the harness
and reconnect the valve electrical lead.
Vent the lever on top of the hydraulic tank to relieve pressure
and connect an in-line "T-style" adapter to the valve pressure
port. Install a 60 bar (1,000 psi) test gauge in the adapter.
Restart the engine and increase engine rpm by turning the
speed control to the maximum speed setting. Warm up the
engine and hydraulic system until hydraulic oil temperature is at
least 45C (113F). Select Power Mode on the Instrument Panel.
Check current readings (in milliamps) on the VOM meter and
hydraulic pressure gauge readings and make sure both conform
to the values in the table below.
NOTE: If recorded values do not conform to the
specified current or pressure in the table, back
off the lock nut on the end of the valve, turn the
adjusting screw 1/4 turn and recheck current
and pressure. Repeat adjustment as required to
obtain specified performance and retighten the
valve lock nut.

SP000273 Hydraulic System Troubleshooting, Testing and


Adjustment
Page 19
Mode Engine RPM Current Pressure
2bar
Power Mode High Idle: 1,880 RPM 200 20 mA
(29 psi)
7 bar
Standard Mode High Idle: 1,770 RPM 350 mA
(102 psi)

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment
Page 20
BOOM/FRONT PRIORITY VALVE

Control Valve Pressure and Current


Adjustments

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.

The front priority control valves are located inside the


compartment behind the cabin.
The same jumper harness used for testing the power mode
(EPOS) control valve is used to test this valve. Shut down
engine, disconnect either of the electrical leads and connect the
test equipment to that side of the valve. An in-line "T-style"
gauge adapter can be used to connect a 60 bar/870 psi (1,000
psi) test gauge to the outlet (pressure) side of the valve. Set the
engine control speed dial to maximum and warm up the engine
to at least 45C (113F) before making any tests.
NOTE: Vent air from the hydraulic system before installing
test equipment. Use the lever on the reservoir, while
the engine is running. Pour clean replacement fluid
back into the system if excessive fluid was lost.
Operate the swing motor in both directions. Measure signal
current and hydraulic pressure through the valve and record the
highest and lowest values as the swing motor rotate clockwise
and counterclockwise several times. Reset the work mode
control to "trenching" mode and repeat the same tests.

DIGGING MODE TRENCHING MODE

VALVE FUNCTION
HAOB730L HAOB740L

VOLTAGE PRESSURE VOLTAGE PRESSURE


0 - 40 bar 0 bar
Front Priority 0V 20 - 30 V
(0 - 580 psi) (0 psi)

NOTE: If recorded values do not conform to the specified


current or pressure in the table, readjust as required.

SP000273 Hydraulic System Troubleshooting, Testing and


Adjustment
Page 21
PRESSURE UP VALVE

Checks and Adjustments

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.

Vent hydraulic pressure from the reservoir to install an in-line "T-


style" adapter and test gauge (60 bar/1,000 psi) at the pilot
pump signal port relief valve outlet.
Start the engine and turn the engine speed dial to maximum.
When normal operating temperature is reached:
Check pilot pressure and readjust it, if required:
Select the Instrument Panel rear pump "pressure
display".
Select Power Mode.
Stall the boom cylinder (towards the extend side).
Read rear pump pressure on the Instrument Panel
display.
Repeat all tests with and without "pressure up" selected through
the console rocker switch and joystick button.
If the two-stage main relief valve was not set correctly and main
relief high-stage pressure ("pressure up") is outside the
tolerance range, begin valve adjustment by loosening the
outside (widest diameter) lock nut on the relief valve. Turn the
adjusting screw clockwise to increase pressure, or
counterclockwise to decrease it. Pressure must be 350 bars
(5075 psi), or up to 10 bars (145 psi) higher.
Because one adjustment can affect the other, check low-stage
main relief pressure by repeating the cylinder stall test without
"pressure up." Readjust standard relief pressure by turning the
innermost (smallest diameter) screw clockwise to increase the
setting, or counterclockwise to decrease it. Pressure should be
at least 320 bars (4,641 psi), but less than 325 bars (4,714 psi).

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.

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment
Page 22
Main Pressure and Pilot Pressure and
Power Mode Operation
Tolerance Tolerance
20 - 40 bar 30 bar +10 bar
Mode Neutral, No Operation
(290 - 580 psi) (435 psi +145 psi)
320 bar +5 bar 30 bar +10 bar
Mode Cylinder Stall
(4,641 psi +75 psi) (435 psi +145 psi)
Mode W/ 350 bar +10 bar 30 bar +10 bar
Cylinder Stall
Pressure Up 5,075 psi +145 psi (435 psi +145 psi)

NOTE: The electrical pressure up (power boost) solenoid


valve alongside the swing priority solenoid and arm
speed control solenoid, in compartment rear of the
operator's cabin, must be operating correctly, or
pressure tests and further adjustments cannot be
made.

SP000273 Hydraulic System Troubleshooting, Testing and


Adjustment
Page 23
PUMP INPUT POWER CONTROL

Pump Regulator Adjustment

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.

To perform these adjustments accurately the use of a flow meter


is strongly recommended, as is consulting the factory (before
starting work) to validate the need for making regulator
adjustments. Vent hydraulic pressure from the reservoir before
breaking the seal on fittings to install the flow meter kit. (Refer to
the "Flow meter Installation and Testing" procedure.)

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.

Use a scribe or other permanent marker to identify a reference


point on adjusting screws with a corresponding reference on the
body of the valve. The adjustment process affects a complex
balance and could require some time to complete. If adjustment
has to be interrupted or postponed, reference marks at the
adjustment point allow immediate restoration of original
performance.
This adjustment procedure is normally performed:
If the engine is being consistently overloaded (and
engine troubleshooting shows engine performance to
be at or above rated output).
If reduced cylinder speed and diminished work
performance provide an indication that rated,
maximum pump flow may not be available (and all
other troubleshooting gives no indication of other
flaws or hydraulic system defects).
If pump output is out of balance and one pump is
failing to keep up with the output flow of the other.
To check pump imbalance without a flow meter, travel the
excavator forward on flat, level terrain. If the machine veers off
despite neutral control input and even, balanced track

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment
Page 24
adjustment, the pump which supplies output to the track frame
toward which the excavator is veering is weak.

2
2

1
1 ASS0320L
Figure 12

Refer to the illustration of the pump regulator control valve


(Figure 12) for the location of adjustment screws (1, 2 and 3).
There are three different adjustments, Qmax, Pi-Q Pd-Q,
adjustment screws (1, 2 and 3). Each one of the adjustment
procedures could affect the setting of the others.
Check and record the arm dump speed performance test before
and after input power adjustment, whether or not a flow meter is
used.
NOTE: Regulator adjustments affect total cumulative
horsepower, since each regulator compensates for
the output of the other. It is not necessary to adjust
both regulators at the same time, but after checking
or adjusting one of them, the remaining unit should
also be checked.

SP000273 Hydraulic System Troubleshooting, Testing and


Adjustment
Page 25
Start the engine and turn the engine speed dial to maximum.
When normal operating temperature is reached, adjust screw 2
clockwise to shift the Pi-Q control valve curve decrease
Q
compensating control pressure.
A 1/2 turn on the adjusting screw is equal to approximately -0.7
kg/cm2 of Pi.
NOTE: For each full turn of adjustment on the screw (2), the
square-tipped adjusting screw should be turned in the
opposite direction turns to avoid changing inner
spring adjustment.
Pi
ATS0850L
Figure 13

Pump input power adjustments are normally made in small


increments, 1/4 turn (90) or less, each time.
Turning the screw (3) clockwise shift Pd-Q curves right and Q
increase input horse power. 1/2 turn on the screw (3) is equal to
approximately +33 kg/cm2 of Pd.

Pd
ATS0870L
Figure 14

The adjusting screw (1), 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. Q

Balance both pumps for equal output.

Pd
FG005205
Figure 15

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment
Page 26
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.

Installation and Testing Procedure


Turn off the engine and operate controls to release
hydraulic pressure from the accumulator.
Vent the reservoir to release all pressure from the
hydraulic system.
Remove guard panels from around the main pump
assembly.
Disconnect the main pump discharge output line.
Install the input flange of the flow meter on the pump
end of the output line.
Cap off the unused (input) end of the pump discharge
line with a blocking flange.
Bolt up a pre-measured length of hydraulic hose,
between the output end of the flow meter assembly
and the top of the reservoir. Use appropriate fittings
and adapter flanges to guarantee a pressure tight
seal.
NOTE: Be sure to maintain even tightening torque
on all flange fittings. Use Loctite brand
"PST 545" (or an alternate manufacturer's
hydraulic system joint seal) if required, to
give an airtight seal.
An assistant who must remain at the operator's
control station at all times should restart the engine
and run it long enough (at minimum rpm) to de-aerate
the system and warm up the engine and hydraulic
system to operating temperature.
Record the values of all test results in three columns, comparing
1) pump pressure (from the instrument panel display) with 2)
measured flow, in gallons or liters per minute, from the installed
flow meter. The third column of test results should provide a
record of engine rpm measured during each of the following
tests with the engine speed control dial set at maximum, the

SP000273 Hydraulic System Troubleshooting, Testing and


Adjustment
Page 27
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."

Engine RPM Pressure Flow


2
100 kg/cm (1,422 psi)
135 kg/cm2 (1,930 psi)
180 kg/cm2 (2,560 psi)
240 kg/cm2 (3,413 psi)
320 kg/cm2 (4,550 psi)*
*See below note.

Compare recorded values with output shown in the P-Q curve in


the specifications section of this book.
If test results do not measure up to specified values, pump
output tests can be repeated using different control levers.
Recheck front pump operation while stroking the bucket cylinder
out lever, and the rear pump by actuating the swing control lever.
NOTE: When testing bucket and swing functions, read
maximum flow tests at 320 kg/cm2 (4,550 psi), not
350 kg/cm2 (4978 psi).

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment
Page 28
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. Turn off 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.
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.

Swing Relief Valve Checking and


Adjustment
Make a check of operating pressures through the swing relief
valve if:
The swing motor fails to turn.
Swings in one direction only.
Swings but continues to coast.

SP000273 Hydraulic System Troubleshooting, Testing and


Adjustment
Page 29
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 250 and 260 bar (3,625
psi and 4,061 psi), with both swing locks engaged.
With swing locks released, during full acceleration
and deceleration, pressure should approach 260 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 4 bar (58
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
with cavitation, stalling and surging are observed, check
the restriction valve. If pressure adjustment to the valve

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment
Page 30
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.

SP000273 Hydraulic System Troubleshooting, Testing and


Adjustment
Page 31
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 valve
continues coasting on past centered. 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.

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment
Page 32
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.

SP000273 Hydraulic System Troubleshooting, Testing and


Adjustment
Page 33
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

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment
Page 34
system is topped up to the required level and free of oil leaks or
air in the system that could cause cavitation problems.

Problem Possible Cause Remedy


Main relief valve. Particulate contamination. Disassemble, clean main poppet.
Broken or damaged spring. Replace.
Adjusting screw loose. Readjust.
Main poppet sticking. Repair/replace.
Clogged orifice in pilot passage to Clean/replace.
control valve.
Cylinder goes down in spool Excessive clearance between Replace spool or casing.
neutral. casing and spool.
Spool does not return to neutral/ Check secondary pilot pressure.
sticking spool.
Spool does not return to neutral Clean.
because of dirt or other
contaminants.
Broken or damaged spring. Replace.
Main relief or port relief not See above.
operating properly.
Impurities in pilot circuit. Clean.
Cylinder drops before start Rod check valve damaged or Clean/replace.
at boom up operation. clogged.
Poppet sticking. Clean/replace.
Broken or damaged spring. Replace.
Slow operation or response. Excessive clearance between spool Check pilot pressure and/or replace
or casing. spool or casing.
Sticking spool. Clean/replace.
Broken or damaged spring. Replace.
Main or port relief valve damaged. Check pressure/replace.
Swing priority not operating Sticking spool. Clean/replace.
correctly. Solenoid valve faulty. Replace.
Boom and arm cylinders do Priority valve faulty or spool Check pilot pressure.
not perform normally in sticking.
combined operation. Broken or deformed spring. Replace.
Excess clearance between right Clean/replace.
and left casing and valve spool.
Clogged spool passage. Clean/replace, replace filter.
Relief valve malfunctions:
Pressure does not increase Main poppet or pilot poppet stuck Clean/replace.
at all. open.
Irregular or uneven Poppet seat damaged or pilot Clean/replace.
pressure. piston sticking to main poppet.
Loose lock nut and adjusting screw. Readjust.
Components worn out, past wear Replace.
limits.

SP000273 Hydraulic System Troubleshooting, Testing and


Adjustment
Page 35
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.

Hydraulic System Troubleshooting, Testing and SP000273


Adjustment
Page 36
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.

SP000273 Hydraulic System Troubleshooting, Testing and


Adjustment
Page 37
Hydraulic System Troubleshooting, Testing and SP000273
Adjustment
Page 38
SP000028
ACCUMULATOR SP000028

Accumulator

Edition 1

Accumulator SP000028
Page 1
MEMO

SP000028 Accumulator
Page 2
Table of Contents

Accumulator
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 6
Specifications .................................................................. 8

Accumulator SP000028
Page 3
MEMO

SP000028 Accumulator
Page 4
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.

MODEL SERIAL NUMBER RANGE


DX300LC 5001 and Up
DX340LC 5001 and Up
DX420LC 5001 and Up
DX480LC 5001 and Up
DX520LC 5001 and Up

SP000028 Accumulator
Page 5
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

Accumulators are solidly constructed to resist the high operating Figure 1


pressures of the fluids they contain. There are only three main
moving parts: a plug at the top allows precharging or expelling
gas from the compressible, precharged upper chamber; a valve
assembly at the bottom of the accumulator for passing hydraulic
fluid in and out, and an elastic diaphragm to separate the two
chambers. The flexible diaphragm changes shape to conform to
the changing pressures and volumes of the two fluids in the
upper and lower chambers.
There are six possible positions the diaphragm can be in and
they are as follows: Pressure Fluid Nitrogen

1. With no gas charge in the upper chamber 0 bar (0 psi,


empty) and no oil in the bottom 0 bar (0 psi, dry) the elastic
diaphragm hangs loosely.
2. When the prepressure charge of gas (usually nitrogen) is
introduced through the port at the top of the accumulator,
the diaphragm expands to maximum size. The valve button 1 2 3
in the center of the diaphragm pushes into the fluid
opening in the bottom chamber, sealing off the lower valve.
If the pressure of the gas charge exceeds system oil
pressure, no fluid enters the accumulator. The button also
keeps the diaphragm from protruding into the lower valve
opening.
NOTE: Precharge pressure is referred to as the "P1"
pressure. The accumulator manufacturer's "P1" 4 5 6
ARS1800L
rated pressure should be stamped or marked on
the accumulator's rating plate. Annual checks of Figure 2
actual precharge pressure should be made by
tapping a hydraulic pressure gauge (and 3-way
adapter coupling) into the valve on the bottom
of the accumulator. When hydraulic fluid is
pushed out the lower valve opening by the
pressure of the gas charge on the other side of
the diaphragm - and there is no
counterpressure from system oil - the valve

Accumulator SP000028
Page 6
button on the bottom 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
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)
10 kg/cm2 320 cc
DX520LC S/N 5001 and Up Pilot / Travel
(140 psi) (19.53 in3)

Accumulator SP000028
Page 8
SP000181
CENTER JOINT (SWIVEL)SP000181

1Center Joint
(Swivel)

Edition 1

Center Joint (Swivel) SP000181


Page 1
MEMO

SP000181 Center Joint (Swivel)


Page 2
Table of Contents

Center Joint (Swivel)


Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 6
Center Joint Disassembly Diagram ................................. 7
Disassembly ......................................................... 8
Reassembly ........................................................ 11

Center Joint (Swivel) SP000181


Page 3
MEMO

SP000181 Center Joint (Swivel)


Page 4
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.

MODEL SERIAL NUMBER RANGE


DX340LC 5001 and Up
DX420LC 5001 and Up
DX480LC 5001 and Up
DX520LC 5001 and Up

SP000181 Center Joint (Swivel)


Page 5
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.

Center Joint (Swivel) SP000181


Page 6
Center Joint Disassembly Diagram

Figure 1

Reference Reference
Description Description
Number Number
1 Body 6 Wear Ring
2 Shaft 7 Slipper Seal
3 Cover 8 O-ring(1AP 120)
4 Spacer 9 O-ring(1BP 100)
5 Shim 10 O-ring(1BG 120)

SP000181 Center Joint (Swivel)


Page 7
DISASSEMBLY

CAUTION!
It is recommended to use a hoist or a similar device for it is
heavy.

CAUTION!
Remove active oil and wash it out before starting
disassembly.

CAUTION!
It should be disassembled after its active oil is cool enough
after it is removed from the system for its active oil is very
hot.

1. Set PF3/4 eye bolts on the cover drain port and use a hoist
to move it to a workplace.
2. Remove active oil remaining on each port with air.
3. Use a 19 mm spanner to loosen spacer bolts and remove
the cover and O-rings (1BG120).

Figure 2

4. Use a 17 mm spanner to disassemble the spacer and the


shim.

CAUTION!
Care should be taken not to make a flaw on the surface
of the shaft when disassembling the body of the shaft
assembly.

Figure 3

Center Joint (Swivel) SP000181


Page 8
5. Disassemble the body from the spindle assembly.
A. It can be disassembled easily by fixing the spindle
assembly, tightening at least 2-12 mm eye bolts on
the body, and lifting it with a hoist slowly.
B. Or, it may be disassembled by setting the continuous
thread studs on the spindle drain port as shown in the
figure.

Figure 4

6. Separate the body into 6 slipper seals, 1 wear ring, and 1


O-ring.

CAUTION!
Care should be taken not to damage the inside of the
body because it is likely to be damaged when
disassembling the slipper seal. It may be
disassembled more easily with a driver whose tip is
bent as shown in the figure below.
Figure 5
7. Remove the PT and PF plugs sealing the shaft.
Internal sealing PF 3/4: 12 mm wrench.
External sealing PT3/8: 8 mm Wrench.

Figure 6

SP000181 Center Joint (Swivel)


Page 9
8. Remove foreign substance at every pieces disassembled
and wash them out.
9. Replace disassembled O-rings and slipper seals with new
ones, for they cannot be reused.

CAUTION!
The inside of the body should be air washed and rust-
proof treated after washing it, as its material is subject
to rust.

Center Joint (Swivel) SP000181


Page 10
REASSEMBLY

CAUTION!
Apply active oil to every functional (moving) part before
assembly to reduce any assembly friction as much as
possible.

Figure 7

1. Wrap the Teflon tape around the PT3/8 about 6 times.


2. Assemble the PT and PF plugs into the washed shaft.

Internal sealing PF3/4: 12 mm wrench External sealing PT3/8: 8 mm wrench


Engagement torque: 151.09 Kg m Engagement torque: 4.5 ~ 9.5 kg m

3. Assemble the sliper seal, the wear ring, and the O-ring into
the body.
4. Assemble the 1AP - 120 O-ring the outside of the body.

CAUTION!
After assembling the sliper seal, a manual test should
be performed to ensure that every part is assembled
for its position properly.

Figure 8

SP000181 Center Joint (Swivel)


Page 11
CAUTION!
For any sliper seal which is protruded, press it with
finger to seat it in its position. Care should be taken
when using a driver or a metal tool, which may cause
damage to it.

CAUTION!
Applying active oil to the surface of the shaft enables
the assembly without any damage to the sliper seal.

5. Fix the position of the shaft and press the body carefully
into shaft with both being parallel each other.
6. Use a plastic (or rubber) hammer to tap the body until it is
inserted completely.

CAUTION!
Tap the body in a zigzag pattern that it does not tilt to
one side.

Figure 9

7. Engage the shim, the spacer, and the spacer bolts on the
top of the shaft.
8. Use a torque wrench to tighten spacer bolts at 5 ~ 6 kg m

Figure 10

Center Joint (Swivel) SP000181


Page 12
9. Set the O-ring (1 BG 120) in its place and assemble the
cover in the direction as shown in the figure.
10. Engage the cover bolt (M 12) at torque of 10 ~ 12.5 kg m.
11. Return the O-ring (1 AP 120) assembled to the outside of
the body to its original position.

CAUTION!
After the completion of the assembly, a start-up and a
rotation torque tests should be performed for the Figure 11
sliper seal to seat in its place properly.

SP000181 Center Joint (Swivel)


Page 13
Center Joint (Swivel) SP000181
Page 14
SP000030
CYLINDERS SP000030

Cylinders

Edition 1

Cylinders SP000030
Page 1
MEMO

SP000030 Cylinders
Page 2
Table of Contents

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

Cylinders SP000030
Page 3
MEMO

SP000030 Cylinders
Page 4
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.

MODEL SERIAL NUMBER RANGE


DX300LC 5001 and Up
DX340LC 5001 and Up
DX420LC 5001 and Up

SP000030 Cylinders
Page 5
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

Cylinder piston rods are extended or retracted by oil flow to the


back side of the cylinder (shown as ("oil path A") or to the front of 3
the cylinder ("oil path B"). 2
The cylinder rod is extended as oil flow is pumped through the
circuit to the back side of the piston. The force (F1) of the piston
stroke can be expressed by the formula below, where P = circuit FG001456
oil pressure and the inside diameter of the cylinder is expressed Figure 1
by D (Figure 1).

F1 = P x D2
4

(P: Pressure, = 3.14, D: Cylinder Inside Diameter)

1 Cylinder Inside Diameter - D


2 Oil Path A
4
3 Oil Path B
4 Rod Diameter - R
1
When the cylinder rod is retracted, oil flow through the circuit
from the pump to the front side of the cylinder generates a force 2
(F2) that can be expressed by the formula in which the diameter
3
of the piston rod is expressed by R, and the other two terms are
the same as in the preceding expression. FG001458

F2 = P x (D2-R2) Figure 2
4

Cylinders SP000030
Page 6
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 (D2)
4

Q2 = S x (D2-R2)
4

Q1 > Q2 FG001459
Figure 3

SP000030 Cylinders
Page 7
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
35 4 11,12 9,10 8 6 27 7 5 15 13,14 1 3 16 17
25 2 35

28, 29, 30, 31


FG005226
Figure 4

32, 33, 34

4 35 11, 12 9, 10 8 6 7 15 13, 14 5 3 1
16 17 20 19 18 21,22 23
24 2 35

FG005227
Figure 5

Cylinders SP000030
Page 8
Reference Reference
Description Description
Number Number
1 Tube Assembly 19 Wear Ring
2 Bushing 20 Ring
3 Rod Assembly 21 O-ring
4 Bushing 22 Backup Ring
5 Rod Cover 23 Piston Nut
6 DD-Bushing 24 Set Screw
7 Retaining Ring 25 Socket Head Bolt
8 Buffer Seal 26 Pipe Band Assembly
9 U-Packing 27 Hex Socket Bolt
10 Backup Ring 28 Check Valve
11 Dust Wiper 29 Spring
12 Retaining Ring 30 Spring Support
13 O-ring 31 Hex Socket Plug
14 Backup Ring 32 Spring Washer
15 O-ring 33 Hex Bolt
16 Cushion Ring 34 Pipe Assembly
17 Piston 35 Grease Nipple
18 Slipper Seal

SP000030 Cylinders
Page 9
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

Cylinders SP000030
Page 10
MODEL CYLINDER A B C D MODEL (CYLINDER)
142.0 mm 102.0 mm 12.0 mm 5.0 mm
BOOM
(5.59 in) (4.02 in) (0.47 in) (0.20 in)
147.0 mm 107.0 mm 12.0 mm 5.0 mm
DX300LC ARM S/ARM
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
140.0 mm 98.0 mm 12.0 mm 5.0 mm
BUCKET S/BUCKET
(5.52 in) (3.86 in) (0.47 in) (0.20 in)
145.0 mm 105.0 mm 12.0 mm 5.0 mm
BOOM OPT BOOM
(5.71 in) (4.13 in) (0.47 in) (0.20 in)
147.0 mm 107.0 mm 12.0 mm 5.0 mm
DX340LC ARM OPT ARM
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
145.0 mm 105.0 mm 12.0 mm 5.0 mm
BUCKET OPT BUCKET
(5.71 in) (4.13 in) (0.47 in) (0.20 in)
147.0 mm 107.0 mm 12.0 mm 5.0 mm
BOOM
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
147.0 mm 107.0 mm 12.0 mm 5.0 mm
DX420LC ARM
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
155.0 mm 115.0 mm 12.0 mm 5.0 mm
BUCKET
(6.10 in) (4.53 in) (0.47 in) (0.20 in)

SP000030 Cylinders
Page 11
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 12
MODEL CYLINDER A ( 0.1) B C D MODEL (CYLINDER)
110.0 mm 13.0 mm 76.0 mm 140.0 mm
BOOM
(4.33 in) (0.51 in) (2.99 in) (5.51 in)
120.0 mm 13.0 mm 85.0 mm 150.0 mm
DX300LC ARM S/ARM
(4.72 in) (0.513 in) (3.35 in) (5.91 in)
110.0 mm 13.0 mm 76.0 mm 140.0 mm
BUCKET S/BUCKET
(4.33 in) (0.51 in) (2.99 in) (5.51 in)
120.0 mm 13.0 mm 85.0 mm 150.0 mm
BOOM OPT BOOM
(4.72 in) (0.51 in) (3.35 in) (5.91 in)
130.0 mm 13.0 mm 93.0 mm 165.0 mm
DX340LC ARM OPT ARM
(5.12 in) (0.513 in) (3.66 in) (6.50 in)
120.0 mm 13.0 mm 85.0 mm 150.0 mm
BUCKET OPT BUCKET
(4.72 in) (0.51 in) (3.35 in) (5.91 in)
130.0 mm 13.0 mm 93.0 mm 165.0 mm
BOOM
(5.12 in) (0.51 in) (3.66 in) (6.50 in)
130.0 mm 13.0 mm 93.0 mm 165.0 mm
DX420LC ARM
(5.12 in) (0.513 in) (3.66 in) (6.50 in)
130.0 mm 13.0 mm 93.0 mm 165.0 mm
BUCKET
(5.12 in) (0.51 in) (3.66 in) (6.50 in)

SP000030 Cylinders
Page 13
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 14
MODEL
MODEL CYLINDER A-0.05 B ( 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)
100.0 mm 115.0 mm 45.0 mm 7.5 mm
BOOM OPT BOOM
(3.94 in) (4.53 in) (1.77 in) (0.30 in)
100.0 mm 115.0 mm 45.0 mm 7.5 mm
DX340LC ARM OPT ARM
(3.94 in) (4.53 in) (1.77 in) (0.30 in)
100.0 mm 115.0 mm 45.0 mm 7.5 mm
BUCKET OPT BUCKET
(3.94 in) (4.53 in) (1.77 in) (0.30 in)
110.0 mm 130.0 mm 70.0 mm 11.0 mm
BOOM
(4.33 in) (5.12 in) (2.76 in) (0.43 in)
110.0 mm 130.0 mm 70.0 mm 11.0 mm
DX420LC ARM
(4.33 in) (5.12 in) (2.76 in) (0.43 in)
110.0 mm 130.0 mm 70.0 mm 11.0 mm
BUCKET
(4.33 in) (5.12 in) (2.76 in) (0.43 in)

SP000030 Cylinders
Page 15
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.

1 Place: Finally work to used DNMG Tip <Nose R0.4>

Cylinders SP000030
Page 16
MODEL CYLINDER A-0.2
-0.3 B -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)
100.0 mm 114.0 mm 6.0 mm 7.0 mm
BOOM OPT BOOM
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
115.0 mm 131.0 mm 6.0 mm 7.0 mm
DX340LC ARM OPT ARM
(4.53 in) (5.16 in) (0.24 in) (2.28 in)
100.0 mm 114.0 mm 6.0 mm 7.0 mm
BUCKET OPT BUCKET
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
115.0 mm 131.0 mm 6.0 mm 7.0 mm
BOOM
(4.53 in) (5.16 in) (0.24 in) (2.28 in)
120.0 mm 136.0 mm 6.0 mm 7.0 mm
DX420LC ARM
(4.72 in) (5.35 in) (0.24 in) (2.28 in)
110.0 mm 126.0 mm 6.0 mm 7.0 mm
BUCKET
(4.33 in) (4.96 in) (0.24 in) (2.28 in)

SP000030 Cylinders
Page 17
Slipper Seal Jig

0
R1
R1
(A+2)
A

(A-14)

10
B

(B+40)

ARS4770L
Figure 10

Cylinders SP000030
Page 18
MODEL CYLINDER A+0.2
+0.1 B+0.2
+0.1
MODEL (CYLINDER)
140.0 mm 28.5 mm
BOOM
(5.51 in) (1.12 in)
150.0 mm 28.5 mm
DX300LC ARM S/ARM
(5.91 in) (1.12 in)
140.0 mm 28.5 mm
BUCKET S/BUCKET
(5.51 in) (1.12 in)
150.0 mm 28.5 mm
BOOM OPT BOOM
(5.91 in) (1.12 in)
170.0 mm 34.5 mm
DX340LC ARM OPT ARM
(6.69 in) (1.36 in)
150.0 mm 28.5 mm
BUCKET OPT BUCKET
(5.91 in) (1.12 in)
165.0 mm 34.5 mm
BOOM OPT BOOM
(6.50 in) (1.36 in)
180.0 mm 41.5 mm
DX420LC ARM OPT ARM
(7.09 in) (1.63 in)
160.0 mm 34.5 mm
BUCKET OPT BUCKET
(6.30 in) (1.36 in)

SP000030 Cylinders
Page 19
Slipper Seal Straightening Jig

1
2-C
R
2-5
(A+15)
A

1
2-R
100

25
50

ARS4780L
Figure 11

Cylinders SP000030
Page 20
MODEL CYLINDER A+0.2
+0.1
MODEL (CYLINDER)
140.0 mm
BOOM
(5.51 in)
150.0 mm
DX300LC ARM S/ARM
(5.91 in)
140.0 mm
BUCKET S/BUCKET
(5.51 in)
150.0 mm
BOOM OPT BOOM
(5.91 in)
170.0 mm
DX340LC ARM OPT ARM
(6.69 in)
150.0 mm
BUCKET OPT BUCKET
(5.91 in)
165.0 mm
BOOM OPT BOOM
(6.50 in)
180.0 mm
DX420LC ARM OPT ARM
(7.09 in)
160.0 mm
BUCKET OPT BUCKET
(6.30 in)

SP000030 Cylinders
Page 21
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.

1. Following removal of cylinder from excavator attachment,


support cylinder on some type of sturdy work platform and
drain all oil. Rotate cylinder so that piping ports are on top,
to allow trapped air to vent.

Figure 12

2. Position piston rod so that it is extended approximately one


half meter (20").

Figure 13

3. Remove bolts (7) on the end of cylinder.


NOTE: Wrap a cloth or other protective material around
piston rod, to avoid possibility of accidentally
scratching or scoring rod surface while
fasteners are being loosened and removed.
Component parts (numbered in parentheses)
are keyed to Figure 4.

Figure 14

Cylinders SP000030
Page 22
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

5. Begin withdrawing piston rod assembly, away from


cylinder. Attach a lifting support when final 1/3 of rod is still
inside barrel of cylinder. Prepare support blocks for piston
rod before it has been completely withdrawn.

Figure 16

6. Lower piston rod to support blocks and detach wear ring


(outer surface) (18) from end of rod.

Figure 17

7. Immobilize piston rod by inserting a wooden or other


nonscoring, nonmetallic support through end of rod.

Figure 18

SP000030 Cylinders
Page 23
8. Remove set screw using socket wrench.

HAOF340L
Figure 19

9. Fabricate or purchase a piston nut removal wrench.


(Dimensions are called off at beginning of this procedure.
This tool may also be ordered through your local DOOSAN
Parts distributor). Remove nut from end of piston.

Figure 20

10. Use second piston tool described at beginning of this


procedure to separate piston. Detach cushion ring (15),
taking care not to damage cushion ring.

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 24
12. Use a dull, rounded tip tool to pry off O-ring (11) and
backup ring (12).

HAOF37OL
Figure 23

13. Find a screwdriver with an appropriate width tip to facilitate


removal of slipper seal (19), wear ring (18) and slide ring
(17) from piston (16).

Figure 24

14. Remove O-ring (20) and backup ring (21) from cylinder
head.

HAOF38OS
Figure 25

15. During disassembly of cylinder head, be careful not to


damage buffer seal (5) and U-packing (4).

HAOF39OL
Figure 26

SP000030 Cylinders
Page 25
16. Disassemble retaining ring (3) and dust wiper (2). Separate
retaining ring (8) and rod bushing (6).

Figure 27

17. Force out pin bushing (1) from body of cylinder.

Figure 28

Cylinders SP000030
Page 26
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.

NOTE: Reassemble the subassemblies of the cylinder in the


following order:
1. Body of the cylinder.
2. Piston rod.
3. Piston assembly.
4. Cylinder head assembly.
1. Reassemble pin bushing (1) to piston rod (13) and body of
cylinder (14).

Figure 29

2. Following reassembly of rod cover components, install the


dust wiper (2) and rod bushing (6) to the rod cover (9).
Insert retaining rings (3 and 8).

Figure 30

SP000030 Cylinders
Page 27
3. Prelubricate O-rings and seals before reassembly (Figure
31).

Figure 31

4. Before starting to rebuild piston assembly, heat slipper seal


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

Figure 32

5. Immobilize piston rod on solid support blocks. Assemble


O-ring (20) and backup ring (21). Prepare to attach rod
cover assembly to piston rod. Push rod cover by tightening
piston nut (22).

Figure 33

6. Assemble cushion ring (15) and attach piston assembly to


piston rod.

Figure 34

Cylinders SP000030
Page 28
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

9. Immobilize body of cylinder before reassembly.

Figure 37

Preapply fastener locking compound (Loctite #242 or #243 or an


alternate manufacturer's equivalent product) to all end cover
retaining bolts. Wrap a protective cushion around end of rod
while tightening fasteners, to prevent possible damage to
polished surface of rod, should a wrench slip during retightening.

Figure 38

SP000030 Cylinders
Page 29
Cylinders SP000030
Page 30
SP000261
SWING MOTOR SP000261

Swing Motor

Edition 1

Swing Motor SP000261


Page 1
MEMO

SP000261 Swing Motor


Page 2
Table of Contents

Swing Motor
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 6
Parts List ......................................................................... 6
Specifications .................................................................. 8
Torques ........................................................................... 8
Theory of Operation ........................................................ 9
Makeup Check Valve .................................................... 12
Operation of Time Delay Valve ..................................... 12
Operation of Swing Reactionless Valve ........................ 12
Tools and Materials ............................................ 13
Tools.............................................................................. 13
Troubleshooting, Testing and Adjustment .......... 14
General Precautions...................................................... 14
How to Check Faults of Hydraulic Motor ....................... 14
Troubleshooting............................................................. 14
Disassembly ....................................................... 16
General Cautions .......................................................... 16
Disassembly of drive shaft subassembly ...................... 16
Disassembly of the cylinder block subassembly ........... 19
Disassembly of the rear cover subassembly................. 20
Cleaning and Inspection (Wear Limits and
Tolerances)........................................................ 23
Reassembly ........................................................ 23
General Cautions .......................................................... 23
Reassembly of drive shaft subassembly ....................... 23
Assembly of Cylinder Block Assembly Subassembly.... 26
Assembly of Rear Cover Assembly Subassembly ........ 30
Air Pressure Test........................................................... 34
Oil Leakage Check ........................................................ 34
Installation of test bench................................................ 35

Swing Motor SP000261


Page 3
MEMO

SP000261 Swing Motor


Page 4
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.

MODEL SERIAL NUMBER RANGE


DX340LC 5001 and Up
DX420LC 5001 and Up

SP000261 Swing Motor


Page 5
GENERAL DESCRIPTION

Parts List

21

20
25
33 42
24
23
9
34
38
36 10 41
37
35 11

26 12
27 43
29
30 22 28
13

14

18
8

19
6

17 5

39
1

31
15
32
16

15

16 4

15
3
16
40
15
2
16
7
FG005164

Figure 1

Swing Motor SP000261


Page 6
Reference Reference
Description Description
Number Number
1 Body 23 Rear Cover
2 Oil Seal 24 Socket Bolt
3 Roller Bearing 25 Socket Bolt
4 Snap Ring 26 Poppet
5 Shaft 27 Spring
6 Pin 28 Plug
7 Stop Ring 29 O-ring
8 Shoe Plate 30 Relief Valve Assembly
9 Cylinder 31 Time Delay Valve
10 Spring 32 Socket Bolt
11 Ball Guide Seat 33 Plug
12 Ball Guide 34 Swing Reactionless Valve
13 Set Plate 35 Plug
14 Piston Assembly 36 O-ring
15 Friction Plate 37 Backup Ring
16 Plate 38 O-ring
17 Brake Piston 39 O-ring
18 O-ring 40 Bushing
19 Spring 41 Rotary Kit
20 Valve Plate 42 Cylinder Block Kit
21 Pin 43 Retainer Kit
22 Needle Bearing

SP000261 Swing Motor


Page 7
Specifications
Items Units
329 l/min
Oil Flow
(86.9 gpm)
Set Pressure of Relief V/V 270 kg/cm2
(Cracking) (3,840 psi)
250 cc/rev
Motor Displacement
(15.26 in3/rev)
107.4 kgm
Motor Output Torque
(777 ft lb)
Motor Speed 1,316 rpm
107 kgm
Brake Torque
(774 ft lb)
Spool Cracking 13 kg/cm2
Brake Pressure (185 psi)
Switching
Delay Period 6.5 1.5 sec
Weight - kg

Torques
No. Tools Measures B Torque
30 Relief Valve M33 36 mm 1700 - 1900 kgcm
(123 - 137 ft lb)
33 Plug PT 1/4 6 mm 2,090 kgcm
(150 ft lb)
32 Wrench Bolt PF 1/4 5 mm 691 kgcm
(50 ft lb)
24 Wrench Bolt M14 12 mm 2,090 kgcm
(150 ft lb)
25 Wrench Bolt M14 12 mm 2,090 kgcm
(150 ft lb)

Swing Motor SP000261


Page 8
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

Figure 2

SP000261 Swing Motor


Page 9
Generation of Rotary Power
High-pressure oil from hydraulic pump flows into the cylinder (9)
through the valve casing (1) and the valve plate (20). 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 (14).
As shown in the Figure 3, 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
FG005170
Figure 3

Swing Motor SP000261


Page 10
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.

Figure 4

Operation of Parking Brake

1. Swing Brake Off


Pilot oil moves the swing spool and flows to port SH of time
delay valve in swing motor through shuttle valve in case
when the swing control lever is in the swing position. This
pressure moves the spool to the left against the spring
force, causing the port PG oil of the time delay valve to
move to the parking piston. The oil moves the parking
piston, pressing the friction plate upwards to release the
parking brake.
2. Swing Brake On
When the swing control lever is returned to the neutral
position, swing pilot pressure applied to the port SH in the Figure 5
time delay valve through shuttle valve will be blocked. The
spool is returned by spring force and the port PG pressure
at the time delay valve, which always is ready if the relief
valve is interrupted by flow to the parking piston. The
orifice then causes a six second time delay at the spool to
prevent the discharge of line oil at that time in order to
avoid any shock when the swing brake is suddenly applied.

SP000261 Swing Motor


Page 11
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. Figure 6

Operation of Time Delay Valve


Capacity of a driving motor depends on the angle of the swash
plate (16) which is controlled by the tilting valve.

External Pilot Pressure: When Pi = 0 (Large Tilt Angle)


The high-pressure oil acting on the motor comes to act on the
port P of the tilting valve with the high-pressure select function
built in the valve casing. The high-pressure oil flows into the port
Sb as the spool assembled in the tilting switching part sticks to
the plug by spring. This high-pressure oil applies pressure on
the chamber A through the valve casing and the channel A' of
the shaft casing from the port Sb. Oil in the chamber B comes to
flow into the drain line through the channel B Sa. The tilting
piston moves to the right side by high-pressure oil and the
swash plate moves to and stops at a position where it sticks to Figure 7
the stopper on the basis of the rotation center, '0'.

Operation of Swing Reactionless Valve


Brake is applied to the lateral port, as the motor receiving pump
action has two ports blocked when a rotating device of hydraulic
motor starts or stops rotating parts by controlling switching
valves. While rotating parts stop operation due to this brake
pressure, 4 or 5 inversions take place. The anti-inversion valve
blocks both ports during ordinary operation but bypasses some
blocked pressure oil to a reverse port for a certain period in case
of inversion to ensure the increase of pressure in the motor and
the decrease of inversion.
Figure 8

Swing Motor SP000261


Page 12
TOOLS AND MATERIALS

Tools
Tools B Length Tools to Be Used
Hex L Wrench 5 mm Wrench bolt (32)
6 mm Plug (33)
12 mm Wrench bolt (24, 25)
17 mm Plug (28)
Socket Wrench 36 mm Relief valve assembly (33)
Spanner
Snap Ring Pliers (For Orifice And Snap Ringp (4)
Axis)
Bar Hammer Needle bearing (22), Pin (6, 21)
Torque Wrench Measure:
Oil Seal Assembly Jig Oil seal (2)
Bearing Induction Heating Device Roller bearing (3)

B B
ARS3980L
Figure 9

SP000261 Swing Motor


Page 13
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.

How to Check Faults of Hydraulic Motor


1. Remove the drain plug and check oil in the case. Too
much chips and metal dust in oil causes the possible wear
of parts in the motor.
2. Abnormal noise. Check any abnormal noise from the main
body of the motor.
3. Pressure measurement at each part. Check any possible
faults by measuring circuit pressure up to the hydraulic
motor before disassembling the motor.

Troubleshooting
Problem Possible Cause Remedy
Abnormal operation of driving devices.
Motor pressure does not Oil bypassing in relief valve (30) Replace or repair relief valve.
increase. Check spring broken. Replace check spring.
Oil channel inside the rear cover Replace rear cover
cracked.
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.

Swing Motor SP000261


Page 14
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.

SP000261 Swing Motor


Page 15
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 of drive shaft subassembly


1. Remove the wrench bolt (32) and take away the time delay
valve assembly (31) from the body(1).

FG000682
Figure 10

Figure 11

Swing Motor SP000261


Page 16
2. Use a hexagonal wrench to remove the wrench bolts (24,
25) and disassemble the rear cover (23) assembly from the
body (1).

Figure 12

3. Disassemble the spring (19) to remove the break piston


(17) and disassemble it from the body (1) using a jig.

FG000687
Figure 13

FG000688
Figure 14

4. Remove cylinder block assembly, friction plate (15), and


plate (16) from body (1).
NOTE: Pay attention to order of plates and friction
plates.

FG000689
Figure 15

SP000261 Swing Motor


Page 17
Figure 16

5. Remove shoe plate (8) from body (1).

Figure 17

6. Remove snap ring (4) from body (1) using snap ring pliers
jig.
7. Turn body over, and separate shaft (5) assembly using
steel bar.

FG000693
Figure 18

Figure 19

Swing Motor SP000261


Page 18
Disassembly of the cylinder block
subassembly
8. Separate piston assembly (14) and the set plate (13) from
cylinder block assembly.

FG000696
Figure 20

FG000697
Figure 21

9. Remove friction plate (15), plate (16), ball guide (12), ball
guide seat (11) and spring (10) from cylinder block (9).

FG000698
Figure 22

SP000261 Swing Motor


Page 19
FG000699
Figure 23

FG000700
Figure 24

Disassembly of the rear cover


subassembly
10. Separate valve plate (20) from rear cover (23).

FG000701
Figure 25

Swing Motor SP000261


Page 20
Figure 26

11. Remove two relief valve assemblies (30) from rear cover
(23) with torque wrench.

FG000706
Figure 27

FG000707
Figure 28

12. Remove check valve assemblies from rear cover (23) with
L wrench, and disassemble it in order of plug (28), spring
(27), and poppet (26).

FG000708
Figure 29

SP000261 Swing Motor


Page 21
FG000709
Figure 30

13. Remove plug (35) from rear cover (23) with L wrench and
disassemble it in order of backup ring (37), O-ring (36), O-
ring (38) and anti-inversion valve assembly (34).

FG000710
Figure 31

FG000711
Figure 32

FG000712
Figure 33

Swing Motor SP000261


Page 22
CLEANING AND INSPECTION
(WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to
"General Maintenance Procedures" section.

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.

Reassembly of drive shaft subassembly


1. Put roll bearing (3) on a heater and apply heat to their inner
3
race (inlet temperature: 290C for 2 minutes). 39

Bushing X 1ea Roll Bearing X 1ea


(SUJ) (NUP2209)
FG001328
Figure 34

FG000715
Figure 35

SP000261 Swing Motor


Page 23
2. Assemble heated roll bearing (3) into the shaft (5). Use a
pliers jig to assemble install stop ring (7).

FG000716
Figure 36

FG000717
Figure 37

3. Assemble oil seal (2) in body (1) using bar hammer.

FG000719
Figure 38

Figure 39

Swing Motor SP000261


Page 24
4. Install shaft in body (1) using bar hammer.

FG000717
Figure 40

Figure 41

5. Secure shaft with snap ring (4) using snap ring pliers.

FG000722
Figure 42

Figure 43

SP000261 Swing Motor


Page 25
6. Coat shoe plate (8) with grease, and assemble it into body.

FG000724
Figure 44

Figure 45

Assembly of Cylinder Block Assembly


Subassembly
7. Insert nine sets of springs (10) in cylinder block (9).

FG000726
Figure 46

FG000727
Figure 47

Swing Motor SP000261


Page 26
8. Insert ball guide seat (11) and ball guide (12) in cylinder
block (9).

FG000728
Figure 48

FG000729
Figure 49

FG000759
Figure 50

FG000730
Figure 51

SP000261 Swing Motor


Page 27
9. Insert nine sets of piston assembly (14) in set plate (13)
and assemble it into cylinder block (9).
NOTE: Coat piston with clean hydraulic oil.

FG000731
Figure 52

FG000696
Figure 53

FG000732
Figure 54

10. Assemble cylinder block into body (1).


11. Assemble friction plate (15) and plate (16) into body (1).

Figure 55

Swing Motor SP000261


Page 28
Figure 56

12. Assemble O-ring (18) into brake piston (17).

FG000704
Figure 57

FG000687
Figure 58

13. Insert brake piston assembly in body and secure it using


jig.
14. Insert eighteen springs (19) into brake piston (17).

FG000736
Figure 59

SP000261 Swing Motor


Page 29
Figure 60

Assembly of Rear Cover Assembly


Subassembly
1. Insert pins (6 and 21) in rear cover (23) with bar hammer
and assemble needle bearing (22) using jig.

FG000738
Figure 61

Figure 62

2. Insert poppet (26), spring (27), and plug (28) in rear cover
(23). Tighten plug with L wrench. (Left and right
symmetrically.)

FG000708
Figure 63

Swing Motor SP000261


Page 30
Figure 64

3. Assemble anti-inversion valve. Assemble body, spring


seat, spring, poppet, poppet seat, stopper, and spring.
Then assemble O-ring (36), backup ring (37), and O-ring
(38) using jig.

FG000745
Figure 65

FG000711
Figure 66

FG000710
Figure 67

SP000261 Swing Motor


Page 31
4. Assemble anti-inversion valve set. Assemble anti-inversion
valve set (34) and plug assembly (35) into rear cover (23)
and tighten them with L wrench.

FG000746
Figure 68

5. Assemble two relief valve assemblies (30) into rear cover


(23) with torque wrench. (Left and right symmetrically.)

FG000706
Figure 69

Figure 70

6. Coat valve plate (20) with grease and attach it to rear cover
(23).

FG000701
Figure 71

Swing Motor SP000261


Page 32
Figure 72

7. Put the rear cover ass'y on the body (1) and tighten its
wrench bolts (24, 25) with impact and then torch wrench.

Figure 73

8. Install time delay valve assembly onto rear cover (23) with
wrench bolts (32).

FG000682
Figure 74

Figure 75

SP000261 Swing Motor


Page 33
Air Pressure Test
Apply air pressure into assembled motor, dip it in treated oil for
one minute and check any leakage from it.

FG000754
Figure 76

Oil Leakage Check


Wash motor with Color Check No.1, spray No.3, and check for
any oil leakage.

FG005165
Figure 77

FG005166
Figure 78

FG005169
Figure 79

Swing Motor SP000261


Page 34
Installation of test bench
Install the motor test bench to test each function.

Figure 80

SP000261 Swing Motor


Page 35
Swing Motor SP000261
Page 36
SP000266
TRAVEL MOTOR (WITH GEARBOX)SP000266

Travel Motor
(With Gearbox)

Edition 1

Travel Motor (With Gearbox) SP000266


Page 1
MEMO

SP000266 Travel Motor (With Gearbox)


Page 2
Table of Contents

Travel Motor (With Gearbox)


Safety Precautions ............................................... 5
Applicable Models ................................................ 5
Travel Motor (M3V270/160A) ............................... 6
Specifications .................................................................. 6
Structure and Function .................................................... 8
Disassembly and Assembly .......................................... 15
Disassembly .................................................................. 16
Reassembly................................................................... 20
Maintenance Standard .................................................. 23
Troubleshooting............................................................. 25
Reduction Gear (M3V270 / 160A-RG7.5)........... 27
Specifications ................................................................ 27
Structure and Operation ................................................ 28
Disassembly and Assembly .......................................... 30
Disassembling Reduction Unit ...................................... 31
Assembling.................................................................... 36
Maintenance.................................................................. 43
Inspection After Assembling.......................................... 45
Brake Valve (RBV - 24DL4)................................ 46
Specification .................................................................. 46
Structure and Operation ................................................ 47
Disassembling and Reassembling ................................ 53
Disassembling Procedure ............................................. 53
Reassembling................................................................ 54
Troubleshooting............................................................. 56

Travel Motor (With Gearbox) SP000266


Page 3
MEMO

SP000266 Travel Motor (With Gearbox)


Page 4
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.

MODEL SERIAL NUMBER RANGE


DX420LC 5001 and Up

SP000266 Travel Motor (With Gearbox)


Page 5
TRAVEL MOTOR (M3V270/160A)

Specifications

Outline Dimensions

Figure 1

Travel Motor (With Gearbox) SP000266


Page 6
Specifications

Item M3V270 / 160A


Major Capacity 273.50 cc/rev (16.69 in3/rev)
Minor Capacity 160.60 cc/rev (9.80 in3/rev)
Rated Pressure 355 kg/cm2 (5,049 psi)
Maximum Pressure 420 kg/cm2 (5,974 psi)
Braking Torque Over 65.7 kgm (644 Nm)
Brake Release Pressure Below 15.7 kg/cm2 (233psi)
Allowable Drain Pressure Normal 2 kg/cm2 (28.5 psi) (Surge 10)
Weight 130 kg (287 lb) wet, (Including Brake Valve 11)

SP000266 Travel Motor (With Gearbox)


Page 7
Structure and Function

Structure

Figure 2

Travel Motor (With Gearbox) SP000266


Page 8
Reference Reference
Description Description
Number Number
1 Case 24 M6 Restrictor (0.6)
2 Rear Cover 25 M6 Restrictor (0.8)
3 Cylinder Block 26 Oil Seal
4 Shoe Retainer 27 Spring for Check Valve
5 Friction Plate 28 Spring for Cylinder Block
6 Brake Piston 29 Brake Spring
7 Separator Platee 30 Bearing HR32209J
8 Valve Plate 31 Bearing HR32207C
9 Shaft 32 CSK Head Cap Screw M18x50
10 Threaded Pin 33 Shim
11 Shoe Plate 34 Parallel Pin 8x12
12 Spherical Coupling 35 O-ring 1B P6
13 Spring Seat 36 O-ring 1B P8
14 Piston Assembly 37 O-ring 1B P9
15 D-ring (Small) 38 O-ring 1B S10
16 D-ring (Big) 39 O-ring 215.57 x 2.62
17 Check Valve 40 Overload Valve ORV-240L5
18 C-type Retaining Ring 41 Pilot Valve MRC03A
19 Round R Retaining Ring 42 Brake Valve RBV-240DL4
20 Control Piston 43 Spacer
22 Pivot 44 O-ring
23 Piston Seal

SP000266 Travel Motor (With Gearbox)


Page 9
Explanation of Structure
The motor mainly consists of rotary group (producing turning
force to drive shaft), negative brake (preventing host machine
from self-running during its rest), capacity control parts (that
changes the motor capacity consequently rotating speed) and
overload valve (attached to the rear cover).
There is another valve that plays an important role in controlling
the hydraulic circuit. it is called the brake valve or counter
balance valve.
1. Rotary Group
The cylinder block (3) is splined to shaft (9). Both ends of
the shaft are supported by bearings (30 and 31). The
cylinder block (3) and valve plate (8) are pushed against
the rear cover (2) by cylinder spring (28).
There are nine piston assemblies (14). They slide inside
cylinder block (3) and along the surface of shoe plate (11)
as the cylinder block rotates.
Bearings are provided on the end surface of piston
assembly (14) to reduce the sliding resistance, and the
ends of piston assembly (14) are pushed toward shoe
plate (11) by cylinder spring (28) through spring seat (13),
spherical coupling (12) and shoe retainer (4).
2. Negative Brake
Five separator plates (7) and four friction plates (5) are
alternately set on the spline of cylinder block (3) and case
(1). Fourteen brake springs (29) push on brake piston (6)
pressing the separator and friction plates together.
3. Capacity Control Parts they consist of;
A. Pivots (22) that support shoe plate (11) and slide in
two half-spherical recesses in shoe plate (11).
B. Control piston (20) that change the angle of shoe
plate (11) on the pivots (22).
C. Stopper (1-1) that limits the angle of shoe plate (11).
D. Pilot valve (41) that leads the oil to control piston (20)
by external pilot signal.
E. Three check valves (17) that select the maximum
pressure from the external pilot pressure, inlet
pressure and outlet pressure of the motor and send it
to pilot valve (41).

Travel Motor (With Gearbox) SP000266


Page 10
4. Overload Valve
This valve is screwed in the motor rear cover (2) and
consists of;
A. Socket (40-1) that Is screwed and fixed in the rear
cover (2) and supports the valve seat (40-3) which
metallically seated in the hole of rear cover (2).
B. Valve (40-2) that contact with valve seat (40-3) by
adjusting spring (40-9) and fitted in the hole of socket
(40-1).
C. Connecting piston (40-4) that fitted in the hole of the
valve (40-2) and functions also as an oil passage.
D. Piston (40-7) that is inserted in the pilot body (40-6).
E. Shim (40-8) that adjust the spring force.

Figure 3 Structure of Overload Valve (2259-3-20776)

Reference Reference
Description Description
Number Number
40-1 Socket 40-8 Shim
40-2 Valve 40-9 Adjusting Spring
40-3 Valve Seat 40-10 O-ring, IB P7
40-4 Connecting Piston 40-11 Back-up Ring, T2 P7
40-5 Plug 40-12 O-ring, IB G25
40-6 Pilot Bod 40-13 Back-up Ring, T2 G25
40-7 Piston

SP000266 Travel Motor (With Gearbox)


Page 11
Function
Table 1: Direction of Rotation

Inlet Outlet
Direction of Rotation
Port Port
VA VB Right (clockwise)
VB VA Left (counterclockwise)

Figure 4 Main Ports

Motor
High pressure oil delivered from hydraulic pump is routed to inlet
port of brake valve (42) and through the rear cover (2) and valve
plate (8), to cylinder block (3). The oil flow and direction of shaft
rotation are indicated in Table 1: Direction of Rotation.
As shown in (A, Figure 5), high pressure oil is supplied to the
pistons which are on one side of the line Y-Y that connects
upper and lower dead points and produces force Fl.
Fl = P x A
(P pressure, A: area of piston section).
The shoe plate (11) with inclined angle of a divides this force F1
into thrust force F2 and radial force F31 ~ F34 (or F35) (B, Figure 5 Main Ports
Figure 5). This radial force is applied to axis Y-Y as turning force
and generate drive torque of T.
T = r1F31 + r2F32 + r3F33 + r4F34
NOTE: In case high pressure oil is applied to five pieces of
pistons, r5F35 should be added.
This drive torque is transmitted via cylinder block (3) to driving
shaft (9).
Negative Brake
Negative brake is released when high pleasure oil, selected by
the brake valve (42, Figure 6) that is connected directly to the
rear cover (2), Is applied to the brake piston (6).
Otherwise the braking torque is always applied.
This braking torque is generated by friction between separator
plates (7), inserted into the case (1), and friction plates (5).
NOTE: The separator plates are splined on the outer
circumference and engage case (1). The friction
plates are splined on the inner diameter and engage
cylinder block (3).
Figure 6
When no hydraulic pressure is applied to the brake piston (6), it
is pushed by the brake springs (29). The piston pushes friction
plates (5) and separator plates (7) towards case (1) and
generates frictional force which stops rotation of cylinder block
(3) and shaft (9).

Travel Motor (With Gearbox) SP000266


Page 12
Capacity Control Mechanism

Figure 7

Figure 7 shows the capacity control mechanism.


When high speed pilot line is pressurized at port PA, spring (41-
7) is compressed and spool (41-2) shifts to the right to connect
ports P and C. Then, the highest pressure is selected by one of
the check valves (17) (from inlet and outlet pressure of the motor
and high speed pilot line pressure) and pushes control piston
(20). As a result, shoe plate (11) pivots on the two pivots (22) as
shown by dotted lines. The pivoting motion of the shoe plate (11)
is limited by stopper (1-1) that holds its position. With the shoe
plate in the near vertical position, the piston stroke become
shorter and motor capacity becomes smaller, this causes the
motor to rotate faster (around 1.5 times) from the same volume
of oil, while producing less torque.
When there is no hydraulic pressure in the high speed pilot line
PA, spool (41-2) is pushed back by spring (41-7). This causes
the pressure that pushed the control piston (20) to be released
to the hydraulic oil tank. The inlet pressure on the cylinder block
pistons force the shoe plate back to its original position. With
shoe plate at its maximum angle the motor returns to low speed/
maximum torque.

SP000266 Travel Motor (With Gearbox)


Page 13
Overload Valve

Figure 8

There are two overload valves in the cross-over portion of the


counterbalance circuit of brake valve. They accomplish the
following functions:
1. When starting the hydraulic motor, they keep the driving
pressure below a predetermined value while accelerating,
and bypasses surplus oil to return line.
2. When stopping the hydraulic motor, they keep the brake
pressure, that develops on the outlet side of motor, under
the predetermined value to stop the inertial force.
3. An anti-shock load / damping device is built into the valve
for abrupt acceleration during initial starting, and to reduce
shock loading while stopping, For these purposes, the
developed pressure is kept comparatively low using an
orifice for a short period. This orifice then allows the line
pressure to rise to its normal value. While the pressure is
low a smooth meshing of reduction gears, crawler and
sprocket etc. can be accomplished while the initial shock is
absorbed.
When starting, "Port A" pressure increases. This pressure
is applied to the effective diameter of valve (40-2, Figure 8)
which is seated on valve seat (40-3). At the same time, this
pressure is delivered, via the orifice, to the connecting
piston (40-4) inside the valve (40-2). The piston bore
pressure increases to "Port A" pressure. The valve (40-2)
opposes to adjusting spring (40-9) by the force of the
pressure exerted on the area difference between valve
seats effective diameter and piston bore and keep the
predetermined pressure.

Travel Motor (With Gearbox) SP000266


Page 14
When hydraulically braking, the piston (40-7, Figure 8) is at
the left position by the driving pressure, and when "A" port
pressure increases, the pressure is applied also to the
piston (40-7) through the small hole in the valve (40-2) and
piston (40-7) moves right ward until it touches the plug (40-
5). In this while, the valve (40-2) maintains "A" port
pressure at comparatively low against the adjusting spring
(40-9) force and exhaust oil to "B" port side. After the
piston reached to the plug, the valve acts the same as at
starting.

Disassembly and Assembly

Tools and Jigs

Description Specification etc.


Hex. Key Width Across Flat 5, 6, 10, 14
Spanner Width Across Flat 19, 27, 32, 35
Snap Ring Prier For Shaft 45
Snap Ring Prier For Bore 32 ~ 80
Plastic Hammer
Screw Driver Minus (-), Medium Size, 2 Pieces
Torque Wrench 0 ~ 38.5 kgm (0 - 300 ft lb)
Gear (Bearing) Puller Work Size: Dia.75 x Width 45 can be handled.
Mount Metal EX L160, W70, H37, with 20 x 100 long hole, 2 Pieces

Jig for Inserting Oil Seal

Jig for Inserting Piston

Others
Seal Tape
Kerosene
Grease
Hydraulic Oil
Compressed Air
Waists etc.

SP000266 Travel Motor (With Gearbox)


Page 15
Disassembly

General Instructions
1. Select clean disassembling place. Place a rubber pad on
the work bench to prevent parts from being damaged.
2. Clean dirt and foreign materials from reduction gear and
motor.
3. Be careful not to damage the contact surface of O-ring, oil
seal, and seal class and the contact or sliding surface of
gear, pin, and bearing class.
4. Numbers in () indicate part numbers in reduction gear and
motor drawing.
5. Piping side of motor indicates rear side and output side
indicates front side.
6. Before applying Loctite, completely remove oil from mating
surfaces using Loctite #587 and uniting them.
7. When tightening bolts, apply Loctite #262 to bolt threads
and tighten to rated torque using a torque wrench. (Apply
when assembling reduction gear only.)
8. Use only a plastic hammer.
9. After cleaning each part, blow dry with moisture free air.
But do not clean friction plates with cleaning oil.

Disassembling Procedure
1. Removing accessory valves.
Before disassembling motor, remove accessory valves.
A. Remove brake valve (42, Figure 9).
B. Remove pilot valve (41).
C. Remove check valve (17).
D. Remove overload valve (40).
E. Remove coupling (10)
NOTE: According to disassembling purpose, select
valves to be removed. Figure 9
Motor can not be disassemble without removing
brake valve.

Travel Motor (With Gearbox) SP000266


Page 16
2. Disassembly of motor
A. Place motor with shaft horizontal.
B. Remove cap screws (32) holding rear cover (2)
leaving two diagonally from each other in the upper
and lower positions.
C. Slowly and simultaneously remove remaining two
cap screws.
D. Remove rear cover (2) and brake springs (29) taking
care cylinder block (3) does not come out from being
stuck in rear cover (2).
NOTE: Do not drop, valve plate (8), brake springs
Figure 10 Removing Rear Cover
(29) and/or O-rings (36).
NOTE: If cylinder block (3) does come out with
rear cover (2), push back into cylinder
block (3) using a rounded point bar (5 - 8
mm) through oil hole of rear cover (2). Be
careful not to scratch any of these parts,
while pulling out rear cover (2).
E. Remove valve plate (8) without pulling out cylinder
block (3).
NOTE: Match mark valve plate (8) and rear cover
(2) so that valve plate (8) will not be
reversed during reassembly.
F. Using removed cap screws, fasten two metal mounts
so they push in on cylinder block (3) without
damaging it. Then remove inner race of rear bearing
(31).
G. Place two fingers of gear (bearing) puller under inner
race of rear bearing (31) and remove it.
H. Hold brake piston (6, Figure 10), and apply
compressed air through brake release oil hole, to
force out piston (6).

CAUTION!
Be aware of piston popping out.

Figure 11

SP000266 Travel Motor (With Gearbox)


Page 17
I. Match mark piston(s) (14) to cylinder block (3), so
that they can be reassembled into same position.
Paper pipe cleaners can be used to help accomplish
this.
J. Remove cylinder block (3), spring seat (13) and
cylinder spring (28).
K. Remove separator plates (7) and friction plates (5).
L. Remove nine piston assemblies (14), shoe retainer
(4) and spherical coupling (12) as an assembly.
NOTE: Place piston assemblies (14) into the
Figure 12 Removing Cylinder Block
cylinder block (3) matching the mating
marks with shoe retainer (4) as if was
assembled. The purpose is to put pistons
(14) into the same bores of cylinder block
(3) as before when assembled.
NOTE: Be careful not to scratch polished
surfaces. Do not reuse damaged ones.
NOTE: It is impossible to disassemble piston and
shoe because they are calked together.
M. Remove shoe plate (11).
N. Do not detach control piston (20) unless necessary. If
it must be detached, hold control piston and using
compressed air through the hole shown, to force it
out.

CAUTION!
Be aware of piston popping out.
Figure 13 Removing Shoe Plate
O. Remove shaft (9).
P. Remove retaining ring (19) and oil seal (26).
Q. If bearings need to be replaced, remove inner races
and outer races using bearing puller. Install new
bearings during reassembly.

IMPORTANT
Under outer race of rear bearing (31), are shims (33).
Reuse them as they are if none of the major
components mentioned in the following notes are
replaced.

NOTE: When changing bearings (30 or 31), shaft


(9), case (1) or rear cover (2), it affects the
clearance of the bearings. So, shim(s) (33)
should be adjusted.

Travel Motor (With Gearbox) SP000266


Page 18
NOTE: Shim adjustment should be performed by
measuring clearance for shim and
adjusting shim pack to meets that
clearance.
Other jigs and tools are needed to
measure and decide the thickness of the
shim.
NOTE: Do not remove pivots (22) unless
necessary. If they must be removed,
match mark each pivot (22) with shoe
plate (11).
NOTE: Do not remove oil seal (26) for the
purpose of inspection. If removed, install a
new oil seal.
3. Disassembly of overload valve
A. Remove overload valve (40, Figure 14) as an
assembly utilizing hexagonal flats on socket (40-1).
B. Normally the overload valve (40) should be replaced
one service part. If disassembly, is necessary,
remove plug (40-5) from socket (40-1) and remove
internal components.
NOTE: Valve seat (40-3) is press fitted to socket
(40-1). Never disassemble them if unless
absolutely necessary. The hole in socket
may be damaged.

Figure 14 Disassembling Overload Valve

SP000266 Travel Motor (With Gearbox)


Page 19
Reassembly

General Instructions
1. Wash each part thoroughly with kerosene, and blow dry
using compressed air.
2. Assemble sliding parts after coating them with clean
hydraulic oil.

Reassembly
1. Coat outer surface of oil seal (26, Figure 15) and inner face
of case (1, Figure 15) with grease. Using jig, press oil seal
(26, Figure 15) into case (1).

Figure 15 Assembling Oil Seal

2. Secure oil seal (26, Figure 16) into position with retaining
ring (19, Figure 16).
3. Place outer race of bearing (30) on case (1) (this is a loose
fit), and press the inner race on shaft (9) (this is a tight fit).
NOTE: It is easier to install inner race if it is heated to
100C. Never over heat.
4. Coat contact surface to oil seal (26) with grease to prevent
damage and install shaft (9) into case (1).
5. Install control piston (20) into case (1).
6. Using match marks made during disassembly, install shoe
plate (11) and pivots (22) into the case (1).
7. Coat three spherical recesses in shoe plate (11) with
ample grease and assemble it in case (1).

Figure 16

Travel Motor (With Gearbox) SP000266


Page 20
8. Insert piston assembly (14, Figure 17), shoe retainer (4),
spherical coupling (12), spring seat (13), cylinder spring
(28) on to cylinder block (3) as shown and then insert the
whole assembly to shaft (9).
NOTE: Piston assembly (14) should be inserted into the
same bore that it was removed from.
9. Lightly tap in the inner race of rear bearing (31) onto rear
end of shaft (9, Figure 17).

Figure 17 Assembling Piston Assembly

10. Install all the separator plates (7, Figure 18) and friction
plate (5) alternately between case (1) and cylinder block
(3). Separator plates (7) are installed first and last.
11. Install D-rings (15,16) on brake piston (6). Insert brake
piston (6) into case (1) using inserting jig after.
NOTE: Two kinds of D-rings are used on brake piston
(6). The larger one (16) is first inserted into the
groove, then the smaller one (15) is installed. It
is impossible to see how the smaller ring goes
into the groove. Therefore, never push it forcibly
into the groove. Otherwise, it may be scraped
off by the edge of case (1).
12. Lay down rear cover (2, Figure 19) to mount valve plate
(8). Align match marks made during disassembly and also
place brake springs (29) with ample grease to be attached
to rear cover (2) while this assembling. Also set O-ring (38) Figure 18
on rear cover (2). Then, insert rear cover (2) to case (1)
and fasten cap screws (32).
13. Install coupling (10) on shaft (9).
NOTE: Tightening torque of cap screw (32) is 33.0 kgm
with rust preventive on the threads.

SP000266 Travel Motor (With Gearbox)


Page 21
Figure 19 Mounting Rear Cover

Travel Motor (With Gearbox) SP000266


Page 22
Maintenance Standard

Maintenance of Parts
The followings are the general maintenance standards.
However, it is important to determine which parts should be
replaced, depending on the characteristics before
disassembling, damages and discoloration of exterior view, the
purpose of disassembling, the expected remaining service life,
etc.

Maintenance Standard

Judging Criteria and Disposition


Item and Measuring Method Check Item Criteria Allowable Disposition
Roughness
1. Sliding surface of: cylinder block, valve plate and shoe plate
Measure the surface Surface roughness of below 0.4Z Below 3.0Z Replace or
roughness using a cylinder block, valve Repair
roughness tester. plate and shoe plate
NOTE: Lap together the surfaces of both cylinder block and valve plate
to remedy their roughness (Lap with #1200 powder).
Measure the surface Shoe plate Over HS78 HS74 Replace
hardness with a hardness
taster
2. Clearance between piston and cylinder block
Measure outer dia. of Outer dia. of piston 0.01 mm 0.05 mm Replace
piston and bore of cylinder d max - d min piston or
block at least 3 places in Inner dia. of cylinder 0.01 mm 0.022 mm cylinder
the longitudinal direction bore block
with micrometer, and D max - D min
obtain:
Clearance D - d 0.037 ~ 0.050 0.065 mm
max. outer dia. = d max mm
min. outer dia. = d min NOTE: In exchanging pistons, replace all of nine pistons at the same
min. inner dia. = D min time.
max. inner dia. = D max
3. Play between piston and Play between calked 0-0.1 mm 0.3 mm Replace
shoe with the jig shown in piston and shoe piston
Figure 20, Hold down the
shoe on work stand, and
pull up the piston in vertical
direction to measure the
play between piston and
shoe.

Figure 20

SP000266 Travel Motor (With Gearbox)


Page 23
Judging Criteria and Disposition
Item and Measuring Method Check Item Criteria Allowable Disposition
Roughness
4. After completion of Parking brake torque 65.7 kgm 60.0 kgm Replace all
assembly, set the torque separator
wrench on the shaft end, and friction
and measure the braking plates and
torque generated when the springs
shafts starts to rotate.
5. Shaft If the depth of shaft wear is less than 0.05mm, the shaft is reusable.
Measure the wear at
NOTE: Incase of replacing the shaft (9), replace oil seal (26) at the
contacting surface of oil
same time.
seal (26) with the surface
roughness tester. NOTE: In case replacing the bearings (30, 31), replace both inner and
6. Bearings outer races at the same time.
Replace bearings (30, 31) NOTE: Also the bearing shims (33) must be re-adjusted when replaced
before hour meter of host shaft (9) and / or bearings (30, 31). Contact dealers for jigs and
machine indicates 10,000 tools required.
hours.
7. Splines If the wear of splines is less than 0.3 mm, the spline is reusable.
Replace if the wear of
splines exceeds the
allowable value.
8. Overload relief valve Replace relief valve (40) as an assembly each time the host machine
Do not try to adjust the works for 10,000 hours.
valve, since special
hydraulic test bench is
required for inspecting and
adjusting the pressure.

Fastening Torque
Use torque wrench when tightening the following cap screws,
plugs and valves. Lubricating with rust preventive oil.

Item Description Size Fastening torque


32 Csk Head Cap Screw M18 33.0 kgm
40 Overload Valve M27 10 ~ 12 kgm
41-10 Csk Head Cap Screw M8 2 kgm
42-14 Csk Head Cap Screw M12 8 0.8 kgm

Travel Motor (With Gearbox) SP000266


Page 24
Troubleshooting

General instructions
The followings are the general instructions to be followed when
some troubles occur with hydraulic motors.
1. Judge the nature of abnormality before troubleshooting,
and ascertain if the same symptom has occurred before or
not. Review if the motor itself is actually causing the
problem.
2. In many cases, the wear is caused by dusts. Take great
care to prevent dusty when disassembling and
assembling.
3. All the parts especially those of moving parts should be
carefully handled, and be careful not to score or scratch
the sliding surfaces.
4. Be careful not to score the seating surface for O-ring, etc.
Replace O-rings with the new ones, once disassembled.

Cause of Trouble and Remedy

Problem Possible Cause Remedy


Hydraulic motor never starts.
Pressure never increases Malfunction of built-in relief valve. Repair or replace relief valve.
Negative brake is not released.
Check clogged passage. Wash or
(Clogged choke of release pressure
replace it.
passage.)
Stuck friction plate or stuck
separator plate provided in negative Replace friction and separator plate.
Pressure increases brake.
Stuck brake piston of negative Repair outer dia. of brake piston or
brake. replace it.
Check, repair or replace piston
Seizure of sliding portion. shoe, shoe plate, cylinder block
valve plate etc.
Hydraulic motor is hard to start.
Set pressure of overload valve
is correct, but brake is released Malfunction of brake valve. Check brake valve.
belatedly.
Negative brake is released, but
High oil viscosity. Raise oil temperature.
motor is hard to start.
Negative brake is not completely Check clogged chock.
released. (Clogged chock of
Wash relief valve or the sear of it or
Negative brake is released, but pressure release passage.)
replace seat.
motor starts weakly.
Relief valve catches small particles.
Check, repair or replace sliding
Seizure of sliding portion. portion.
Drive shaft never rotate up to the set valve.

SP000266 Travel Motor (With Gearbox)


Page 25
Problem Possible Cause Remedy
Shortage of oil coming in. Check oil flow or hydraulic circuit to
Rotation of drive shaft never motor.
reaches the set value. Large wear or flaw made on shoe,
cylinder block or valve plate. Check, repair or replace the parts.
Brake refuses to work
Malfunction of negative brake.
Check, repair or replace brake
Brake refuses to work. Worn friction plate.
piston, friction plate, spring, etc.
Broken spring.
Oil leakage.
Loose cap screw or plug. Fasten it with given torque.
Oil leakage. O-ring is torn off. Replace O-ring.
Oil leaks inside gear case. Replace oil seal.
Would not shift from high to low.
Would not shift from high to
Stick of spool of pilot valve. Replace pilot valve assembly.
low.

Travel Motor (With Gearbox) SP000266


Page 26
REDUCTION GEAR (M3V270 /
160A-RG7.5)

Specifications

Outline Dimensions

Figure 21

Specifications

Item M3V270 / 160A-RG7.5


Motor Displacement 273.5 / 160.6 cc/rev
(16.69 / 9.80 in3/rev)
Rated Pressure 355 kg/cm2 (5,049 psi)
Gear Ratio 50.324
Number of Stages 2
Oil Capacity 11.0 liters
(2.9 U.S. gal.)
Oil Specification Gear Oil SAE 90 API GL-4
Weight w/accessory valves 430 kg (wet)
(950 lb)

SP000266 Travel Motor (With Gearbox)


Page 27
Structure and Operation

Structure

Figure 22

Travel Motor (With Gearbox) SP000266


Page 28
Reference Reference
Description Description
Number Number
1 Cover 15 Spring Pin 8x56
2 Carrier 1 16 Thrust Washer 2
3 Carrier Pin 1 17 Ring Gear
4 Needle Bearing 18 Housing
5 Thrust Washer 1 19 Angular Bearing
6 Planetary Gear 1 20 Shim
7 Spring Pin 4x32 21 Lock Washer
8 Thrust Plate 22 Support Ring
9 Sun Gear 1 23 Floating Seal 368
10 Sun Gear 2 24 Socket Head Cap Screw
11 Carrier 2 M10x30
12 Carrier Pin 2 25 Socket Head Cap Screw
M18x100
13 Needle Bearing
26 Socket Head Taper Plug PT3/4
14 Planetary Gear 2

Operation
1. The reduction unit slows down the rotating speed of motor
and converts motor torque to stronger rotating force. This
reduction unit utilizes a two stage, planetary reduction
system. Planetary reduction system consists of sun gear,
planetary gears, (planetary) carriers, and ring gear. When
the sun gear (a) is driven through input shaft, planetary
pinions (b), rotating on their center, also move, meshing
with fixed ring gear (a), around sun gear (5). This
movement is transferred to carrier (k) and deliver the
torque. This mechanism is called a planetary gear
mechanism.

Figure 23 Planetary Gear Machanism

SP000266 Travel Motor (With Gearbox)


Page 29
2. When the sun gear S1 is driven by input shaft, planetary
action occurs among gears S1, a and b and revolution of
gear b transfers the rotation of carrier K1 to second sun
gear S2, and also evokes planetary action between gear
52, a and d. This time, because carrier K2 is fixed to frame,
gear d drivers ring gear a and then ring gear a rotates to
drive sprocket.

Figure 24

Disassembly and Assembly

Tools
Prepare following tools and instruments before disassembling or
assembling.

Description Remarks
Torque Wrench 0 ~ 0.5 kgm (0 ~ 4.9 Nm)
Hex. Socket Wrench Width across flats 8mm and 14mm

Work Stand

Micro Depth Gauge 0 ~ 25 mm (0 ~ 0.98 in)


For knocking in spring pins
Pin
3.5x7.5, 7x70
Eye Bolt M10 and M20 3 pieces each
Kerosene as cleaner, solvent, gear oil, grease, Loctite #242 and no. 515,
Others
seal tape, waists etc.

Travel Motor (With Gearbox) SP000266


Page 30
Disassembling Reduction Unit

Preparation for disassembling


1. The reduction units removed from machine are usually
coverer with mud. Wash outside of propelling unit and dry
it.
2. Remove taper screw plug from drain port. Drain oil from
reduction gears.

CAUTION!
While oil is still hot, inside of the unit may be
pressurized. Take care of the hot oil gushing out of the
unit when loosening the plug.

3. Match Marking Components


Put match marks on ever mating parts when disassembling
so it can be properly reassemble.
NOTE: Numeral in ( ) after the part name corresponds
to the number on Structure on page 1-28.

Setting Reduction Unit on Work stand for Disassembling


1. Remove three M10 cap screws (24) at three places from
cover (1) almost equally apart from each other. Install three
eye bolts and lift unit and place it on work stand with cover
(1) facing up.

CAUTION!
Take great care not to pinch your hand between parts
while disassembling or let parts fall on your foot while
lifting them.

Figure 25

SP000266 Travel Motor (With Gearbox)


Page 31
Removing Cover
1. Remove lifting eyes and remaining M10 cap screws (24)
that secure cover (1).

Figure 26

2. Cover (1) is adhered to ring gear (17). Remove cover (1)


by lightly hammering slantwise upward using a wooden bar
aiming at projection of cover (1)

Figure 27

Removing Carrier 1 Assembly


1. Remove thrust plate (8).
2. Remove sun gear 1 (9).
3. Screw three M10 eye bolts into carrier 1 (2) and lift up and
remove carrier 1 assembly (2, 3, 4, 5, 6, 7).

Figure 28

Travel Motor (With Gearbox) SP000266


Page 32
Removing Carrier 2 Assembly
1. Remove sun gear 2 (10).
2. Screw three M10 eye bolts into carrier 2 (11) and lift up and
remove carrier 2 assembly (11, 12, 13, 14, 15, 16).

Figure 29

Removing Housing Assembly


1. Remove support ring (22, Figure 22).

Figure 30

2. Take off lock washers (21) by hammering on chisel or on


similar tool placed at parting surface.
3. Screw three eye bolts into ring gear (17) and remove
housing assembly including ring gear (17), housing (18),
bearing (17) and floating seal (23).

Figure 31

SP000266 Travel Motor (With Gearbox)


Page 33
Figure 32

Disassembling Housing Assembly


1. Place housing assembly on steel stands with ring gear (17)
below. Match mark housing (18) and ring gear (17).
2. Remove floating seal (23) from housing (18).
3. Remove M18 cap screws (25), leaving two 180 apart from
each other.
4. Loosen two remaining cap screws (25) two turns and tap
lightly on there heads. This will help to remove ring gear
(17) from housing (18).
NOTE: Be careful not to damage sliding surface of
floating seal (23) or its O-ring.
Figure 33 A Set Of Three Of Steel
NOTE: Bearings (19) have been tightly press fitted in Stands Of Same Height
housing (18). Dont remove the bearings (19)
unless otherwise their exchange is needed.
If case bearings were removed, do not re-use
them. New bearings should be used and
properly adjusted with shims.

Removing Floating Seal


1. Remove floating seal (23) from motor side.

Figure 34

Travel Motor (With Gearbox) SP000266


Page 34
Disassembling Carrier 1 Assembly
NOTE: When carrier pins 1 (3) are to be re-used, match
mark each pin with its mating hole in carrier 1 (2) to
assure the same combination as before.

Figure 35

1. Drive spring pins (7) into carrier pins 1 (3).


2. Remove carrier pins 1 (3) from carrier 1 (2).

Figure 36

3. Remove thrust washers 1 (7), planetary gears 1 (6), and


needle bearings (4).
4. Drive out spring pins (7) from carrier pins 1 (3) for
reassembling.
NOTE: When carrier pin 1 (3) or planetary gear 1 (6) is
replaced, all three pins or three gears should be
replaced.

Figure 37

SP000266 Travel Motor (With Gearbox)


Page 35
Disassembling Carrier 2 Assembly
NOTE: When carrier pins 2 (12) are to be re-used, mark
each pin wish its mated hole of carrier 2 (11) to
assure the same combination as before.
1. Drive spring pins (15) into pins 2 (12).
2. Remove carrier pins 2 (12) from carrier 2 (11).

Figure 38

3. Remove thrust washers 2 (16), planetary gears 2 (14), and


needle bearings (13).
4. Drive out spring pins (15) from carrier pins 2 (17) for
reassembling.
NOTE: When carrier pin 2 (12) or planetary gear 2 (14)
is replaced, all four pins or four gears should be
replaced.

Assembling
Figure 39
General Notes
1. Clean every part with kerosene and dry them with
compressed air. Surfaces to be coated with Loctite must
be degreased with solvent.
2. Check every part for any abnormalities.
3. Each cap screw should be coated with Loctite #242
applied on its threads.
4. Apply gear oil lightly on each part before assembling.
5. Be careful not to pinch your hand between parts while
assembling nor let parts fall on your foot while lifting them.

Assembling Carrier 2 Assembly


1. Install planetary gears 2 (14), needle bearings (13) and
thrust washers 2 (16) into carrier 2 (11).
2. Install carrier pins 2 (12) into carrier 2 (11). Align holes for
spring pins (15) with those in carrier 2 (11).

Figure 40

Travel Motor (With Gearbox) SP000266


Page 36
3. Install spring pins (15) into carrier 2 (11) and carrier pins 2
(12).

Figure 41

Assembling Carrier 1 Assembly


1. Install planetary gears 1 (6), needle bearings (4), and
thrust washers 1 (5) into carrier 1 (2).
2. Install carrier pins 1 (3) into carrier 1 (2). Align holes for
spring pins (7) wish those in carrier 1 (2).

Figure 42

3. Install spring pins (7) into carrier 1 (2) and carrier pins 1
(3).

Figure 43

SP000266 Travel Motor (With Gearbox)


Page 37
Installing Floating Seal
1. Install floating seal (23) on motor case.

Figure 44

Figure 45

Travel Motor (With Gearbox) SP000266


Page 38
Assembling Housing
1. Apply Loctite #515 on mating surfaces of housing (18) and
ring gear (17).

Figure 46

2. Install three M20 eye bolts equally apart from each other in
housing (18). Using the eye bolts, position housing (18) on
ring gear (17), aligning match marks.
3. After applying Loctite #242 on threads of M18x100 cap
screws (25), tighten them with torque wrench to 41kgm.
4. Install floating seal (23) on housing (18).
NOTE: Clean the groove for floating seals (23) to
eliminate oil, dust, paint or other foreign
material.
NOTE: Apply gear oil lightly on sliding surfaces of
Figure 47
floating seals (27) before assembling. Keep O-
rings and mounting surfaces dry and free of oil.
NOTE: Make sure floating seal (23) O-are not twisted
and that floating seal is correctly installed i.e.
parallel to each other between housing (18) and
motor case after assembled as shown in Figure
48.

Figure 48

SP000266 Travel Motor (With Gearbox)


Page 39
Determining Shim Thickness For Angular Bearings
NOTE: This work should be done only when you have
changed; motor (case), housing (18), bearing (19) or
lock washer (21). Unless otherwise instructed use the
same shim removed during disassembly.
1. Pressing inner races of two bearings (19) evenly, measure
the assembling width (A) of inner laces.
2. Measure motor side assembling width (B) for bearings
(19).
3. Measure groove width (C) of motor.
4. Measure thickness (D) of lock washer (21).
NOTE: Measure them at 4 places, spaced evenly apart
on the circumferences, then calculate and use
there mean average value.
Figure 49

5. When thickness of shim (20) to be used is placed as (S,


Figure 49) the clearance X can be calculated as follows:
X = (B + C) - (A + D + S)
6. Select a shim (20) so that clearance X comes to -0.08
(interference) ~ +0.02 (clearance) on this unit.

Figure 50

Pressing Motor Into Assembly


1. Place motor on work stand with shaft pointing up, and
place the selected shim (20) (Refer to Step 6 above) on
bearing end of motor case.
2. Install three M10 eye bolts on ring gear (17) spaced
equally apart from each other and lift it up. Lower it
concentrically with motor and put bearings (19) of housing
(18) into motor case. Use a press, and press inner lace of
bearing (19) into its full depth.
3. While pressing flange of housing (18), install lock washer
(21) into groove.

Figure 51

Travel Motor (With Gearbox) SP000266


Page 40
4. Install support ring (22) over outside of lock washer (21).

Figure 52

Installation Carrier 2 Assembly


1. Position three planetary gears 2 (14) as shown, and place
carrier 2 assembly into ring gear (17) and engage splines
to those of motor.

Figure 53

2. Position sun gear 2 (10) on center.


NOTE: Positioning carrier 2 assembly as above is
important to obtain better lubrication.

Figure 54

SP000266 Travel Motor (With Gearbox)


Page 41
Carrier 1 Assembly
1. Place carrier 1 assembly into ring gear (17). Rotate
planetary gears 1 (6) by hand and adjust carrier 1 (2) to
mesh with sun gear 2 (10).
2. Install sun gear 1 (7) into center.

Figure 55

3. Place thrust plate (8) on carrier 1 (2).

Figure 56

Installing Cover
NOTE: Gear oil can be added before installing cover (1) if
you can measure proper volume of oil.
1. Apply Loctite #515 on mating surfaces of cover (1) and ring
gear (17). Install cover (1) on ring gear (17).
2. Apply Loctite #242 on threads of 18 - M10x25 cap screws
(24) and tighten them with to a torque of 8 kgm.

Filling Gear Oil


1. Fill gear oil (SAE #90 API class GL-4, 10.5 litters) from two
PT3/4 ports for taper screw plugs (26).
Figure 57
2. Wrap taper plugs (26) with seal tape and put and tighten
them on cover (1).

Travel Motor (With Gearbox) SP000266


Page 42
Maintenance

Inspection Before Re-assembling


Thrust Washer
1. Check if there is seizure, abnormal wear or uneven wear.
2. Check if wear is over allowable wear limits.
Gears
1. Check if there are pitching or seizure on tooth surface.
2. Check if there are cracks on root of tooth by using a die
check.
Bearings
1. Rotate by hand to see if there are something unusual such
as noise or uneven rotation.
Floating seal
1. Check for flaws or scoring on sliding surfaces or on O-
rings.

Maintenance Standards
1. The followings are general maintenance standards.
However, it is important to determine which parts should
be replaced, depending on the characteristics shown
before disassembling, damage or discoloration, the
purpose of disassembling, the expected remaining service
life etc.

SP000266 Travel Motor (With Gearbox)


Page 43
Maintenance Standard

Figure 58

Mark Item Criteria Allowable Limit Disposition


A Wear of planetary shaft Smooth, w/out <- Change a set
B Condition of tooth abnormal wear 1.6 of pitching, no Change a set for plane
surface or seizure cracks at root opinion
C Thrust clearance of -0.08 ~ 0.02 <- Adjust shim. See
angular bearings Determining Shim
Thickness For Angular
Bearings on page -40.
D Thickness of thrust 7 0.2 wear 0.1 Replace
washer 1
E Thickness of thrust 4 0.2 wear 0.1 Replace
washer 2

Fastening Torque
Use a torque wrench when tightening the following cap screws
and plugs.

Item Description Size Fastening Torque


24 Socket Head Cap Screw M10 x 25 8 kgm (78.5 Nm) with Loctite #242
25 Socket Head Cap Screw M18 x 100 41 kgm (402 Nm) with Loctite #242
26 Taper Plug PT 3/4 10 kgm (98.1 Nm) with Seal tape

Travel Motor (With Gearbox) SP000266


Page 44
Inspection After Assembling

Lubrication
After installing the travel motor and gearbox assembly, position
the drain port at its lowest position and check if lubrication oil
comes out when loosening the level plug. If not oil is present at
the level plug, add oil.

Rotating Inspection
Place the unit on a test stand and rotate it with no load and
check if there are any abnormal noises or oil leaks.
NOTE: This inspection can be done while mounted on the
track frame before attaching track.

SP000266 Travel Motor (With Gearbox)


Page 45
BRAKE VALVE (RBV - 24DL4)

Specification

Outline Dimensions

Figure 59

Number Description
13 O-ring
14 Socket Head Cap Screw
15 Plug
16 O-ring
17 O-ring
18 O-ring

Travel Motor (With Gearbox) SP000266


Page 46
Specifications

Item M3V270 / 160A-RG7.5


Rated Pressure 355 kg/cm2 (5,049 psi)
Spool changeover pressure 7.8 ~ 13 kg/cm2 (111 ~ 185 psi)
Cracking pressure of check valve 0.3 kg/cm2 (4.27 psi)

Structure and Operation

Structure

Figure 60

Reference Reference
Description Description
Number Number
1 Body 7 Cover
2 Spool Assembly 8 Restricto
3 Spring Seat 9 Spring
4 Spring 10 Plug
5 O-ring 11 O-ring
6 O-ring 12 Socket Head Cap Screw

SP000266 Travel Motor (With Gearbox)


Page 47
Function
Spool
By shifting the spool, the discharged oil from hydraulic motor is
automatically shut off or restricted according to the operating
condition and gives the effect of holding, accelerating, stopping
and counterbalance operations.
Check Valve (Built into Spool)
This valve is located in the oil supplying passage to hydraulic
motor, and at the same time functions to block oil displacement.
Therefore, this valve serves as not only as a make-up suction
valve but also as a holding valve for hydraulic motor.
Relief Valve (Built in the Hydraulic Motor)
When the oil is pressurized in either the, oil-supply or oil-
discharge passage, of hydraulic motor, to a pressure that is
higher this valves pressure setting value, the pressurized oil is
relieved to the passage of lower pressure side. Thus this relief
valve functions as a safety valve for the circuit.

Travel Motor (With Gearbox) SP000266


Page 48
Operation
Figures shown in this portion of the manual show the oil flow and
the movement of component parts in each operating condition,
The figures are altered for ease of understanding and the correct
arrangement of components can be ascertained from Figure 59
and Figure 60.
Neutral/Holding Position
When the main control valve is in neutral position, ports VA and
VB, are connected to the hydraulic oil tank, and the springs 4
(one each located on both ends of spool) holds spool 2 in a
centered position. This causes passages from, VA to MA, and
VB to MB, to be closed, which result In closing ports MA and MB
connected to hydraulic motor.
Since a passage to parking brake is also connected to tank line,
brake cylinder pressure is equal to that of tank pressure, and
brake is applied by springs. This prevents mechanical rotation of
motor. If an external force/torque is exerted on motor shaft, it will
not rotate.
If brake should be released for some reason, pressure will rise
at either port MA or MB. Due to normal oil leakage inside
hydraulic motor and other components, high-pressure oil will
escape from the closed circuit and the motor will rotated a little.
During this rotation, cavitation tends to occur in the lower
pressure side of the closed circuit. This is when check valve
opens (built into spool) between, ports VA to MA, or ports VB to
MB, to prevent cavitation. The oil is drawn from the hydraulic oil
tank line into the closed circuit to replace the leakage oil.

Figure 61 Holding

SP000266 Travel Motor (With Gearbox)


Page 49
Acceleration Operation
When operating control valve, and port VA is connected to
pump, and port VB is connected tank, pressurized hydraulic oil
from pump, flows through port VA, to push open check valve,
inside spool. This allows oil to flow to motor via port MA which
then rotates the motor. While oil pressure increases, the
negative brake is released. At the same time, the oil pressure of
pilot chamber increases to move the spool to the left,
overcoming spring force. This allows return line from MB to VB
to open and start to rotate motor.
When the starting inertia load is too large to start rotation,
acceleration pressure reaches the pressure setting of relief
valve and high pressure oil is relieved while the motor gains its
rotational speed.
As the rotational speed goes up, the relieved volume of oil
decreases, and finally the motor rotates at a fixed speed.

Figure 62

Travel Motor (With Gearbox) SP000266


Page 50
Stopping Operation
When returning control valve to neutral position when running
motor, oil supplied ports VA and VB is cut off. These ports are
then connected to the tank line. Pressure in each pilot chamber,
one located on each end of spool, becomes equal, and spool
returns to neutral position by spring force. Thus, the passage
from MA to VA is closed.
Due to inertia force from the upper structure load, the hydraulic
motor will be forced to continue to rotate.
Now the motor functions as a pump, and starts to flow oil out of
port MB, but the passage is blocked and so the port MB port
increases. Now the relief valve opens to relieve this pressure
and rotational speed starts to decelerate and final stops the
motor. Negative brake release pressure is gradually lowered
due to the restrictor and finally the brake works and the motor is
mechanically stopped.

Figure 63 Stopping

SP000266 Travel Motor (With Gearbox)


Page 51
Counterbalance Operation
A counterbalance operation is required to slowly decelerate the
hydraulic motor rotation while absorbing inertia force. It also
helps during the acceleration process.
When hydraulic oil is gradually decreased from pump to port VB,
the drive shaft of hydraulic motor tends to rotates faster than the
volume of oil supplied by the pump. Consequently, the pilot
chamber pressure on MB to VB side decreases and the spring
force moves the spool towards the left into the neutral position.
Therefore, the passage from MA to VA becomes smaller and the
pressure on MA side rises due to increased resistance in the
passage. This resistance causes a hydraulic braking effect on
the motor.
When motor is rotating slower than volume of oil being supplied,
pilot chamber pressure on port VB increases, and spool moves
to the right to enlarge passage from MA to VA. This reduces the
braking effect and rotational speed of motor is increased to
correspond to the volume of oil being supplied.
In order to give a very stable counterbalance operation,
restrictors are set in the pilot chamber to dampen the spool
movement, reducing shock loading and erratic operation.
The negative brake is released during pressure adjusting action
of the spool.

Figure 64 Counterbalancing

Travel Motor (With Gearbox) SP000266


Page 52
Disassembling and Reassembling

Preparation for Disassembling


1. Select clean disassembling place. Place a rubber pad on
the work bench to prevent parts from being damaged.
2. Clean dirt and foreign materials from reduction gear and
motor.
3. Be careful not to damage the contact surface of O-ring, oil
seal, and seal class and the contact or sliding surface of
gear, pin, and bearing class.
4. Numbers in () indicate part numbers in reduction gear and
motor drawing.
5. Piping side of motor indicates rear side and output side
indicates front side.
6. Before applying Loctite, completely remove oil from mating
surfaces using Loctite #587 and uniting them.
7. When tightening bolts, apply Loctite #262 to bolt threads
and tighten to rated torque using a torque wrench. (Apply
when assembling reduction gear only.)
8. Use only a plastic hammer.
9. After cleaning each part, blow dry with moisture free air.
But do not clean friction plates with cleaning oil.

Tools

Descriptions Width across flats Remarks


Hex. Key 10 for item 12 and 14
Spanner 19 for item 10

Disassembling Procedure
1. Remove valve from hydraulic motor.
2. Detach O-rings (I6 and 17) from gasket surface.
3. Remove countersunk head cap screw (12) and cover (7).
4. Pull out O-rings (5 and 6), spring (4) and spring seat (3).
5. Pull out spool (2) from body (1). It is impossible to
disassemble this spool any further.
6. Remove plug (10) from cover (7), spring (9) and restrictor
(8).

SP000266 Travel Motor (With Gearbox)


Page 53
Reassembling

Inspection Before Reassembling.


After disassembling, wash all the parts with clean kerosene, and
check as the following, and coat them with hydraulic oil.
1. Spool
No burrs, no dust, no Indents, no rust should be found on
oil groove etc.
2. Sliding parts
All parts should easily slide and move. No foreign particles,
or rust should exist in the grooves, holes, and passages.
3. Check valve
No pitting, scratching or other damage should exist.
4. Seal surface
Seal surface should have no burrs, dust, rust, etc.
5. Restrictor
No pitting, scratches or other damage should be found on
seat surface.
The hole should not be clogged.
6. O-ring
O-rings must be replaced with the new ones each time
valve is disassembled.
7. If damage is found on body or spool, replace valve as a
complete assembly.

Instructions on Reassembling
1. Perform the reassembling work on clean place.
2. Be careful to install the parts at the same position as
mounted before.
3. Remedy the Indents and the like, if made during
disassembling, by oil stone etc.
4. Coat each part by hydraulic oil, and you can perform
reassembly more easily.
5. Replace O-rings with new ones, as a rule.

Fastening Torque

Item Description Size Torque


12 and 14 Socket Head Cap Screw M12 x 45 and 80 8 0.8 kgm
10 Plug PF 1/4 4 - 8 kgm

Travel Motor (With Gearbox) SP000266


Page 54
Reassembling Procedure
1. Fix the restrictor (8) and spring (9) with cover (7).
2. Put the O-rings (5 and 6) in body (1).
3. Install spool (2), spring seat (3) and spring (4) with the
body (1) in this order. Pay attention to installation direction
of spool.
4. Mount cover (7) on body (1) with hex. head cap screw (12).
5. Position O-rings (16 and 17) on gasket surface.

SP000266 Travel Motor (With Gearbox)


Page 55
Troubleshooting
Problem Possible Cause Remedy
Hydraulic motor never rotates.
Malfunction of relief valve built in
Pressure never increases. Repair or replace relief valve.
hydraulic motor.
Malfunction of spool.
Stuck between spool and body. Repair or replace.

Pressure increases. Clogging of restrictor.


Negative brake is not released.
Spool is installed in wrong Install the spool in correct direction.
direction.
Hydraulic motor rotates weakly
The set pressure is correct, but Malfunction of spool.
Repair or replace.
brake is applied with time lag. Stick between spool and body.
Brake applies normal but motor Warm up hydraulic oil or replace
Sticky oil.
starts to rotate with time lag. hydraulic oil.
Negative brake is not fully released.
Brake applies normal but motor Inspect the passage for negative
rotates weakly. Clogged pilot line for negative brake built in hydraulic motor.
brake.
Have no brake effect when the control lever returned to neutral
Malfunction of spool.
Stick between spool and body.
Brake works on counter lever
Stick of check valve or that by Repair or replace or clean.
operation.
small particle.
Clogged restrictor.
Abnormal noise
Abnormal noise appear Malfunction of spool.
together with big vibration when Bleed air.
Air is caught inside brake valve.
brake is slowly applied or oil is
supplied to other circuit while Stick between spool and body. Repair or replace.
motor is running.
Hunting occurs while descending the slope.
Malfunction of spool.
Stick between spool and body.
Severe hunting while inching. Repair or replace.
Restrictor is not seated
completely.
Interference with negative brake.
Repair or replace.
Permanent set or broken spring.

Travel Motor (With Gearbox) SP000266


Page 56
SP000186
MAIN PUMP SP000186

Main Pump

Edition 1

Main Pump SP000186


Page 1
MEMO

SP000186 Main Pump


Page 2
Table of Contents

Main Pump
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
ectional View ........................................................ 6
A8VO200LA1KH1/63 ...................................................... 6
General Repair Guidelines ................................... 8
Seal Kits and Sub-assemblies ............................ 10
Sealing the Drive Shaft ....................................... 14
Gear Pump Sealing ............................................ 16
Remove the Control Housing ............................. 18
Control Module ................................................... 22
Control Module LR ........................................................ 22
Control Module H .......................................................... 23
Removing the Controller ..................................... 24
Valve Plate With Valves ..................................... 26
Remove the Rotary Groups ................................ 27
Remove the Intermediate Wheel ........................ 30
Remove Auxiliary Drive ...................................... 32
Inspection ........................................................... 35
Re-fitting the Rotary Group................................. 40
Pump Assembly.................................................. 42
Hydraulic Component - Measurement "D".......... 45
Measuring Device - Hydraulic Component 452 269...... 45
Mounting Position.......................................................... 46
Measuring Procedure .................................................... 48
Installation of Control Housing............................ 49
Assembly of Intermediate Wheel ........................ 52
Installation of Gear Pump ................................... 53
Installation of Cover / Auxiliary Drive .................. 54
Assembly Guidelines for Tightening Torques ..... 55

Main Pump SP000186


Page 3
Bolts (To N 08.001) ....................................................... 55
Plugs with Internal Hexagon and Profile Seal Ring
(to N 02.009). ................................................................ 56
Seal-lock - Sealing Nuts (to N 02.100) .......................... 57

SP000186 Main Pump


Page 4
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.

MODEL SERIAL NUMBER RANGE


DX420LC 5001 and Up
DX480LC 5001 and Up
DX520LC 5001 and Up

SP000186 Main Pump


Page 5
ECTIONAL VIEW

A8VO200LA1KH1/63

ASS0010L
Figure 1

Main Pump SP000186


Page 6
ASS0020L
Figure 2

SP000186 Main Pump


Page 7
GENERAL REPAIR GUIDELINES
NOTE: Observe the following cautions when carrying
out repairs on hydraulic units.

ASS1140L
Figure 3

1. Close off all openings of hydraulic unit.

ASS0030L
Figure 4

2. Replace all seals.


Use only original spare parts

ASS0040L
Figure 5

3. Check all sealing and sliding surfaces for wear.


NOTE: Rework of sliding surfaces using crocus cloth or
other similar materials, can damage the
surface.

ASS0050L
Figure 6

Main Pump SP000186


Page 8
4. Fill hydraulic unit with hydraulic oil before putting into
operation.

ASS0060L
Figure 7

SP000186 Main Pump


Page 9
SEAL KITS AND SUB-
ASSEMBLIES
1. Seal kit for drive shaft.

ASS0070L
Figure 8

2. Peripheral seal kit.

ASS0080L
Figure 9

3. Rotary group 1, ready to install.

ASS0090L
Figure 10

Main Pump SP000186


Page 10
4. Rotary group 2, ready to install.

ASS0100L
Figure 11

5. Rotary group, hydraulic component (order rotary groups 1


and 2 separately).
NOTE: Adjustment is necessary. Pay attention to
direction of rotation.

ASS0110L
Figure 12

6. Rotary group 1, mechanical section, ready to install.

ASS0120L
Figure 13

7. Rotary group 2, mechanical section, ready to install.

ASS0130L
Figure 14

SP000186 Main Pump


Page 11
8. Control, pre-adjusted.

ASS0140L
Figure 15

9. Gear pump, complete.

ASS0150L
Figure 16

10. Intermediate gear.

ASS0160L
Figure 17

Main Pump SP000186


Page 12
11. Auxiliary drive.

ASS0170L
Figure 18

12. Valve plate with valves.

ASS0180L
Figure 19

13. Pipe, complete with fittings.

ASS0190L
Figure 20

SP000186 Main Pump


Page 13
SEALING THE DRIVE SHAFT

ASS0200L
Figure 21

1. Protect drive shaft. (e.g. with tape).

ASS0210L
Figure 22

2. Remove retaining ring and shim.

ASS0220L
Figure 23

Main Pump SP000186


Page 14
3. Screw sheet metal screw(s) into holes fitted with rubber.
Pull out seal with pliers.

ASS0230L
Figure 24

4. Press in shaft seal ring and shim with bushing to stop.


NOTE: Take note of press-in depth. Install mark for
press-in depth of safety ring.

ASS0240L
Figure 25

SP000186 Main Pump


Page 15
GEAR PUMP SEALING

ASS0250L
Figure 26

Remove gear pump.


Visually check:
1. O-ring (1, Figure 27).

1 ASS0260L
Figure 27

Main Pump SP000186


Page 16
2. Sealing surface of housing (2, Figure 28).

ASS0270L
Figure 28

SP000186 Main Pump


Page 17
REMOVE THE CONTROL
HOUSING

ASS0280L
Figure 29

Main Pump SP000186


Page 18
1. Place pump into a disassembly / assembly device with a
crane and secure it into position.

ASS0290L
Figure 30

2. Remove screws holding port plate.


3. Using a suitable lifting device, remove port plate.
NOTE: Mark installation position.
NOTE: Be careful, control lenses can fall out.

ASS0300L
Figure 31

SP000186 Main Pump


Page 19
4. Remove paper seal, and clean sealing surface.

ASS0310L
Figure 32

2
2

1
1 ASS0320L
Figure 33

Number Description
1 Setting Screw: Qmax
2 Setting Screw: Hydraulic Stroke Limitation
3 Setting Screw: Power Characteristic (Begin of Regulation)

Main Pump SP000186


Page 20
NOTE: Before carrying out setting or disassembly of
regulator, measure distance "X" of adjustment
screw and record value.

X
ASS0330L
Figure 34

SP000186 Main Pump


Page 21
CONTROL MODULE

Control Module LR

ASS0340L
Figure 35

Remove and disassemble control module LR.


* *

ASS0350L
Figure 36

Main Pump SP000186


Page 22
Control Module H

ASS0360L
Figure 37

Remove and disassemble control module H.

ASS0370L
Figure 38

SP000186 Main Pump


Page 23
REMOVING THE CONTROLLER

(1)
ASS0380L
Figure 39

1. Remove cover.
NOTE: Do not change the setting of adjustment screw
(1, Figure 39).

ASS0390L
Figure 40

Main Pump SP000186


Page 24
2. Remove screws.
NOTE: Install control lens - torque support.

ASS0400L
Figure 41

3. Remove locking screw and replace with a new one.


NOTE: Loosen adhesive with a "gentle" flame
(approximately 120C).

ASS0410L
Figure 42

ASS0420L
Figure 43

4. Remove swivel pin.

ASS0430L
Figure 44

SP000186 Main Pump


Page 25
VALVE PLATE WITH VALVES

ASS0440L
Figure 45

1. Pressure relief valve.


2. Electro- proportional pressure reducing valve (EPPR).

Main Pump SP000186


Page 26
REMOVE THE ROTARY GROUPS

ASS0450L
Figure 46

1. Keep cylinder with device (Remove it completely along


with drive shaft).

ASS0460L
Figure 47

2. Remove cylinder (Take out the drive shaft without


cylinder).

ASS0470L
Figure 48

SP000186 Main Pump


Page 27
3. Remove cup springs 1 and spring cup 2.

ASS0480L
Figure 49

4. Note disassembly position: (1, 2 and 3, Figure 50). I


3

2
Rotary Group 2

Rotary Group 1

ASS0490L
Figure 50

5. Press out rotary group with an appropriate device. I

2
1

ASS0500L
Figure 51

Main Pump SP000186


Page 28
Fixing screws are glued

A Adjustment of measurement D

*
1. Holding device

Drive shaft 2

Drive shaft 1

1. Holding device
*
A
Adjustment of measurement D

Fixing screws are glued


ASS0510L
Figure 52

NOTE: 1) Position (*) drive shafts with bearing set are


the smallest assembly group.
2) The assembly group is adjusted to
measurement A.
3) The tapered roller bearings are adjusted to
the specified through-torque.
NOTE: 1) Fixing screw - Retaining device.
2) Removal of screws is only possible if drive
shaft is warmed up to a temperature of
approximately 120C for 1/2 hour in an oil bath
or heat air furnace.
3) Remove screw quickly.

SP000186 Main Pump


Page 29
REMOVE THE INTERMEDIATE
WHEEL
1. Press bolt (*, Figure 53) into gear wheel. (Fixed pressing I
fit).
NOTE: Can only be disassembled with a hydraulic
press.
*

ASS0520L
Figure 53

2. Install sleeve. I
NOTE: Press out bolt with a hydraulic press.

ASS0530L
Figure 54

Main Pump SP000186


Page 30
3. Remove gear wheel through side drive opening. I

ASS0540L
Figure 55

4. Remove bearing with extraction device. I

ASS0550L
Figure 56

SP000186 Main Pump


Page 31
REMOVE AUXILIARY DRIVE

ASS0560L
Figure 57

1. Remove screws and auxiliary drive.

ASS0570L
Figure 58

2. Press off bearing cap.

ASS0580L
Figure 59

Main Pump SP000186


Page 32
3. In the event of oil leakage, visually check O-ring, housing
and groove.

ASS0590L
Figure 60

4. Install extractor device.

ASS0600L
Figure 61

5. Pull out output pinion.

ASS0610L
Figure 62

6. Install bearing extractor device.

ASS0620L
Figure 63

SP000186 Main Pump


Page 33
7. Completely mount device and pull out bearing.

ASS0630L
Figure 64

8. Pull out pinion bearing.

ASS0640L
Figure 65

Main Pump SP000186


Page 34
INSPECTION
1. Check to see that bearing bore is free of scores and that
there is no evidence of wear.

ASS0650L
Figure 66

2. Visually check:
To ensure that bearing seats are free of scores.

ASS0660L
Figure 67

3. Visually check:
Check to see that bearing bores are free of scores and that
there is no evidence of wear.

ASS0670L
Figure 68

4. Axial piston play:


Checked with retaining plate installed.

ASS0680L
Figure 69

SP000186 Main Pump


Page 35
5. Drive shafts:
Check to ensure that cups are free of scores and that there
is no pitting (1. Figure 70).
Check to see that there is no evidence of corrosion and
wear steps (2, Figure 70).

ASS0690L
Figure 70

6. Piston:
Check to ensure that they are free of scores and that there
is no pitting.

ASS0700L
Figure 71

7. Central pin:
Check to ensure that it is free of scores and that there is no
pitting.

ASS071L
Figure 72

8. Retaining plate:
Check to ensure that it is free of scores and that there is no
evidence of wear.

ASS0720L
Figure 73

Main Pump SP000186


Page 36
9. Check cylinder block / control lens.
Bores (1, Figure 74) are free of scores, no evidence of
wear.
Faces (2, Figure 74) are even, that there are no cracks, no
scores.
Side guides (3, Figure 74) show no evidence of wear, free
of scores.

ASS0730L
Figure 74

10. Check:
Control land (1, Figure 75), internal control drilling (2,
Figure 75) and pin cups (3, Figure 75).

ASS0740L
Figure 75

11. Check:
That sliding surfaces (1, Figure 76) are free of scores.
Seal (2, Figure 76).

ASS0750L
Figure 76

SP000186 Main Pump


Page 37
12. Complete rotary group.
NOTE: Adjustment of the hydraulic component is
necessary.
Mechanical component: drive shaft is adjusted with the
bearing (1, Figure 77).
Hydraulic component (2, Figure 77): Adjustment is
necessary (*, Figure 77).

2
1

1
ASS0760L
Figure 77

Main Pump SP000186


Page 38
13. Rotary group: All of the components.
* Adjustment (Figure 78).
For adjustment values and torque values, see service
information.

*
*

*
*

ASS0770L
Figure 78

SP000186 Main Pump


Page 39
RE-FITTING THE ROTARY
GROUP
1. Threads must be free of oil, grease, dust or any other
contaminants which may impair locking of screws.

ASS0780L
Figure 79

2. Assemble retaining plate with pistons and center pin in


position. Use screws that have a Precoat coating.
NOTE: For tightening torques, see service information.

ASS0790L
Figure 80

3. Insert spring plate (1, Figure 81) and cup springs (2, Figure
81) into their correct position (and orientation) using grease
to hold them into place.

ASS0800L
Figure 81

Main Pump SP000186


Page 40
4. Ensure that all parts are assembled in correct order and
orientation.

ASS0810L
Figure 82

5. Insert pistons into cylinder. Using a soft surface as a


support to prevent sliding surfaces from being damaged.
Pre-assemble both rotary groups in this manor.

ASS0820L
Figure 83

SP000186 Main Pump


Page 41
PUMP ASSEMBLY
1. Warm up housing to approximately 80C.

ASS0830L
Figure 84

2. Insert pre-assembled rotary group 2, being sure to align


gear tooth marks.

ASS0840L
Figure 85

3. Insert rotary group 1. Align the marked gear teeth.

ASS0850L
Figure 86

4. Gear tooth marks must align with each other.

ASS0860L
Figure 87

Main Pump SP000186


Page 42
5. Adjustment of measurement D.
NOTE: Hydraulic control portion.

Stop
D
A

A
D
Stop

ASS0870L
Figure 88

NOTE: Drive shafts with bearing set.


The assembly group is adjusted to dimension
(A). The tapered roller bearings are adjusted to
the stipulated breakaway torque.

Assembly Guideline
Retaining force:
After rotary group has been installed into housing, it has to be
pressed in until the end stop is reached. Allow housing to cool
down from its assembly temperature (approximately 80C) to
room temperature.

SP000186 Main Pump


Page 43
Adjustment of the Hydraulic Component of the Rotary
Group
The adjustment of dimension "D" is carried out using spring
plates of differing thickness, so that the correct clearance is
achieved between the rotary group which is installed in housing
and center pin, and spring plates.
NOTE: Dimension (D) = 0.4 0.1 mm.
After assembling complete unit, the breakaway torque of the
rotary group has to be checked with a torque wrench.

Main Pump SP000186


Page 44
HYDRAULIC COMPONENT -
MEASUREMENT "D"

Measuring Device - Hydraulic Component


452 269

Size 80-107 Size 140 - 200

ASS0880L
Figure 89

Measuring Centering Intermediate Intermediate


Size Shim (5) S.H.C.S (6)
Device (*) Device (1) Ring (4) Plate (7)
1x 2x 2x 2x 2x
80 9452269 9452019 9452014 9083277 9083105
107 9452269 9452022 9452014 9083277 9083105
140 9452269 9452026 9452015 9083279 9083134 2775186
200 9452269 9452025 9452015 9083279 9083134 2775187

SP000186 Main Pump


Page 45
Mounting Position
NOTE: Be sure that the correct mounting position is used.
The numbers on the top of the measuring device (*,
Figure 89) refer to the piston diameter.

ASS0900L
Figure 90

Size Mounting Position


80 22
107 25
140 28
200 28

ASS0890L
Figure 91

1. Install intermediate ring or plates onto the housing.


A. Size 80 - 107 (Figure 92).

ASS0910L
Figure 92

Main Pump SP000186


Page 46
B. Only Size 140 - 200 (Figure 93).

ASS0920L
Figure 93

2. Zero adjustment - measuring device.


Turn using the hand wheel until the stop is reached. Set
dial gauge to zero.
A. Size 80 - 107 (Figure 94).

Figure 94

B. Size 140 - 200 (Figure 95).

Figure 95

SP000186 Main Pump


Page 47
Measuring Procedure
1. Turn down by 4 turns on the dial gauge.
Check: 2 mm clearance, set dial gauge to "Zero."
NOTE: Clearance: Size 28 - 160 0.4 mm 0.1.
A. Size 82 - 107 (Figure 96).

ASS0950L
Figure 96

B. Size 140 - 200 (Figure 97).

ASS0960L
Figure 97

2. Turn down, using the hand wheel, until resistance is met.


Read the measured value.
NOTE: Do not use excessive force.
A. Size 82 - 107 (Figure 98).

Figure 98

B. Size 140 - 200 (Figure 99).

Figure 99

Main Pump SP000186


Page 48
INSTALLATION OF CONTROL
HOUSING

ASS0990L
Figure 100

1. Install swivel pin into correct position and orientation. Take


hardening time and tightening torque into account.
NOTE: Tightening Torques (*):
M6 = 8.5 Nm (0.87 kgm (6.27 ft lb))
M8 = 14 Nm (1.43 kgm (10.33 ft lb))
M10 = 35 Nm (3.57 kgm (25.81 ft lb))
M12 = 69 Nm (7.04 kgm (50.89 ft lb))

* ASS1000L
Figure 101

SP000186 Main Pump


Page 49
2. Push on piston ring by hand. Fix adjustment piston. Take
the tightening torques into account.

ASS1010L
Figure 102

3. Install control housing.

ASS1020L
Figure 103

4. Install control lens in their correct position using grease to


hold them in place. Direction of rotation Direction of rotation
counterclockwise clockwise

Pressure Pressure
side side

Suction side
ASS1030L
Figure 104

Main Pump SP000186


Page 50
ASS1040L
Figure 105

5. Install seal and controller.

ASS1050L
Figure 106

SP000186 Main Pump


Page 51
ASSEMBLY OF INTERMEDIATE
WHEEL
1. Press bearing (1, Figure 107) into housing.
2. Install and align intermediate wheel (2, Figure 107) through 1
side drive opening. New Assembly
Position 3
3. Cool down bolt (3, Figure 107) with nitrogen and install it.
4. Press in bearing (4, Figure 107).

2
ASS1060L
Figure 107

5. Press bearing into housing.

ASS1070L
Figure 108

Main Pump SP000186


Page 52
INSTALLATION OF GEAR PUMP

ASS1080L
Figure 109

1. Assemble shaft seal, disc and safety ring. Press-in with


assemble sleeve.
NOTE: Take care of press-in depth!

ASS1090L
Figure 110

SP000186 Main Pump


Page 53
INSTALLATION OF COVER /
AUXILIARY DRIVE

ASS1100L
Figure 111

Main Pump SP000186


Page 54
ASSEMBLY GUIDELINES FOR
TIGHTENING TORQUES

Bolts (To N 08.001)


Values stated are valid for bolts with metric ISO threads to DIN
13 part 13, as well as head areas to DIN 912 socked head cap
screws, DIN 931 hexagon bolt or DIN 933 hexagon bolts with
threads up to the head.

ASS1110L
Figure 112

Tensile Strength Class


Thread 8.8 10.9 12.9
Tightening Torque M A In Nm
M3 1.1 1.6 1.9
M4 3.1 4.5 5.3
M5 6.1 8.9 10.4
M6 10.4 15.5 18
M8 25 37 43
M 10 51 75 87
M 12 87 130 150
M 14 140 205 240
M 16 215 310 370
M 18 300 430 510
M 20 430 620 720
M 22 480 830 970
M 24 740 1060 1240

SP000186 Main Pump


Page 55
Plugs with Internal Hexagon and Profile
Seal Ring (to N 02.009).

G
Seal
ASS1120L
Figure 113

Thread Tightening Torque M A In Nm Thread Tightening Torque M A In Nm


M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1.5 20 G 3/8 A 35
M14 x 1.5 30 G 1/2 A 60
M16 x 1.5 35 G 3/4 A 90
M18 x 1.5 40 G1A 140
M20 x 1.5 50 G 1 1/4 A 240
M22 x 1.5 60 G 1 1/2 A 300
M26 x 1.5 70
M27 x 2 90
M30 x 1.5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300

Main Pump SP000186


Page 56
Seal-lock - Sealing Nuts (to N 02.100)
Tightening Torque M A In
Thread
Nm
M6 10
M6 x 0.5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69 ASS1130L
M12 x 1.5 72 Figure 114
M14 110
M14 x 1.5 120
M16 170
M16 x 1.5 180

SP000186 Main Pump


Page 57
Main Pump SP000186
Page 58
SP000187
CONTROL VALVE (KVMG-400-DA)SP000187

1 Control Valve
(KVMG-400-DA)

Edition 1

Control Valve (KVMG-400-DA) SP000187


Page 1
MEMO

SP000187 Control Valve (KVMG-400-DA)


Page 2
Table of Contents

Control Valve (KVMG-400-DA)


Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 6
When All Spools are in Neutral ....................................... 6
Single Operation............................................................ 10
Combined Operation ..................................................... 22
Anti Drift Valve............................................................... 25
Main Relief Valve .......................................................... 26
Overload Relief Valve.................................................... 27
Low Pressure Relief Valve ............................................ 29
Parts List ....................................................................... 30
Specifications ................................................................ 39
Troubleshooting, Testing and Adjustment .......... 40
General.......................................................................... 40
Relief Valve ................................................................... 41
Hydraulic System .......................................................... 41
Adjustment of Relief Valve ............................................ 41
Disassembly ....................................................... 43
General Instructions for Disassembly............................ 43
Disassembly of Main Spool (3) - (11) ............................ 44
Disassembly of Subspool (24)....................................... 45
Disassembly of Subspool (20)....................................... 45
Disassembly of Anti Drift Valve of Boom and Arm ........ 45
Disassembly of Swing Load Check ............................... 46
Disassembly of Load Check.......................................... 46
Disassembly of Other Check Valves ............................. 47
Disassembly Of Flange ................................................. 47
Disassembly of Relief Valve.......................................... 47
Disassembly of Other Flange ........................................ 48
Disassembly of Main Relief Valve ................................. 49
Disassembly of Overload Relief Valve .......................... 50
Disassembly of Low Pressure Relief Valve................... 50

Control Valve (KVMG-400-DA) SP000187


Page 3
Cleaning and Inspection (Wear Limits and
Tolerances)......................................................... 51
Cleaning ........................................................................ 51
Inspection ...................................................................... 51
Reassembly ........................................................ 52
Subassembly................................................................. 52
Reassembly of Control Valve ........................................ 54
Installation .......................................................... 60
Start-up Procedures ........................................... 60

SP000187 Control Valve (KVMG-400-DA)


Page 4
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.

MODEL SERIAL NUMBER RANGE


DX420LC 5001 and Up
DX480LC 5001 and Up
DX520LC 5001 and Up

SP000187 Control Valve (KVMG-400-DA)


Page 5
GENERAL DESCRIPTION

When All Spools are in Neutral

Neutral Passage (Figure 1 and Figure 2)


1. Oil supplied to port (P1) flows through neutral passage (L1)
to low pressure relief valve throttle (Lc1), to tank passage
(Ta), and returns to ports (T1 and T3).
2. Oil supplied to port (P2) flows through neutral passage
(R1), to low pressure relief valve throttle (Rc1), to tank
passage (Ta), and returns to ports (T1 and T3).
3. The pressures of low pressure relief valve chambers (L2
and R2) reach through ports (Ps1 and Ps2) to pumps, and
control displacement of pumps (P1 and P2).
4. If too much oil flows into neutral passages, low pressure
relief valves are activated, and protect ports (Ps1 and Ps2)
from rising pressures.

Control Valve (KVMG-400-DA) SP000187


Page 6
Figure 1

SP000187 Control Valve (KVMG-400-DA)


Page 7
Signal Passage (Figure 2)
1. Oil supplied to port (PP, Figure 2), after passing through
orifice (Lc3), is divided into two flows. One flow is sent to
port (PT), and the other flows through land (Lc4) and
passage (5) to land (Rc3) and into tank passage (Ta).
2. The same oil supplied from port (PP), after passing
through orifice (Lc5), flows partly to port (PA) and passes
partly through passages (L4), (8) and (R4), to boom spool
1 land (Rc4) and flows into tank passage (Ta).
3. The oil passing through orifice (Lc6) flows partly from land
(Lc7), to tank passage (Ta), and passes partly through
passage (4) to travel spool land (Rc5) and flows into tank
passage (Ta).

Control Valve (KVMG-400-DA) SP000187


Page 8
Figure 2

SP000187 Control Valve (KVMG-400-DA)


Page 9
Single Operation

Travel Spool Shifting (Figure 3 and Figure 4)


1. When shifting travel spool by increasing pressure of travel
(section 1) pilot port (Pb1 (Pa1)), oil supplied to port (P1)
flows through neutral passage (L1), to spool, and flows to
port (B1 (A1)). Return oil flows through port (A1 (B1)) to
spool and returns to tank passage (Ta).
2. When shifting travel spool by increasing pressure of travel
(section 6) pilot port (Pb6 (Pa6)), oil supplied to port (P2)
flows through neutral passage (R1), and spool, to passage
(S6-1) and flows to port (B6 (A6)). At this time poppet (S6-
2) is not opened because parallel passage (R3) pressure
equals passage pressure (S6-1). Return oil flows through
port (A6 (b6)) to spool and returns to tank passage (Ta).
3. When shifting either spool (section 1 or 6), land (Lc4) or
(Rc3) is closed. Oil supplied from port (PP) does not flow
into tank passage, so that pressure at port (PT) rises.

Control Valve (KVMG-400-DA) SP000187


Page 10
Figure 3

SP000187 Control Valve (KVMG-400-DA)


Page 11
Swing Spool Shifting (Figure 4)
1. When shifting swing spool by increasing pressure of swing
(section 2) pilot port (Pb2 (Pa2)), neutral port (L1) is
closed. Oil supplied to port (P1) flows through, parallel
passage (L3), load check valve (S2-1), and spool to port
(B2 (A2)). Return oil flows through port (A2 (B2)), to spool,
and returns to tank passage (Ta).

Figure 4

Control Valve (KVMG-400-DA) SP000187


Page 12
Boom Spool Shifting
1. Neutral (Figure 5)
This valve also works with anti drift valves that are installed
on the bottom side of each boom cylinder.
When in neutral, poppet (AD1) is closed by pressure from
port (A7), that is sent through passage (AD2), spool (AD3),
and passage (AD4) to poppet (AD1).

Figure 5 Neutral Condition

SP000187 Control Valve (KVMG-400-DA)


Page 13
2. Boom up (2 speed junction) (Figure 6)
When boom spool 1 (section 7) is shifted by increasing
pressure of boom 1 pilot port (Pa7), neutral passage (R1)
is closed. Oil supplied to port (P2) flows through parallel
passage (R3), and load check valve (S7-1), to spool and
flows into port (A7). When boom 2 (section 3) spool is
shifted by increasing pressure of boom 2 pilot port (Pa3)
also, neutral passage (L1) is closed. Oil supplied to port
(P1) flows through parallel passage (L3), load check valve
(S3-1), and spool to passage (6) and it then joins at port
(A7). Return oil flows through port (B7) to spool and returns
to tank passage (Ta).

Figure 6 Boom Up

Control Valve (KVMG-400-DA) SP000187


Page 14
3. Boom down (regeneration) (Figure 7)
When boom spool 1 (section 7) is shifted by increasing
pressure of boom 1 pilot port (Pb7), neutral passage (R1)
is closed. Oil supplied to port (P2), flows through parallel
passage (R3), and load check valve (S7-1), to spool, and
flows into port (B7). When spool (AD3) of anti drift valve is
shifted by increasing pressure of port (Pc2) also, poppet
(AD1) is opened by decreasing of pressure in spring
chamber (AD5), and return oil from port (B7) returns to
tank passage. Some return oil opens poppet (S7-3), in
boom 1 spool, flows through passage (S7-2), it then joins
with port (B7), and prevents cavitation on cylinder rod side.

Figure 7 Boom Down

SP000187 Control Valve (KVMG-400-DA)


Page 15
Spare Spool Shifting (Figure 8)
1. When spare spool is shifted by increasing pressure of
spare (section 4) pilot port (Pb4 (Pa4)), neutral passage
(L1) is closed. Oil supplied to port (P1) flows through,
parallel passage (L3), load check valve (S4-1), passage
(S4-2), and spool, into port (B4 (A4)). When neutral-cut
spool (R) is shifted by increasing pressure of port (pa10)
(Figure 1) also, oil supplied from port (P2) flows through
passage (11), and poppet (S4-3), it then joins with passage
(S4-2). Return oil returns through port (A4 (B4)) and spool
to tank passage (Ta).

Bucket Spool Shifting (Figure 8)


1. When bucket spool is shifted by increasing pressure of
bucket (section 8) pilot port (Pb8 (Pa8)), neutral passage
(R1) is closed. Oil supplied to port (P2), flows through,
parallel passage (R3), load check valve (S8-1), passage
(S8-2), and spool, into port (B8 (A8)). When neutral-cut
spool (L) is shifted by increasing pressure of port (Pa11)
(Figure 1) also, oil supplied from port (P1) flows through
passage (7) and poppet (S8-3), it then joins with passage
(S8-2). Return oil returns through port (A8 (B8)) and spool
to tank passage (Ta).

Figure 8

Control Valve (KVMG-400-DA) SP000187


Page 16
Arm Spool Shifting
1. Arm dump (2 speed junction) (Figure 9)
When arm spool 1 is shifted by increasing pressure of arm
1 (section 5) pilot port (Pb5), oil supplied from port (P1)
flows through, neutral passage (L1), load check valve (S5-
1), passage (S5-2), and spool, into port (B5). When arm 2
spool is shifted by increasing pressure of arm 2 (section 9)
pilot port (pb9) also, oil supplied from port (P2) flows
through neutral passage (R1), load check valve (S9-1),
passage (S9-2), spool, and passage (10), it then joins with
port (B5). Return oil returns through port (A5) and spool to
tank passage (Ta).

Figure 9 Dump

SP000187 Control Valve (KVMG-400-DA)


Page 17
2. Arm crowd (2 speed junction)
When arm spool 1 is shifted by increasing pressure of arm
1 (section 5) pilot port (Pa5), oil supplied from port (P1)
flows through, neutral passage (L1), load check valve (S5-
1), passage (S5-2), and spool, into port (A5). When arm 2
spool is shifted by increasing pressure of arm 2 (section 9)
pilot port (pa9) also, oil supplied from port (P2) flows
through neutral passage (R1), load check valve (S9-1),
passage (S9-2), spool and passage (9), it then joins with
port (A5). When spool (AD3) of anti drift valve is shifted by
increasing pressure of port (pc1) also, poppet (AD1) is
opened by decreasing of pressure of spring chamber
(AD5), and return oil from port (B5) returned through spool,
passage (S5-3) and arm variable regeneration throttle
(Lc8) to tank passage (Ta). Some of return oil open poppet
(S5-4) in boom 1 spool, flows through passage (S5-2), it
then joins with port (A5), increases cylinder speed, and
then prevents cavitation on cylinder bottom side.
3. Variable regeneration (when crowding) (Figure 10)
When crowding arm, spool (S5-6) is stroked according to
pressure of passage (S5-2) connected to passage (S5-5),
and opening size of arm variable regeneration throttle
(Lc8) varies. When pressure of passage (S5-2) is high,
stroke of spool (S5-6) is increased, so that opening size of
throttle (Lc8) is increased. In contrary, when pressure of
passage (S5-2) is low, stroke of spool (S5-6) is decreased,
so that opening size of throttle (Lc8) is decreased.
Therefore regeneration flow varies according to pressure
of bottom of arm cylinder.

Control Valve (KVMG-400-DA) SP000187


Page 18
Figure 10

SP000187 Control Valve (KVMG-400-DA)


Page 19
Neutral-cut Spool Shifting (Figure 11)
1. This valve has a neutral-cut spool that is installed in lowest
flow side (the upper flow side of low pressure relief valve).
When spool (L (R)) is shifted by increasing pressure of port
(pa10 (pa11)), neutral passage (L1 (R1)) is closed. Oil
supplied to port (P1) flows through passage (7) and poppet
(S8-3, Figure 8), it then joins with bucket (section 8)
passage (S8-2, Figure 8). Oil supplied to port (P2) flows
through passage (11) and poppet (S4-3, Figure 8), it then
joins with spare (section 4) passage (S4-2, Figure 8).

Parallel Throttle for Arm (Figure 11)


1. The throttle, that is installed in the parallel circuit for arm of
this valve, one in each of arm 1 (section 5) and the arm 2
(section 9) prevents the arm speed from increasing during
combined operation.
2. The parallel circuit of arm 2 (section 9), after narrowing at
the throttle (Rc6) in poppet (S9-3) allows oil from parallel
passage (R3), to join with oil in passage (S9-2, Figure 11).
3. The parallel circuit of arm 1 (section 5), after narrowing at
the throttle (Lc9) in poppet (S5-8) allows oil from parallel
passage (L3), to join with oil in passage (S5-2, Figure 10).

Figure 11

Control Valve (KVMG-400-DA) SP000187


Page 20
Relief Valve
1. Main relief valve (Figure 12)
Oil supplied to port (P1) flows through poppet (LP), oil
supplied from port (P2), flows through poppet (RP), and
passage (3) also, it then joins with the main relief valve.
The highest pressure of pump (P1) and (P2) is controlled
by actuating of main relief valve.
2. Over load relief valve
The over load relief valve, that is installed in each cylinder
port of boom 1, arm 1 and bucket, prevent the actuator
pressure from increasing to extremely high pressures by
external forces.
This relief valve, when pressure of cylinder port is a
negative pressure, also has the function to prevent
cavitation by drawing oil from the tank.

Figure 12

SP000187 Control Valve (KVMG-400-DA)


Page 21
Combined Operation

Travel Combined Operation (Figure 13)


1. When applying simultaneously the operation except travel
while travel left and right simultaneous operating (while
forward traveling, backward traveling, or pivot turning) or
when applying travel left and right simultaneous operating
while applying the operation except travel, oil supplied from
port (PP) is disconnected with the tank passage (Ta) at the
signal land part of section of exception of travel shifted with
the land (Lc4) (Lc7) (Rc3) (Rc5), and the pressure of signal
passage increases up to the relief setting pressure of
pressure source for signal.
By increasing of signal pressure, the travel straight spool is
shifted and the pressures of ports (PT) and (PA) increase.
When travel straight spool is shifted, oil supplied from port
(P1) flows through neutral passage (L1), to travel (section
1), and simultaneously flows through, passage (2), travel
straight spool, and passage (R1), into travel (section 6). Oil
supplied to port (P2) flows through, travel straight spool
and passage (1) into parallel passage (L3).
If the section load pressure except the travel is higher than
the travel (section 6) load pressure, some oil supplied from
port (P2) opens poppet (S6-2), it then joins through throttle
in head of poppet with passage (S6-1).
Because travel (section 1 and 6) is activated by oil supplied
from port (P1) and the implement except the travel is
activated by oil supplied from port (P2), when applying the
combined operation with the travel left and right
simultaneous operation and the implement operation
except the travel, the travel is prevented from veering.

Control Valve (KVMG-400-DA) SP000187


Page 22
Figure 13

SP000187 Control Valve (KVMG-400-DA)


Page 23
Swing Combined Operation (Figure 14)
1. When applying the combined operation with the swing and
another implement, poppet (S2-1) is fixed by increasing
port (pc6) pressure, poppet (S2-3) is opened, and pressure
supplied to port (L3) is increased through throttle (S2-4).
Accordingly, even in the case that the swing load pressure
is low, the simultaneous operation character with the other
implement can be secured.

Figure 14

Control Valve (KVMG-400-DA) SP000187


Page 24
Anti Drift Valve
1. The anti drift valve is installed in the cylinder port of arm
rod (boom bottom) side to prevent the arm (boom) cylinder
from natural lowering.
In neutral condition (Figure 15), cylinder port pressure is
sent through passage (AD2), spool (AD3), and passage
(AD4) to spring chamber (AD5).
Poppet (AD1) is completely closed by spring strength or
pressure differential due to difference of poppet sizes.

Figure 15

When arm dumping (boom up) (Figure 16) oil supplied


from pump opens poppet (AD1) it allows oil to flow to
cylinder port.

Figure 16

When crowding arm (boom down) (Figure 17), spool (AD3)


is shifted by increasing pressure of port (pc1 (pc2)), and oil
in spring chamber (AD5) is allowed to flow through,
passage (AD6) to drain port (DR1' (DR2')) This allows
poppet (AD1) to open and let return oil flow into tank
passage (Ta).

Figure 17

SP000187 Control Valve (KVMG-400-DA)


Page 25
Main Relief Valve
1. The main relief valve is located between neutral oil
passage (HP, Figure 18) 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 difference in areas between (A) and (B), on
which hydraulic pressure acts, main poppet (C) seats on
sleeve (E).

Figure 18

2. When pressure in neutral oil passage (HP) rises and


exceeds relief valve setting, pilot poppet (F) opens.
Pressurized oil flows through pilot poppet (F) into low
pressure oil passage (LP), passing through hole (G).

Figure 19

3. As pilot poppet (F) opens, pressure in internal cavity (D)


lowers to move main poppet (C) so that pressurized oil
flows into neutral oil passage (HP) and directly into low
pressure oil passage (LP).

Figure 20

4. Pressure up operation
When pressure at pilot port (Pi) is increased, piston (H)
moves to the pressure setting position of plug (I) so that
the force of spring increases, thus increasing pressure in
the neutral oil passage (HP).

Figure 21

Control Valve (KVMG-400-DA) SP000187


Page 26
Overload Relief Valve
1. The overload relief valve is located between cylinder port
(HP) and low pressure oil passage (LP). Pressurized oil at
cylinder 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).

Figure 22

2. When pressure in cylinder port (HP) rises and exceeds the


relief valve setting, pilot poppet (E) opens. Pressurized oil
then flows through pilot poppet (E) into low pressure oil
passage (LP), passing through hole (H).

Figure 23

3. As pilot poppet (E) opens, pressurized oil flows through


orifice (I) so that pressure on back of piston (C) lowers to
move piston (C). As a result, piston (C) seats on pilot
poppet (E).

Figure 24

4. Pressurized oil in passage (HP) flows through orifice (F) in


piston (C) so that pressure on back of main poppet (D)
moves main poppet (D). Pressurized oil then flows into
passage (HP) and directly into passage (LP).

Figure 25

SP000187 Control Valve (KVMG-400-DA)


Page 27
5. Sucking operation
An anti void unit is installed in cylinder port (HP) to prevent
the development of cavitation. If pressure at cylinder port
(HP) becomes lower than that of oil passage (LP), sleeve
(K) moves so that oil is supplied from the low pressure oil
passage (LP) to cylinder port (HP) to eliminate cavitation.

Figure 26

Control Valve (KVMG-400-DA) SP000187


Page 28
Low Pressure Relief Valve
1. When oil does not pass

Figure 27

2. When spool is in neutral


Oil in neutral oil passage (HP) flows through signal orifice
(A) into low pressure oil passage (LP). The pressure of the
signal port (4Ps (5Ps)) increases by the negacon signal
orifice (A).

Figure 28

3. Low pressure relief valve operation


When the excessive quantities of oil in the neutral oil
passage (HP) flow, pressure in neutral oil passage (HP)
exceeds spring setting pressure (C). This causes poppet
(B) to open. Oil then flows from neutral oil passage (HP)
into low pressure oil passage (LP) so excessive pressure
is prevented in neutral oil passage (HP).

Figure 29

SP000187 Control Valve (KVMG-400-DA)


Page 29
Parts List

Figure 30

Control Valve (KVMG-400-DA) SP000187


Page 30
Figure 31

SP000187 Control Valve (KVMG-400-DA)


Page 31
Figure 32

Control Valve (KVMG-400-DA) SP000187


Page 32
Reference Reference
Description Description
Number Number
1 Valve Housing 40 O-ring
2 Valve Housing 41 Backup Ring
3 Spool Assembly (Arm-2) 42 Body
4 Spool Assembly (Bucket) 43 Piston
5 Spool Assembly (Boom 1) 44 Flange
6 Spool Assembly (Travel) 45 O-ring
7 Spool Assembly (Straight 46 Poppet
Travel) 47 Body Assembly
8 Spool Assembly (Arm-1) 48 Relief Valve Assembly
9 Spool Assembly (Service) 49 Relief Valve Assembly
10 Spool Assembly (Boom 2) 50 Relief Valve Assembly
11 Spool Assembly (Swing) 51 Plug Assembly
12 Cap 52 Poppet
13 Cap 53 Spring
14 O-ring 54 Plug
15 Poppet 55 O-ring
16 Spring 56 Flange
17 Spacer 57 O-ring
18 O-ring 58 Plug Assembly
19 Backup Ring 59 Plug Assembly
20 Spool Assembly 60 Plug Assembly
21 Spring Seat (A) 61 Plug Assembly
22 Spring 62 Plug Assembly
23 Plug 63 Soket-Head Bolt
24 Spool Assembly 64 Soket-Head Bolt
25 Spring 65 Soket-Head Bolt
26 O-ring 66 Name Plate
27 Plug 67 Drive Screw
28 Poppet 68 Soket-Head Bolt
29 Spring 69 O-ring
30 Poppet 70 O-ring
31 Poppet 71 O-ring
32 Poppet 72 O-ring
33 Spring 73 Cap
34 Flange 74 Cap
35 O-ring 75 Steel Ball
36 Poppet Assembly 76 Flange Cap
37 Spring 77 Soket-Head Bolt
38 Sleeve 78 O-ring
39 Piston 79 Poppet

SP000187 Control Valve (KVMG-400-DA)


Page 33
Spool Assembly (4, Bucket)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End

Figure 33

Spool Assembly (5, Boom)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
6 Poppet
7 Spring Figure 34
8 Plug
9 O-ring
10 Backup Ring

Spool Assembly (6, Travel)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End

Figure 35

Control Valve (KVMG-400-DA) SP000187


Page 34
Spool Assembly (7, Straight Travel)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End

Figure 36

Spool Assembly (8, Arm1)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
6 Poppet
7 Spring Figure 37
8 Plug
9 O-ring
10 Backup Ring

Spool Assembly (9, Service)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End

Figure 38

SP000187 Control Valve (KVMG-400-DA)


Page 35
Spool Assembly (10, Boom 2)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End

Figure 39

Spool Assembly (11, Swing)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End

Figure 40

Spool Assembly (3, Arm 2)

Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End

Figure 41

Spool Assembly (20, Arm Regeneration Release Valve

Reference
Description
Number
1 Spool
2 Sleeve
3 Sleeve
4 Piston
5 O-ring
6 Backup Ring
7 O-ring Figure 42
8 Backup Ring

Control Valve (KVMG-400-DA) SP000187


Page 36
Spool Assembly (24)

Reference
Description
Number
1 Spool
2 Spool End

Figure 43

Poppet Assembly (36)

Reference
Description
Number
1 Poppet
2 Poppet
3 Spring
4 Plug

Figure 44

Plug Assembly (51)

Reference
Description
Number
1 Plug
2 O-ring
3 O-ring
4 O-ring

Figure 45

Plug Assembly (58)

Reference
Description
Number
1 Plug
2 O-ring
3 O-ring
4 Backup Ring

Figure 46

SP000187 Control Valve (KVMG-400-DA)


Page 37
Relief Valve Assembly (48)

Figure 47

Item Specification
Serial No. 1001 thru 1050 1051 and Up
Hi: 34.3 0.5 MPa Hi: 34.3 0.5 MPa
Relief Valve Pressure
Low: 31.4 0.5 MPa Low: 31.4 0.3 MPa
Flow 250 liter/min. 150 liter/min.

Relief Valve Assembly (49)

Reference
Description
Number
1 O-ring
2 O-ring
3 O-ring
4 Backup Ring
5 O-ring
6 Backup Ring
7 O-ring Figure 48

Item Specification
Relief Valve
35.3 0.5 MPa
Pressure
Flow 20 liter/min.

Control Valve (KVMG-400-DA) SP000187


Page 38
Relief Valve Assembly (50)

Reference
Description
Number
1 Plug
2 Spring
3 Poppet
4 Sleeve
5 O-ring
6 O-ring
Figure 49

Specifications
Component Name Specification
Rated Flow 400 liter/min.
500 liter.min at Neutral
Max. Pressure 31.9 MPa
Allowable Back Pressure Peak Pressure: Below 1.5 MPa
Normal Pressure: Below 0.5 MPa
Allowable Working Temperature Range -20 ~ 90C

SP000187 Control Valve (KVMG-400-DA)


Page 39
TROUBLESHOOTING, TESTING
AND ADJUSTMENT

General
Problem Possible Cause Remedy
Spool does not stroke. Hydraulic oil excessively hot. Remove blockage in oil piping.

Hydraulic oil contaminated. Change oil and clean oil


passages.
Overtightened piping port fittings. Check torque.

Valve housing deformed when Remove assembling bolts and


assembling. check.
Pressure too high. Check pump port pressure and
cylinder port pressure with
pressure gauge.
Spool bent. Replace valve assembly.

Return spring damaged. Replace damaged parts.

Spring or cap crisscrossed. Remove and center cap.

Valve temperature uneven. Warm up entire system.

Dirt in valve. Clean valve.

Lack of pilot pressure. Check pilot valve and pilot relief


pressure.
Fails to bear load Leaky cylinder. Check seal parts of cylinder.

Leaky spool. Check spool.

Leaky overload relief valve. Clean valve housing and relief


valve seat parts.
Leaky anti drift valve. Remove anti drift valve and clean
every seat parts.
If seat parts are damaged,
replace poppet or lap poppet and
seat parts. If drift valve is out of
order, replace spool and sleeve at
the same time.
Load drops when changing Dirt in load check valve. Remove and clean check valve.
the spool from neutral to up.
Poppet or seat parts in check valve Remove poppet or lap poppet and
damaged. seat parts.

Control Valve (KVMG-400-DA) SP000187


Page 40
Relief Valve
Problem Possible Cause Remedy
Pressure does not rise. Pressure does not rise. Replace relief valve.

Pressure unstable Pressure unstable

Relief pressure is incorrect. Seat parts worn due to dirt.

Lock nut and adjuster deformed. Reset pressure and tighten lock
nut in rated torque.
Oil leaks Relief valve seat parts damaged. Replace relief valve.

Every parts stuck due to dirt.

O-ring worn. Replace adjuster or O-ring.

Hydraulic System
Problem Possible Cause Remedy
Hydraulic system is poor or Hydraulic pump failed. Check pressure or replace pump.
none of the controls function
Relief valve failed. Replace pump.

Some kinds of cylinders failed. Repair or replace.

Pump load pressure too high. Check circuit pressure.

Valve cracked. Replace valve assembly.

Spool does not fully stroke. Check spool operation.

Hydraulic oil level in tank too low. Add hydraulic oil.

Filter in circuit plugged. Clean or replace filter.

Circuit piping snarled. Check piping.

Adjustment of Relief Valve

Main Relief Valve


1. Connect an accurate pressure gauge to inlet port.
2. Start engine and maintain rated pump speed.
3. Shift control valve spool and read pressure gauge from
stroke end of cylinder.
NOTE: Shift a spool that the actuator pressure setting
of the over load relief valve is higher than the
pressure of the main relief valve.

SP000187 Control Valve (KVMG-400-DA)


Page 41
4. High pressure adjustment (See Figure 51 on page -49).
A. Loosen lock nut (5) and tighten plug (6) until piston
contacts the end (* mark) of plug (4). Plug (6) should
be torqued below 2 kgm (15 ft lb). While plug (6) is
tightened, plug (4) should not be turned. The distance
A (See Figure 18 on page -26) should be more than
15 mm (0.59 in). Tighten lock nut (5).
B. Loosen lock nut (3) and turn adjusting plug (4)
clockwise to raise relief pressure at the condition of
step A. Turn adjusting plug (4) counterclockwise to
lower relief pressure. One turn varies pressure by
approximately 25.7 MPa. Tighten lock nut (3) after
pressure has been adjusted.
5. Low pressure adjustment
A. Loosen lock nut (5) and turn adjusting plug (6)
counterclockwise to lower relief pressure at step 4.
One turn varies pressure by approximately 21.3
MPa.Tighten lock nut (5) after pressure has been
adjusted.
B. Recheck the setting pressure by raising pressure.

Over Load Relief Valve

IMPORTANT
If pressure of main relief valve is higher than the specified
pressure for it, change main relief valve assembly setting
without adjusting over load relief valve.

1. Shift the control valve spool and read the pressure gauge
from the stroke end of the cylinder.
2. Loosen lock nut (3) and turn adjusting plug clockwise to
raise pressure. One turn varies pressure by approximately
21.2 MPa.
3. Tighten lock nut (3) after pressure has been adjusted. Lock
nut (3) should be torqued to 2.80 - 3.2 kgm (20 - 23 ft lb).
4. Recheck the pressure setting again.

Control Valve (KVMG-400-DA) SP000187


Page 42
DISASSEMBLY

General Instructions for Disassembly


1. Stop engine at low actuator pressure.
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, it 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.

2. Vent pressurized air from hydraulic oil tank.


3. Clean all exterior surfaces of valve before to disassembly
and protect it from dirt and foreign materials.
4. Match mark the disassembled parts to ensure proper
reassembling position.
5. Replace all sealing parts such as O-rings and backup rings
with a new ones.
6. Do not replace spools, they are matched with valve
housing and sleeve.
NOTE: The further part numbers of an assembly part
are shown as (assembly part number - further
part number).

SP000187 Control Valve (KVMG-400-DA)


Page 43
Disassembly of Main Spool (3) - (11)
1. Remove socket head bolt (63, width across flats: 10 mm)
and long cap (12 and 73). Remove O-ring (14) from valve
housing.
2. Remove all spool subassemblies from valve housing.

WARNING!
When removing spool, be careful not to damage it.
Attach label to each spool in order to install it in the
correct position when reassembling.

3. Remove socket head bolts (63) and short cap (13 and 74).
Remove O-ring from valve housing.
4. Remove spool end (further part number - 5, width across
flats: 22 mm) of spool (3, 4, 6, 7, 9 10 and 11), spring seat
(further part number - 2) and spring (further part number - 3
and 4).
5. Remove spool end (5-5, width across flats: 22 mm) of
spool (5), spring seat (5-2) and spring (5-3,4). Remove
plug (5-8: groove width; 3 mm), O-ring (5-9) and backup
ring (5-10).
6. Remove spool end (8-5, width across flats: 22 mm) of
spool (8), spring seat (8-2) and spring (8-3,4). Remove
plug (8-8: groove width; 3 mm), spring (8-7) and poppet (8-
6).
7. Disassembly of spool

IMPORTANT
Work with spool gripped in vise with wood (see Figure
50) 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 Figure 50
remove immediately after heating it to 200 - 250C.
If it is over heated, change spring to new one.

Control Valve (KVMG-400-DA) SP000187


Page 44
Disassembly of Subspool (24)
1. Remove plug (27, width across flats: 36 mm), spring (25),
spring seat (21), and spool (24). Remove the other spool in
a similar manner.
2. Remove O-ring (26) from plug.
3. Spool (24-1) and spool end (24-2) are secured with Loctite.
Heat spool end to loosen it (Heating temperature: 200 -
250C) to prevent damage of thread.

Disassembly of Subspool (20)


1. Remove plug (23, width across flats: 32 mm) and O-ring
(72).
2. Remove spring (22), spring seat (21) and spool (20-1).
3. Pull off sleeve (20-2,3) and piston (20-4).

Disassembly of Anti Drift Valve of Boom


and Arm
1. Remove socket head bolt (63) and body assembly (47)
and O-ring (35 and 70).

WARNING!
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.

2. Remove spring (33) and poppet (46).


3. Grip body assembly (47, width across flats: 8 mm) in vise
taking care not to scratch O-ring (35 and 70) surface.
4. Remove plug (47-5) and O-ring (47-10).
5. Remove spring (47-4), spool (47-2) and O-ring (47-3).
6. Remove plug assembly (47-7, width across flats: 6 mm)
and O-ring.

IMPORTANT
The filter in plug assembly (47-7) is pressed into place
and can not be removed. If filter replacement is
necessary, replace it with a new plug assembly.

SP000187 Control Valve (KVMG-400-DA)


Page 45
7. Remove plug (47-8, width across flats: 8 mm) and O-ring.
8. Remove plug (47-9, width across flats: 5 mm) and O-ring.
NOTE: Steel ball (75) should not be disassembled
since it is a press fit.

Disassembly of Swing Load Check


1. Remove socket head bolt (68, width across flats: 10 mm)
and flange (44).
2. Remove body (42), piston (43) and O-ring (45).
3. Pull off sleeve (38) and remove spring (37) and piston (39).
4. Remove O-ring (40, 35) and backup ring (41).
5. Remove poppet assembly (36).
6. Grip plug (36-4, width across flats: 12 mm) in vise and
remove poppet (36-1), spring (36-3) and poppet (36-2).

Disassembly of Load Check


1. Remove travel semi parallel check from port P2. Remove
plug (54, width across flats: 27 mm). Remove O-ring (54)
from plug. Remove spring (53) and poppet (52).

WARNING!
At this time, be careful not to drop spring into
passage. If valve is operated with spring in passage, a
broken piece may penetrated in main spool sliding
surface and a serious accident may occur by a
runaway or not being able to stop.

2. Remove travel load check from port P1. Remove socket


head bolt (63, width across flats: 10 mm) and flange (34).
Remove poppet (32), spring (33) and O-ring (35).
3. Remove the remaining load check. Remove socket head
bolt (63, width across flats: 10 mm) and flange (34).
Remove poppet (31), spring (33) and O-ring (35).

Control Valve (KVMG-400-DA) SP000187


Page 46
Disassembly of Other Check Valves
1. Remove two common check valves from main relief valve.
Remove socket head bolt (64, width across flats: 8 mm)
and flange (56). Pull off collar from spacer (17). Remove
O-ring (18) and backup ring (19). Remove spring (16) and
poppet (15).
2. Remove parallel check valve from spare junction, bucket
junction and arm one. Remove plug (61, width across flats:
10 mm) and O-ring.
3. Remove spring (29) and poppet (28).
4. Remove semi parallel check valve from arm two. Remove
plug (61, width across flats: 10 mm) and O-ring. Remove
spring (29) and poppet (30).

Disassembly Of Flange
1. Remove flange from spare port. Remove socket head bolt
(77, width across flats: 10 mm) and flange (76) and O-ring
(78).
2. Remove flange from boom two. Remove socket head bolt
(64, width across flats: 8 mm) and flange (56) and O-ring
(57).

Disassembly of Relief Valve


1. Remove eight overload relief valves (49, (8 places, width
across flats: 32 mm)).
2. Remove main relief valve (48, width across flats: 41 mm).
3. Remove two negacon relief valves (50, width across flats:
46 mm).

SP000187 Control Valve (KVMG-400-DA)


Page 47
Disassembly of Other Flange
1. Remove plug assemblies (60, 61, 62, 58, 52, 59) and O-
rings.

Reference
Size Quantity
Number
60 6 mm 5
61 10 mm 17
62 12 mm 6
58 24 mm 1
52 27 mm
59 8 mm

NOTE: Valve housings (1 and 2) should not be


disassembled because O-rings and housings
can be deformed and mating surfaces can be
crisscrossed when reassembling them.
Steel ball (75) should not be disassembled
since it is a press fit.

Control Valve (KVMG-400-DA) SP000187


Page 48
Disassembly of Main Relief Valve
1. This relief valve should be replaced as an assembly. When
replacing it, loosen cap (8, width across flats: 41) and O-
ring (1, Figure 51). If oil leaks from nut (3), remove nut (3)
and plug (4) and replace O-ring and backup ring.

Figure 51

SP000187 Control Valve (KVMG-400-DA)


Page 49
Disassembly of Overload Relief Valve
1. This relief valve should be replaced as an assembly. When
replacing it, loosen cap (1, width across flats: 31.75 mm)
and O-ring (2). If oil leaks from nut (3), remove adjusting kit
and replace O-ring (4).
NOTE: When disassembling adjusting kit, be careful
not to allow components to spring out by force
of spring or to lose the poppet.

Figure 52

Disassembly of Low Pressure Relief Valve


1. This relief valve is a press fit at area (D) making it a non-
serviceable item, that should be replaced as a whole
assembly.

Figure 53

Control Valve (KVMG-400-DA) SP000187


Page 50
CLEANING AND INSPECTION
(WEAR LIMITS AND
TOLERANCES)

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 surface for inspection.

Inspection
Inspect all parts for scratches, notches and the 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. Inspect all grooves and passages of sliding parts for
foreign materials.
4. Replace any springs that are damaged, heavy deformed or
worn.
5. If relief valve malfunctions, inspect it by using relief valve
procedure (see page).
6. Replace all O-rings and backup rings with new ones.
7. After disassembling cap or plug, check whether there are
paint chips around valve body hole or plug. If paint chips
penetrate into valve, they can cause malfunction or leaks
to occur.

SP000187 Control Valve (KVMG-400-DA)


Page 51
REASSEMBLY
NOTE: Before reassembling, confirm number of
components, reassembling position, tools and etc.

Subassembly
Before reassembling valve housing, subassemble parts as
needed.

Main Spool (3) - (11)


1. Apply Loctite to threads of spools (3, 4, 6, 7, 9, 10 and 11).
Assemble spring seat (above parts numbers - 2), spring
(above parts numbers - 3, 4) and spool end (above parts
numbers - 5), and assemble spool end in spool that is
gripped in vise with wood. Torque is 2.45 - 2.65 kgm (18 -
19 ft lb).

IMPORTANT
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.

2. After assembling poppet (above parts numbers - 6) and


spring (above parts numbers - 7) in middle hole of spool
(5), apply Loctite to thread of spool. Grip spool in vise with
wood. Assemble plug (5-8) into which O-ring (5-9) and
backup ring (5-10) are inserted. Torque is 2.45 - 2.65 kgm
(18 - 19 ft lb). Assemble spring seat (5-2), spring (5-3, 4)
and spool end (5-5) and tighten spool end. Torque is 2.45 -
2.65 kgm (18 - 19 ft lb).
3. Assemble poppet (8-6) and spring (8-7) in middle hole of
spool (8). Apply Loctite to thread of spool and assemble
plug (8-8). Torque is 2.45 - 2.65 kgm (18 - 19 ft lb). Apply
Loctite to thread of spool. Grip spool in vise with wood.
Assemble spring seat (8-2), spring (8-3, 4) and spool end
(8-5) and tighten spool end. Torque is 2.45 - 2.65 kgm (18
- 19 ft lb).

Subspool (20)
1. Assemble backup ring (20-8) and O-ring (20-7) in sleeve
(20-3). Assemble backup ring (20-6) and O-ring (20-5) in
sleeve (20-2).
2. Assemble piston (20-4) in sleeve (20-3) with O-ring.
3. Assemble piston in sleeve (20-2).

Control Valve (KVMG-400-DA) SP000187


Page 52
Subspool (24)
1. Apply Loctite to thread of spool (24-1).

IMPORTANT
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.

2. Tighten spool end (24-2) in spool (24-1). Torque is 1.94 -


2.24 kgm (14 - 16 ft lb).

Boom, Arm Anti Drift Valve


1. Grip body in vise, taking care not to scratch O-ring (35 and
70) surface of body (47-1).
2. Insert spring seat (47-3) in spool (47-2), and insert spool in
body (47-1) hole.
3. Assemble spring (47-4).
4. Tighten plug (47-5) with O-ring (47-10) in body (47-1).
Torque is 2.86 - 3.06 kgm (21 - 22 ft lb).
5. Tighten plug (47-9) with O-ring to body (47-1). Torques
1.43 - 1.73 kgm (10 - 23 ft lb). Tighten plug (47-8) with O-
ring in body (47-1). Torque is 2.86 - 3.06 kgm (21 - 22 ft
lb).
6. Tighten plug (47-7) with O-ring and filter in body (47-1).
Torque is 2.86 - 3.06 kgm (21 - 22 ft lb).

Swing Load Check


1. Insert poppet (36-2) and spring (36-3) in poppet (36-1),
and tighten plug (36-4). Torque is 3.98 - 4.38 kgm (29 - 32
ft lb).

IMPORTANT
Insert spring into poppet. Large end of spring should
be facing the poppet. If spring is not inserted properly,
it can break.

SP000187 Control Valve (KVMG-400-DA)


Page 53
Reassembly of Control Valve

Reassembly of Load Check Valve


1. Assemble travel semiparallel check for P2 port. Assemble
poppet (52) and spring (53), and fasten plug (54) with O-
ring (55). Torque is 10.50 - 11.52 kgm (76 - 83 ft lb).
2. Assemble travel load check for P1 port. Assemble poppet
(32), spring (33) and O-ring (35), and fasten flange (34)
with socket head bolt (63). Torque is 10.50 - 11.52 kgm
(76 - 83 ft lb).

IMPORTANT
When fastening flange, spring (33) should be inserted
into flange. If it is not properly installed, the spring can
be broken. When tightening socket head bolts, they
should be tightened evenly.

3. Assemble remaining load check. Assemble poppet (31),


spring (33) and O-ring, and fasten flange (34) with socket
head bolts (63). Torque is 10.50 - 11.52 kgm (76 - 83 ft lb).

Reassembly of Swing Load Check


1. Install O-ring (40) and backup ring (41) on sleeve (38).
2. Install piston (39), spring (37) and poppet assembly (36) in
sleeve (38).
3. Install sleeve assembly in body. Install O-ring (35) on body.
4. Install piston (43) and O-ring (45) in body (42).
5. Install body assembly in sleeve (38).
6. Fasten flange (44) and body (42) with socket head bolt
(68). Torque is 10.81 - 11.52 kgm (78 - 83 ft lb).

Control Valve (KVMG-400-DA) SP000187


Page 54
Reassembly of Other Check Valve
1. Assemble two common check valves of main relief valve.
Install poppet (15) and spring (16). Insert spacer (17) with
O-ring (18) and backup ring (19). Fasten flange (56) with
socket head bolts (64). Torque is 5.91 - 6.53 kgm (43 - 47
ft lb).

IMPORTANT
When fastening flange, spring (33) should be inserted
into flange. If it is not properly installed, the spring can
be broken. When tightening socket head bolts, they
should be tightened evenly.

2. Assemble parallel check valve for spare junction, bucket


junction and arm one. Install poppet (28) and spring (29),
and tighten plug (61) with O-ring. Torque is 11.83 - 13.05
kgm (86 - 94 ft lb).
3. Assemble arm two semiparallel check valve. Install poppet
(28) and spring (29), and tighten plug (61) with O- ring.
Torque is 11.83 - 13.05 kgm (86 - 94 ft lb).

Reassembly of Flange
1. Assemble flange for spare port. Install O-ring (78) on
flange (76), and fasten flange with socket head bolts (77).
Torque is 10.50 - 11.52 kgm (76 - 83 ft lb).
2. Assemble flange for boom two. Install O-ring (57) on valve
housing, and fasten flange (56) with socket head bolt (64).
The good surface of flange should be facing the O-ring
side. Torque is 5.91 - 6.53 kgm (43 - 47 ft lb).

Reassembly of Boom and Arm Anti Drift Valve


1. Install poppet (46) and spring (57), and fasten body
assembly (47) with socket head bolt (63). Torque is 10.50 -
11.52 kgm (76 - 83 ft lb).

IMPORTANT
When installing body assembly (47), spring (33) should
be completely installed in spring position of body
assembly.

SP000187 Control Valve (KVMG-400-DA)


Page 55
Reassembly of Relief Valve
1. Tighten eight over load relief valves (49). Torque is 7.95 -
8.97 kgm (58 - 65 ft lb).
2. Tighten main load relief valve (48). Torque is 9.48 - 11.01
kgm (69 - 80 ft lb).
3. Tighten negacon relief valve (50). Torque is 10.50 - 11.52
kgm (76 - 83 ft lb).

Reassembly of Subspool (24)


1. Install spool (24) in valve hole it was removed from during
disassembly.
2. Install spring seat (24) and spring (25).
3. Tighten plug (27) with O-ring. Torque is 9.48 - 11.01 kgm
(69 - 80 ft lb).

IMPORTANT
Insert spool in hole perpendicularly. Make sure that
spool is in correct position. If it is not in correct
position, a malfunction can occur.

Reassembly of Subspool (20)


1. Install spool assembly in valve hole it was removed from
during disassembly.
2. Install spring seat (21) and spring (22).
3. Tighten plug (23) with O-ring (72). Torque is 9.48 - 11.01
kgm (69 - 80 ft lb).

Reassembly of Main Spool (3) - (11)


1. Install O-ring on valve housing (1,2).
2. Fasten short cap (74) with socket head bolt (63) for travel
straight spool (7). Fasten short cap (13) with socket head
bolt (63) for the other travel straight spools. Torque is
10.50 - 11.52 kgm (76 - 83 ft lb).
3. Install spools (3 - 11) in valve holes they were removed
from during disassembly.
4. Fasten long cap (73) with socket head bolt (63) on travel
straight spool (7). Fasten long cap (12) with socket head
bolt (63) on other travel straight spools. Torque is 10.50 -
11.52 kgm (76 - 83 ft lb).

IMPORTANT
When assembling, be careful not to drop O-ring from
mating surface.

Control Valve (KVMG-400-DA) SP000187


Page 56
Reassembly of Other Plugs
1. Tighten plug assembly (60) with O-ring. Torque is 3.16 -
4.28 kgm (23 - 31 ft lb).
2. Tighten plug assembly (61) with O-ring. Torque is 11.83 -
13.05 kgm (86 - 94 ft lb).
3. Tighten plug assembly (62) with O-ring. Torque is 7.44 -
8.06 kgm (54 - 58 ft lb).
4. Tighten plug assembly (58) with O-ring and backup ring.
Torque is 7.95 - 8.97 kgm (58 - 65 ft lb).
5. Tighten plug assembly (51) with O-ring. Torque is 10.50 -
11.52 kgm (76 - 83 ft lb).
6. Tighten plug assembly (59) with O-ring. Torque is 7.44 -
8.06 kgm (54 - 58 ft lb).

IMPORTANT
After reassembly is completed, recheck tightening
torque of all components. If they are not properly
tightened, an oil leak can occur. The torque values are
based on the threads being lubricated.

SP000187 Control Valve (KVMG-400-DA)


Page 57
Reassembly of Main Relief Valve
Check whether there is dirt or paint chips around plug (4, Figure
54) and nut (3). Reassemble with new O-rings. Clean the
installation portion of relief valve and install it. Tighten cap (8:
Width across flats 41). Torque is 9.48 - 11.01 kgm (69 - 80 ft lb).
When adjusting the position of port (Pi), adjust it before adjusting
pressure and tightening plug (2, Width across flats 41 mm). After
adjusting plug (2), move cap (7, Width across flats 54 mm).
Torque is 7.95 - 8.97 kgm (58 - 65 ft lb). If plugs are
disassembled, Adjust pressure by referring to Main Relief
Valve on page 1-41.
NOTE: The torque values are based on the threads being
lubricated.

Figure 54

Control Valve (KVMG-400-DA) SP000187


Page 58
Reassembly of Overload Relief Valve
Check whether there is dirt or paint chips around cap (1, width
across flats: 31.75 mm) and reassemble with a new O-ring.
Clean the installing part of relief valve and install it. Tighten cap
(1). Torque is 7.95 - 8.97 kgm (58 - 65 ft lb).
If adjusting kit is disassembled, clean around threads and adjust
pressure by referring to Over Load Relief Valve on page 1-42.
NOTE: The torque values are based on the threads being
lubricated.

Figure 55

Reassembly of Low Pressure Relief Valve


Check whether there is dirt or paint chips around plug (1, width
across flats: 46 mm) and reassemble it with new O-rings (3 and
4).
NOTE: The torque values are based on the threads being
lubricated.

Figure 56

SP000187 Control Valve (KVMG-400-DA)


Page 59
INSTALLATION
1. Be careful not to work other foreign strength to control
valve by pipe laying.
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. Clean the installation portion of relief valve and install it.
Tighten plug (1). Torque: 10.50 - 11.52 kgm (76 - 83 ft lb).
5. 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 82-113C should
be used in the hydraulic system.
3. Relief valve pressure should not be raised above specified
pressure setting.
4. The difference between main relief valve setting pressure
and over load relief valve setting pressure should not be
over 2.0 MPa.
5. Before operating machine, the hydraulic 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 over load
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.

Control Valve (KVMG-400-DA) SP000187


Page 60
SP000189
REMOTE CONTROL VALVE (WORK LEVER /
JOYSTICK) SP000189

Remote Control
Valve (Work
Lever / Joystick)
Edition 1

Remote Control Valve (Work Lever / Joystick) SP000189


Page 1
MEMO

SP000189 Remote Control Valve (Work Lever / Joystick)


Page 2
Table of Contents

Remote Control Valve


(Work Lever / Joystick)
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 7
Function........................................................................... 7
Parts List ......................................................................... 8
Specifications ................................................................ 10
Torques .............................................................. 10
Tools and Materials ............................................ 10
Disassembly ....................................................... 11
Cleaning and Inspection (Wear Limits and
Tolerances)......................................................... 15
Reassembly ........................................................ 15
Start-up Procedures ........................................... 21

Remote Control Valve (Work Lever / Joystick) SP000189


Page 3
MEMO

SP000189 Remote Control Valve (Work Lever / Joystick)


Page 4
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.

MODEL SERIAL NUMBER RANGE


DX420LC 5001 and Up
DX480LC 5001 and Up
DX520LC 5001 and Up

SP000189 Remote Control Valve (Work Lever / Joystick)


Page 5
Remote Control Valve (Work Lever / Joystick) SP000189
Page 6
GENERAL DESCRIPTION
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.

SP000189 Remote Control Valve (Work Lever / Joystick)


Page 7
Parts List

28

24

18
25A
16 23
17
35
12 18
22 16
32 17
25 35
8 20 12
7

6
33 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
FG004596
Figure 1

Remote Control Valve (Work Lever / Joystick) SP000189


Page 8
Reference Reference
Description Description
Number Number
1 Case 22 Swash Plate
2 Plug 23 Nut
3 Bushing 24 Nut
4 Spool Handle Assembly (L)
25
5 Shim Handle Assembly (R)
6 Spring 25A Cap
7 Spring Seat 26 Handle Bar
8 Stopper 27 Spring Pin
9 Spring 28 Bellows
12 Push Rod 29 Bushing
16 Plug 30 Connector Assembly
17 O-ring 32 Switch Assembly
18 Rod Seal 33 Spool Kit 1, 3
19 Plate 35 Plug Kit 1, 3
20 Boot Handle Kit (Left)
37
Handle Kit (Right)
21 Joint Assembly

SP000189 Remote Control Valve (Work Lever / Joystick)


Page 9
Specifications

Performance

Figure 2

Torques

No. Tool Standard Remark


500 kgcm
3 Plug PF 3/8
(36 ft lb)
1,660 kgcm
19 Swash Plate 27 mm
(120 ft lb)
1,660 kgcm
20 Hex Nut 22 mm
(120 ft lb)
1,660 kgcm
22 Nut 22 mm
(120 ft lb)

TOOLS AND MATERIALS


No. Tool Standard Remark
3 L Wrench 8 mm
19 Spanner 27 mm
20 Spanner 22 mm
22 Spanner 22 mm

Remote Control Valve (Work Lever / Joystick) SP000189


Page 10
DISASSEMBLY
1. Remove lead wire from bushing (29).

FG000804
Figure 3

2. Remove lever assembly from case (1).

FG000805
Figure 4

3. Remove hex nut (23) and swash plate (22) from case.

FG000806
Figure 5

4. Remove joint assembly (21) from case.

FG000807
Figure 6

SP000189 Remote Control Valve (Work Lever / Joystick)


Page 11
5. Remove plate (19) from case (1).

FG000808
Figure 7

6. Remove plug kit assembly from case (1).

FG000810
Figure 8

FG000811
Figure 9

7. Remove four spool kit assemblies from case (1).

FG000812
Figure 10

Remote Control Valve (Work Lever / Joystick) SP000189


Page 12
FG000813
Figure 11

8. The bushing (3) and plug cannot be removed from case


(1).

FG000814
Figure 12

FG000815
Figure 13

FG000816
Figure 14

SP000189 Remote Control Valve (Work Lever / Joystick)


Page 13
FG000817
Figure 15

Remote Control Valve (Work Lever / Joystick) SP000189


Page 14
CLEANING AND INSPECTION
(WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to
"General Maintenance Procedures" section.

REASSEMBLY
1. Install four plugs (2) into case (1).

FG000815
Figure 16

FG000817
Figure 17

2. Install bushing (3) into case (1) using jig.

FG000814
Figure 18

SP000189 Remote Control Valve (Work Lever / Joystick)


Page 15
FG000816
Figure 19

FG000818
Figure 20

3. Take care when assembling spool kit assemblies (1 and 3,


2 and 4). They should be assembled in same way).
The assembly order is; spool (4), shim (5), spring (6),
spring seat (7), and stopper (8).

FG000819
Figure 21

FG000812
Figure 22

Remote Control Valve (Work Lever / Joystick) SP000189


Page 16
4. Install spring (9) into case (1).

FG000820
Figure 23

5. Install spool kit assembly into case (1). (The same way is
used for four parts.)

FG000821
Figure 24

6. Assemble plug kit insert rod seal (18), O-ring (17), and
push rod (12) into plug (16) in proper order.

FG000822
Figure 25

FG000810
Figure 26

SP000189 Remote Control Valve (Work Lever / Joystick)


Page 17
7. Assemble plug kit (35) and insert assembled set in case (1)
to form a plug kit assembly.

FG000811
Figure 27

FG000811
Figure 28

FG000823
Figure 29

8. Install plate (19) into case (1).

FG000808
Figure 30

Remote Control Valve (Work Lever / Joystick) SP000189


Page 18
9. Install joint assembly (21) into case (1).

FG000807
Figure 31

10. Install wash plate (22) and hex nut (23) into case (1).

FG000806
Figure 32

11. Insert bar and tighten it with a spanner to check balance of


joint assembly.

FG000824
Figure 33

12. Install boot (20) and bushing (29) into case (1).

FG000825
Figure 34

SP000189 Remote Control Valve (Work Lever / Joystick)


Page 19
13. Install lever assembly into case (1).

FG000805
Figure 35

14. Put lead wire in bushing (29), tie it, and arrange boot.

FG000826
Figure 36

FG000827
Figure 37

15. Install lead wire terminal into connector terminal pressing


them together.

FG001097
Figure 38

Remote Control Valve (Work Lever / Joystick) SP000189


Page 20
16. Assemble connector assembly (30), and connect it to lead
wire terminal, and properly route wiring.

FG000828
Figure 39

FG000829
Figure 40

START-UP PROCEDURES
1. Start engine and set throttle at "LOW IDLE."
2. Set safety lever on "UNLOCK" position.

HAOB290L
Figure 41

3. Slowly cycle boom, arm, bucket cylinders and swing motor


about five times without a load to vent air from pilot lines.
Do this for five minutes.

ARO0470L
Figure 42

SP000189 Remote Control Valve (Work Lever / Joystick)


Page 21
Remote Control Valve (Work Lever / Joystick) SP000189
Page 22
SP000070
TRAVEL CONTROL VALVE (WITH DAMPER)
SP000070

Travel Control
Valve (With
Damper)
Edition 1

Travel Control Valve (With Damper) SP000070


Page 1
MEMO

SP000070 Travel Control Valve (With Damper)


Page 2
Table of Contents

Travel Control Valve (With Damper)


Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 6
Theory of Operation ........................................................ 6
Deceleration Valve .......................................................... 7
Dampening Parts of the Control Section ......................... 8
Causes of Faults and Measures ......................... 11
Parts List ....................................................................... 12
Specifications ................................................................ 13
Torques ......................................................................... 13
Removal ............................................................. 14
Disassembly ....................................................... 15
Cleaning and Inspection (Wear Limits and
Tolerances)......................................................... 18
Assembly ............................................................ 19
Installation .......................................................... 26
Start-up Procedures ........................................... 27

Travel Control Valve (With Damper) SP000070


Page 3
MEMO

SP000070 Travel Control Valve (With Damper)


Page 4
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.

MODEL SERIAL NUMBER RANGE


DX300LC 5001 and Up
DX340LC 5001 and Up
DX420LC 5001 and Up
DX480LC 5001 and Up
DX520LC 5001 and Up

SP000070 Travel Control Valve (With Damper)


Page 5
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

Travel Control Valve (With Damper) SP000070


Page 6
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)

OPERATING TORQUE (kg.cm)

112.6
251.5
Operating Torque 91.8

46.4
7.51
Secondary Pressure

0 10.5 4.80.5 5.5

PUSH-ROD STROKE (mm)


FG003924

Figure 2

SP000070 Travel Control Valve (With Damper)


Page 7
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.

Travel Control Valve (With Damper) SP000070


Page 8
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

Thus, a dampening force is generated at both ways.


4

HB4M033L-1
Figure 3

B. Operation of forward and reverse lever control 1


12.5
Oil outside the damper spool runs out through the
channel from the top of the casing to the port (T). And
2
oil in the damper spool is discharged through orifice,
generating pressure that creates a dampening force.

HB4M032L-1
Figure 4

SP000070 Travel Control Valve (With Damper)


Page 9
Travel Control Valve (With Damper) SP000070
Page 10
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.

Problem Possible Cause Remedy


Secondary pressure will not Low primary pressure. Adjust primary pressure.
increase. Defective secondary pressure Replace with new spring.
select spring.
Gap between damper spool and Replace damper spool casing assembly.
casing is abnormally large.
Defective operating parts and Disassemble/reassemble and replace
components. defective parts.
Unstable secondary Jamming of interconnected parts. Repair/replace cause of jamming.
pressure. Unstable tank line pressure. Install direct line to hydraulic tank.
Air in hydraulic lines. Vent air from system.
Abnormally high secondary High tank line pressure. Install direct line to hydraulic tank.
pressure. Jamming of interconnected parts. Repair/replace cause of jamming.
No dampening. Air in piston chamber. Vent air from system.
Jamming of interconnected parts. Repair/replace cause of jamming.
Worn damper springs. Replace with new parts.
Worn damper spool and housing. Replace damper spool and housing
assembly.
Defective/damaged check valve. Disassemble and examine check valve.
Worn damper spool orifice. Replace damper spool.
Damper spool feels heavy. Defective interconnected Repair/replace defective parts.
components.
Restricted movement of damper Repair/replace damaged piston.
spool.

SP000070 Travel Control Valve (With Damper)


Page 11
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

Travel Control Valve (With Damper) SP000070


Page 12
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)

Pressure / Stroke 25 kg/cm2 @ 4.8 mm Stroke


(356 psi @ 0.1890 in Stroke)
7.8 kg
Weight
(17 lb)

Torques
Part Reference
Bolt Size Tool Tightening Torque
Number
88 kgcm
26 M6 5 mm L-Wrench
(6 ft lb)
100 kgcm
30 M8 4 mm L-Wrench
(7 ft lb)
440 kgcm
32 M10 17 mm Spanner
(32 ft lb)
440 kgcm
37 M10 8 mm L-Wrench
(32 ft lb)

SP000070 Travel Control Valve (With Damper)


Page 13
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

DON'T TOUCH WHEN

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.

6. Fully stroke work levers (joysticks) in all directions to


relieve any pressure from accumulators.
7. Set safety lever on "LOCK" position.
8. Turn key to "O" (OFF) position and remove from starter
switch.
9. Hang a maintenance warning tag on controls.
10. Disconnect negative (-) battery cable leading to frame from
battery.
11. Remove cabin under cover by loosening bolts.
2
12. Tag and disconnect hoses from pedal valve (1, Figure 7).
Plug and cap hoses and ports to prevent contamination
from entering hydraulic system or component. 1

FG003016
Figure 7

Travel Control Valve (With Damper) SP000070


Page 14
DISASSEMBLY
1. Remove bellows (33).

ARS1870P
Figure 8

2. Remove set screw (30) from cam (27).

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

SP000070 Travel Control Valve (With Damper)


Page 15
5. Remove hex socket head bolt (26) and cover (25) from
each body (1 and 2).

FG000988
Figure 12

FG000989
Figure 13

6. Remove push rod assembly from each body (1 and 2).

FG000990
Figure 14

7. Remove retaining ring (13).

FG000991
Figure 15

Travel Control Valve (With Damper) SP000070


Page 16
8. Remove rod guide (11) from each body (1 and 2).

FG000992
Figure 16

FG000993
Figure 17

9. Remove damper spool assembly and spring (10) from


each body (1 and 2).

FG000994
Figure 18

FG000995
Figure 19

SP000070 Travel Control Valve (With Damper)


Page 17
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

CLEANING AND INSPECTION


(WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to
"General Maintenance Procedures" section.

Travel Control Valve (With Damper) SP000070


Page 18
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

SP000070 Travel Control Valve (With Damper)


Page 19
2. Insert spring (10) into each body (1 and 2).

FG000995
Figure 26

3. Assemble in proper order, damper spool (8), shim (7),


spring (6), spring seat (5), and stopper (9).

FG000999
Figure 27

FG001000
Figure 28

4. Install damper spool assembly into each body (1 and 2).

FG000994
Figure 29

Travel Control Valve (With Damper) SP000070


Page 20
5. Install O-ring (12) on rod guide (11). Coat guide assembly
with grease, and slide it into each body (1 and 2).

FG000992
Figure 30

FG000993
Figure 31

6. Install retaining ring (13). Make sure that it is properly


seated.

FG000991
Figure 32

7. Assemble rod seal (23), dust seal (24), and O-ring (22) into
plug (21).

FG001001
Figure 33

SP000070 Travel Control Valve (With Damper)


Page 21
FG001002
Figure 34

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

9. Assemble push rod and plug.

FG001005
Figure 37

Travel Control Valve (With Damper) SP000070


Page 22
10. Install push rod assembly into each body (1 and 2).

FG000990
Figure 38

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

SP000070 Travel Control Valve (With Damper)


Page 23
13. Install set screws (31) and hex nut (32) into cam (27) and
tighten it.

FG000987
Figure 42

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

16. Check cam balance.

FG001009
Figure 45

Travel Control Valve (With Damper) SP000070


Page 24
17. Install bellows.

ARS2250P
Figure 46

SP000070 Travel Control Valve (With Damper)


Page 25
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

4. Connect hoses as tagged during removal to pedal valve (1,


Figure 49). 2

5. Install cabin under cover by tightening bolts.


1

FG003016
Figure 49

Travel Control Valve (With Damper) SP000070


Page 26
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

SP000070 Travel Control Valve (With Damper)


Page 27
Travel Control Valve (With Damper) SP000070
Page 28
SP000191
SOLENOID VALVE ASSEMBLYSP000191

1Solenoid Valve
Assembly

Edition 1

Solenoid Valve Assembly SP000191


Page 1
MEMO

SP000191 Solenoid Valve Assembly


Page 2
Table of Contents

Solenoid Valve Assembly


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

Solenoid Valve Assembly SP000191


Page 3
MEMO

SP000191 Solenoid Valve Assembly


Page 4
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.

MODEL SERIAL NUMBER RANGE


DX420LC 5001 and Up
DX480LC 5001 and Up
DX520LC 5001 and Up

SP000191 Solenoid Valve Assembly


Page 5
PARTS LIST
Components used for the solenoid valve package are the same
as in the parts list below.

Figure 1

Reference
Description Sizes Quantity Remarks
Number
1 Block Body 95x120x240 1 1-A1079-05-0
2 Solenoid valve TF-S34-00-VDL24VDC 6 C1, C2, C3, C4, C5
3 Check Valve FD-DCP-0-A 1 C6
4 Pilot Shift Valve FD-PSS1-0005 1 C7
5 Plug PF 1/4" 3 P5, P6, H0
6 Plug PT 1/4" 1
7 Plug PT 1/8" 14

Solenoid Valve Assembly SP000191


Page 6
FUNCTIONS OF 5-SOLENOID
VALVE ASSEMBLY PACKAGE

Functions of Solenoid Valve Assembly


Package

This solenoid valve assembly package have the following


functions.
1. Pilot cut-off
2. Breaker pressure supply
3. High travel speed
4. Main pressure increase
5. Work modes control - Swing Priority

Functions and Operations of Solenoid Valves

Reference
Function Operations Remarks
Number
Provides pressure and oil coming from the pilot pump
C1 Pilot cut-off for the pilot pressure supply solenoid valve to drive
each work system.
Breaker Supplies pilot pressure for the breaker valve assembly
C2
operation and the breaker pressure supply solenoid valve.
Sets low travel speed and high travel speed, of shifts
speed between both depending on the state of the
C3 High travel speed
solenoid valve operation or a signal detected in the e-
EPOS controller.
Main pressure Increases the pressure set for the main relief valve
C4
increase temporally to increase the excavation power.
Operating the C5 solenoid valve starts the Swing
Work modes
C5 Priority valve of the main control valve to improve
control
swing operation.

Detailed Functions and Operations of Solenoid Valves


1. Pilot Cut-Off
It provides pressure and oil coming from the pilot pump for
breaker solenoid valve (C2), high travel speed solenoid
valve (C3), main pressure increase solenoid valve (C4),
and the work modes control solenoid valve (C5). Push
down the Cut-Off lever located on the left side of the
driver's seat, and the electrical signal of the limit switch
starts the pilot cut-off valve to supply pressure and oil to
each pilot pressure supply solenoid valve.

SP000191 Solenoid Valve Assembly


Page 7
2. Breaker pressure supply
Pressing the breaker switch on the joystick operates the
breaker solenoid valve (C2) to supply pilot pressure to the
option valve of the main control valve. The pressure
switches the spool of the option valve, which transfers
pressure and oil from the main pump to the breaker system
for excavation.II
3. High travel speed control
When the automatic travel switch is "Off", the travel speed
switches to "0" (low speed); when the switch turned to the
1st place, the travel speed switches to " I " (high speed);
when the switch turned to the 2nd place, the travel speed
switches to " II ", automatically. In this case, the high travel
speed control shows "Off" when the automatic travel switch
is "Off", "On" when it is in the 1st place, and "On/Off" when
it is in the 2nd place. Specifically speaking, turning the
automatic travel switch to the 2nd place, the e-EPOS
controller detects the discharge pressure from the main
pump, and automatically turns the high travel speed control
"On" or "Off" depending on if the travel load is high or low
to switch the travel speed to speed 1 or 2. The travel load
is detected by 2 pressure sensors located on the discharge
line of the front and rear pumps. If the load is high
(pressure about 300 kgfcm2), the solenoid valve turns
"Off" for the travel at low; If the load is low (pressure about
160 kgfcm2), the solenoid valve turns "On" for the travel at
high. If the engine control dial is set equal and below 1400
RPM, however, the solenoid valve always turns "On" for
the travel at low, though the automatic travel switch is set
to the automatic travel (2nd place).
4. Boost main pressure
It increases the pressure of the main relief valve temporally
to increase the excavation power. Pressing the power
boost switch on the work lever sends a signal of the e-
EPOS controller to start the pressure increase solenoid
valve. Then, as it turns "On", the pressure of the main relief
valve increases about 330 kgfcm2 to 350 kgfcm2, which
in turn increases the excavation power.
5. Work modes control
A work mode can be choses as either Excavation or
Trenching mode using a Trenching mode switch on the
operation panel.
Turning on the Start-on switch, Excavation is automatically
accepted as the work mode and the Swing Priority
solenoid valve turns "Off".
This Excavation mode is used for ordinary excavation
work, loading, and fast levelling work.
Choosing the Trenching mode on the operation panel the
Swing Priority solenoid valve for the control valve turns
"On" and starts to work, reducing the oil lines to booms and
arms to increase the swing capacity.

Solenoid Valve Assembly SP000191


Page 8
Assembly Diagram and Tools Required
Table 1 shows assembly torques recommended for components
of the solenoid valve package. Designated tools and torques
should be followed.

Figure 2

Reference Torques
Components Screw Sizes Tools
Number (kg/cm)
2 Solenoid valve UNF7/8 - 14" 200 25 Hex torque
wrench/1", socket
2-1 Coil Lock Nut UNF1/2 -20" 60 2 Hex torque wrenc