Professional Documents
Culture Documents
Dx340lca en э
Dx340lca en э
Shop Manual
950106-00268E
Serial Number 5001 and Up
DOOSAN reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
Instructions
Specifications
Specification for DX340LCA ................................................................. SP002320
General Maintenance
General Maintenance Procedures ........................................................ SP000016
Standard Torques ................................................................................. SP000813
Upper Structure
Cabin .................................................................................................... SP001737
Counterweight....................................................................................... SP001738
Fuel Tank.............................................................................................. SP002321
Fuel Transfer Pump (Opt)..................................................................... SP000021
Swing Bearing....................................................................................... SP001856
Swing Reduction Gear.......................................................................... SP001740
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ............... SP002451
Accumulator.......................................................................................... SP000028
Center Joint (Swivel)............................................................................. SP000181
Cylinders............................................................................................... SP000030
Table of Contents
Page I
Swing Motor.......................................................................................... SP000261
Travel Motor.......................................................................................... SP000253
Main Pump............................................................................................ SP000186
Gear Pump ........................................................................................... SP000260
Main Control Valve ............................................................................... SP000034
Remote Control Valve (Work Lever / Joystick) ..................................... SP000069
Travel Control Valve (With Damper)..................................................... SP001743
Solenoid Valve Assembly ..................................................................... SP001622
Breaker EPPR Valve (Opt) ................................................................... SP000192
Hydraulic Schematic DX300LC/DX300LCA/DX340LCA ...................... SP001752
Electrical System
Electrical System .................................................................................. SP002453
Electrical Schematic DX300LCA / DX340LCA ..................................... SP002031
Attachments
Boom and Arm...................................................................................... SP001851
Bucket................................................................................................... SP001852
Table of Contents
Page II
1Safety
SP002025
TRACK EXCAVATOR SAFETYSP002025
Track
Excavator
Safety
Edition 1
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.
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.
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 threat of a hazardous situation that, if not
avoided, could result in serious injury or death. It may also
be used to alert against 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 detonate or explode if handled or treated carelessly.
Accessory Applications
The excavator has been primarily designed for moving earth
with a bucket. For use as a grapple or for other object handling,
contact DOOSAN for proper installation and application. Lifting-
work applications (unless restricted or prohibited by local
regulations) are permitted in approved lift configuration, to rated
capacity only, with no side-loading. DO NOT use the machine
for activities for which it was not intended. DO NOT use the
bucket for lifting work, unless lift slings are used in the approved
configuration.
Use of an accessory hydraulic hammer (breaker), work in rough
terrain, demolition applications or other hazardous operation
may require installation of additional protective structures to
safeguard the operator.
IMPORTANT
Before using the excavator to make lifts check municipal
and regional regulations or statutes that could apply.
Governing ordinances may require that all heavy lifting be
done with single purpose equipment specifically designed
for making lifts, or other local restrictions may apply.
Making heavy lifts with a general purpose excavator that
can be used for digging, loading, grading or other work may
be expressly forbidden by a regional injunction or other
legal prohibition. Always follow all of the other instructions,
guidelines and restrictions for Safe Lifting in the Operation
and Maintenance Manuals.
DANGER
Unsafe use of the excavator while making rated lifts could
cause serious, potentially fatal injuries or extensive
damage to the machine or nearby property. Do not let
anyone operate the machine unless they've been properly
trained and understand the information in the Operation
and Maintenance Manual.
WARNING
NEVER wrap a tag line around your hands or body.
NEVER rely on tag lines or make rated lifts when wind gusts
are more than 48.3 km/h (30 MPH). Be prepared for any wind
gust when working with loads that have a large surface
area.
WARNING
If you need more information or have any questions or
concerns about safe operating procedures or working the
excavator correctly in a particular application or in the
specific conditions of your individual operating
environment, please consult your local DOOSAN
representative.
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 judgment 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.
FG000355
Figure 2
To prevent hot coolant from spurting out, shut down engine, wait
for the coolant to cool, then loosen the cap slowly to relieve the
pressure.
To prevent hot oil from spurting out, shut down engine, wait for
the oil to cool, then loosen the cap slowly to relieve the pressure.
HAOA060L
Figure 5
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 the attachments
that owners may wish to install on their machines, please
contact DOOSAN for authorization and approval of attachments,
and their compatibility with optional kits.
Indoor Ventilation
Engine exhaust gases can cause fatal accidents, and
unconsciousness, loss of alertness, judgment 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
where exhaust may be carried, or blown by the wind, exposing
others to danger.
ARO1770L
Figure 11
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 that requires the breaking
of glass to exit from the operator's cabin. Grip the handle firmly
and use the sharp point to break the glass.
WARNING
FG000178
Protect your eyes when breaking the glass. Figure 12
lines may be buried under the work site. Contact each utility and No Entry
Check the condition of the riverbed, and the depth and flow of
the water before operating in water or crossing a river. NEVER
work in water that is more than the permissible water depth.
Any object in vicinity of boom could represent a potential hazard,
or cause the operator to react suddenly and cause an accident.
Use a spotter or signal person when working near bridges,
phone lines, work site scaffolds, or other obstructions.
FG000363
Figure 14
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.
Look around the work site area for potential hazards, people or
property 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.
FG000365
Figure 18
FG000368
Figure 19
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
tip over and injury. Travel without a load or a balanced load may
also be hazardous.
Never rely on lift jacks or other inadequate supports when work
is being done. Block tracks fore and aft to prevent any
movement.
FG000170
Figure 20
FG000112
Figure 24
Parking Machine
Avoid making sudden stops, or parking the machine wherever it
happens to be at the end of the workday. Plan so the excavator 120
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. Park the machine so
the machine, flags, and fences do not obstruct traffic.
After the front attachment has been lowered to an overnight
Lock
storage position and all switches and operating controls are in
FG000666
the "OFF" position, the safety lock lever must be set to the
Figure 27
"LOCKED" position. This will disable all pilot circuit control
functions.
Always close the door of the operator's cabin.
ARO1310L
Figure 28
Warning Tag
Alert others that service or maintenance is being performed and WARNING
tag operator's cabin controls – and other machine areas if
required – with a warning notice. OSHA mandated control lever DO NOT OPERATE
lockout can be made with any OSHA certified lockout device and
a length of chain or cable to keep the safety lever in the fully when performing inspection
lowered, nonactive position.
or maintenance
Warning tags, for controls are available from DOOSAN
190-00695A
distributors.
FG012195
Figure 29
HDO1037L
Figure 31
Use of Lighting
When checking fuel, oil, battery electrolyte, or window washing
fluid, always use lighting with antiexplosion specifications. If
such lighting equipment is not used, there is a 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 a danger of fire. There is also danger the HDO1040L
battery gas may catch fire and cause an explosion.
Figure 32
DANGER
DOOSAN warns any user, that 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 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 35
front attachment has been removed.
WARNING
Improper lifting can allow load to shift and cause injury or
damage.
Specification
for DX340LCA
Edition 1
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.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
40
39
38
37 20
36
21
35
34 22
33 26
32
31 23
30
29
28 27
24
25
FG003644
Figure 1
A
H
I J B C
G
O
F
N
M D
E
K
FG004621
Figure 2
WARNING
The actual value for dimension "L" Digging Reach, depends
on the stability and support provided by ground conditions.
Digging too far underneath the excavator if soil conditions
are wet, loose or unstable can collapse ground support,
which could cause injury and/or equipment damage.
11
10
5 F
4 G
D
3
G.L 0
0 1 2 3 4 5 6 7 8 9 10 11 12
-1
-2
-3
H J C
-4
-5
-6
-7
-8
K 8’
I
B
A
FG005208
Figure 3
120
110
TORQUE (kg.m)
100
250
POWER OUTPUT (ps)
200
160
150
140
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/yd 3)
Coal, bituminous r. of m., 881 kg/m3
--------------------- ---------------------
piled (1,485 lb/yd 3)
897 kg/m3
Coal, anthracite --------------------- ---------------------
(1,512 lb/yd 3)
Clay, DRY, in broken 1,009 kg/m3
--------------------- ---------------------
lumps (1,701 lb/yd 3)
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)
Test Conditions
1. All tests should be performed on a flat, level, firm
supporting ground surface.
2. All recommended, applicable maintenance and adjustment
service should be completed before testing.
3. Hydraulic fluid and engine oil should be of appropriate
viscosity for ambient weather conditions. Warm up
hydraulic oil to standard operating temperature, between
45° - 55°C (112° - 135°F).
4. Run all tests with the engine speed control set to maximum
rpm.
5. Repeat tests with Power Mode engine control settings at
both Standard Mode (standard work mode) and Power
Mode (high speed mode). Travel speed tests should also
be repeated at both high and low speed.
Speed Test
Prepare the excavator for travel speed tests by extending all
hydraulic cylinders - boom, arm and bucket - to the fully
extended position, shown in Figure 5.
FG000466
Figure 5
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 15.4 ±1.0 sec 14.7 ±1.0 sec
Low Speed 24.7 ±1.5 sec 23.5 ±1.5 sec
3M - 5M
3M - 5M 20M
(10' - 15')
(10' - 15') (65' 7-1/2'')
FG000467
Figure 6
1.5M
FG000468
Figure 7
Record how far the turntable drifts past the stop point,
measuring the distance between paint marks. Maximum
distance should be less than 1200 mm (47-1/4"), in both Power
Mode and Standard Mode.
Reference
Description
Number
1 Start Swing
1
2 90° Swing
FG000659
3 Swing Force
Figure 8
4 Swing Stop
General
Maintenance
Procedures
Edition 1
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.
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.
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.
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 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.
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.
Figure 1
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.
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.
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
Figure 4
Galling
Metal smears on roller ends due to overheat, lubricant failure or
overload.
Replace bearing - check seals and check for proper lubrication.
Figure 5
Figure 6
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
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
Figure 13
Figure 14
Smears
Smearing of metal due to slippage caused by poor fitting,
lubrication, overheating, overloads or handling damage.
Replace bearings, clean related parts and check for proper fit
and lubrication.
Replace shaft if damaged.
Figure 15
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
Standard
Torques
Edition 1
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) ..................... 14
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.
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 1.25
(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 1.25
(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 2.0
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)
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.
Torque
Radiator, Air Cleaner, Boots, Etc. Hydraulic System
Clamp Type And Size
Kilogram Meter Inch Pounds Kilogram Meter Inch Pounds
(kg•m) (in lb) (kg•m) (in lb)
"T" Bolt (Any Diameter) 0.68 - 0.72 59 - 63 ------- ------
Worm Drive - Under
44 mm (1-3/4 in) Open 0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50
Diameter
Worm Drive - Over 44 mm
0.5 - 0.6 40 - 50 ------- ------
(1-3/4 in) Open Diameter
Worm Drive - All
0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50
"Ultra-Tite"
Bolt Torque
Flange Bolt
Kilogram Meter Foot Pounds
Size (*) Size
(kg•m) (ft lb)
1/2" 5/16" 2.1 - 2.5 15 - 18
3/4" 3/8" 3.0 - 3.7 22 - 27
1" 3/8" 3.7 - 4.8 27 - 35
1 - 1/4" 7/16" 4.8 - 6.2 35 - 45
1 - 1/2" 1/2" 6.4 - 8.0 46 - 58
2" 1/2" 7.6 - 9.0 55 - 65
2 - 1/2" 1/2" 10.9 - 12.6 79 - 91
3" 5/8" 19.1 - 20.7 138 - 150
3 - 1/2" 5/8" 16.2 - 18.4 117 - 133
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
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. DOOSAN
does not specifically endorse a specific manufacturer or
brand name but the following table of "Loctite" applications
is included for which cross-references to other makers'
products should also be widely available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of
fastener adhesives, with Thread locker sealers 222, 242/243,
262, 271, 272, or 277.
Breakaway Cure
Product Application Color Removal Strength (in lb) of
Sealer Alone
Low strength for 6 mm (1/4") or
222 Purple Hand tools 45
smaller fasteners.
Medium strength for 6 mm (1/4") and
242 or 243 Blue Hand tools 80
larger fasteners.
Heat/260°C (500°F)
High strength for high grade fasteners Remove HOT
262 Red 160
subject to shock, stress and vibration.
(NO solvent)
Extra high strength for fine thread Heat/260°C (500°F)
271 Red 160
fasteners up to 25 mm (1") diameter. Remove HOT
High temperature/high strength for
Heat/316°C (600°F)
272 hostile environments to 232°C Red 180
Remove HOT
(450°F).
Extra high strength for coarse thread
Heat/260°C (500°F)
277 fasteners 25 mm (1") diameter and Red 210
Remove HOT
larger.
V. "Loctite" Adhesives
Cabin
Edition 1
Cabin SP001737
Page 1
MEMO
Cabin SP001737
Page 2
Table of Contents
Cabin
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
Removal ............................................................... 6
Installation .......................................................... 10
Cabin SP001737
Page 3
MEMO
Cabin SP001737
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.
Cabin SP001737
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.
WARNING
or maintenance
190-00695A
FG014348
If engine must be run while performing maintenance, Figure 1
use extreme care. Always have one person in the
cabin at all times. Never leave the cabin with the
engine running.
Cabin SP001737
Page 6
12. Remove floor mat (1, Figure 2).
13. Remove seat (2, Figure 2).
NOTE: Be careful not to damage seat covering.
14. Remove cup holder (3, Figure 2).
Remove front cover (4, Figure 2) and side covers (5 and 6,
Figure 2). When removing cover(4, Figure 2), disconnect
hour meter connector.
NOTE: Don't remove monitor panel (7, Figure 2) and
switch panel (8, Figure 2).
Figure 2
15. After removing rear mat (1, Figure 3), remove rear center
cover (2, Figure 3), cassette cover(3, Figure 3) and rear
side covers (4 and 5, Figure 3).
Figure 3
16. Remove fuse box bracket (1, Figure 4) from left side wall
without disassembly harness connector.
17. Disconnect cabin ground cable located near fuse box
bracket.
18. Remove cassette bracket (2, Figure 4) and disconnect
antenna and speaker wire.
19. Remove electric box (4, Figure 4) without disassembly
harness connectors.
Figure 4
Cabin SP001737
Page 7
20. Remove air ducts (1, 2, 3 and 4, Figure 5) from cabin rear
panel.
21. Remove across bar (5, Figure 5) between left and right
side of cabin.
Figure 5
Figure 6
25. Remove four mounting nuts from four corners of cabin floor
(1, Figure 7).
26. Remove four M12 hex bolts (2, Figure 7) and two M10 hex
bolts (3, Figure 7).
Figure 7
Cabin SP001737
Page 8
27. Using a suitable lifting device, attach slings to four lift
points on top of cab (Figure 8).
NOTE: Cabin weights approximately 315 kg (700 lb).
28. Lift cab from 25 ~ 50 mm (1" ~ 2") above deck height.
Check that all electrical connections have been
disconnected and all other items unbolted.
29. Continue lifting with the assist crane to remove the cab
shell. Lower the shell to a prepared safe blocking support.
Figure 8
Cabin SP001737
Page 9
INSTALLATION
1. Using a suitable lifting device, attach slings to four lift
points on top of cab (Figure 9).
NOTE: Cabin weights approximately 315 kg (700 lb).
2. Lower cab into position on cab floor.
Figure 9
Figure 11
Cabin SP001737
Page 10
9. Install across bar (5, Figure 12) between left and right side
of cabin.
10. Install air ducts (1, 2, 3 and 4, Figure 12) from cabin rear
panel.
Figure 12
Figure 13
15. Install rear side covers (4 and 5, Figure 14), cassette cover
(3, Figure 14) and rear center cover (2, Figure 14), last
install rear mat (1, Figure 14).
Figure 14
Cabin SP001737
Page 11
16. Install front cover (4, Figure 15), and side covers (5 and 6,
Figure 15), when install cover (4, Figure 15) connect hour
meter connector.
17. Install seat (2, Figure 15).
NOTE: Be careful not to damage seat covering.
18. Install floor mat (1, Figure 15).
19. Connect negative (-) battery cable leading to frame from
battery.
Figure 15
Cabin SP001737
Page 12
SP001738
COUNTERWEIGHT SP001738
Counterweight
Edition 1
Counterweight SP001738
Page 1
MEMO
Counterweight SP001738
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 ............................................................ 9
Counterweight SP001738
Page 3
MEMO
Counterweight SP001738
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.
Counterweight SP001738
Page 5
GENERAL
DANGER
DOOSAN warns any user, that the removal of the
counterweight from the machine, front attachment or any
other part, may affect the stability of the machine. This
could cause unexpected movement, resulting in death or
serious injuries. DOOSAN is not liable for any misuse.
Never remove the counterweight or front attachment unless
the upper structure is in-line with the lower structure.
FG000371
Never rotate the upper structure once the counterweight or
Figure 1
front attachment has been removed.
WARNING
The weight of counterweight is given in the following table.
Use only rated and approved slings and hardware when
removal or installation lifts are being made. Lifting slings,
shackles and all other hardware must be rigged safely. An
assist crane that is rated above weight capacity is required.
Counterweight SP001738
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.
90 ~ 110
15 FG000325
Figure 1
15
FG000326
Figure 2
Counterweight SP001738
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
DO NOT OPERATE
when performing inspection
WARNING
or maintenance
190-00695A
FG014348
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.
2
FG014381
Figure 4
Counterweight SP001738
Page 8
INSTALLATION
1. Using suitable lifting device capable of handling a heavy
5
load, raise counterweight (1, Figure 5) into position just
above support frame (4) leaving counterweight suspended.
Verify that counterweight is level and even.
NOTE: Leave counterweight (1, Figure 5) suspended 1
3 mm (0.125") above support frame (4) until all
four mounting bolts (2) are started in
counterweight mounting holes.
2. Slide washers (3, Figure 5) onto bolts (2). Apply Loctite
#242 to mounting bolt threads.
4
3. Install four bolts (2, Figure 5) with washers (3) into
counterweight until washers contact support frame. Fully 3
lower counterweight onto support frame and finish
tightening bolts.
2
NOTE: Torque bolts (2, Figure 5) to values shown in FG014381
following table. Figure 5
Counterweight SP001738
Page 9
Counterweight SP001738
Page 10
SP002321
FUEL TANK SP002321
Fuel Tank
Edition 1
Fuel Tank
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 6
Parts List ......................................................................... 6
Specifications .................................................................. 7
Removal ............................................................... 8
Installation .......................................................... 12
Start-up Procedures ........................................... 15
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.
WARNING
Engine fuel is highly flammable and potentially explosive.
To prevent possible injury and/or damage to equipment,
extinguish or move to a safe distance all potential fire
hazards.
Parts List
12
11
16
15 1
2
21
20
19 52
51
18
17
18
17
14
9
13 3
8 4
10
6 13
5 7
23 8
22
FG018632
Figure 1
Specifications
Fuel tank capacity is 550 liters (145 U.S. gal).
FG013666
Figure 2
FG005210
Figure 3
WARNING
FG018633
Figure 5
FG003872
Figure 6
14. Tag and disconnect fuel supply line (21, Figure 7) and fuel
return line (19) from fuel tank (1) and carefully drain
remaining fuel from lines.
1
15. Remove clamp (9, Figure 7) holding fuel return line (19) to
tank (1).
19
21
FG005213
Figure 7
26
FG005214
Figure 8
17. Remove eight bolts (24, Figure 9) and cover (25) from fuel
tank. 24
25
F0005216
Figure 9
18. Remove eight bolts (25 and 26, Figure 10) and stay (27)
from fuel tank and frame.
Remove four bolts (28 and 29) and fuel tank cover (30)
from fuel tank. 28
26 36
27
Remove two bolts (31) and bracket (32) from tank.
35
Remove four bolts (33) and battery cover (34) from frame. 29
33
32
31
30
25
34
FG018634
Figure 10
FG005217
Figure 11
FG005217
Figure 14
6. Install four bolts (33, Figure 15) and battery cover (34) on
frame.
Install two bolts (31) and bracket (32) on fuel tank.
Install four bolts (28 and 29) and fuel tank cover (30) on 26 36
28
27
fuel tank.
35
Install eight bolts (25 and 26) and stay (27) on fuel tank 29
and frame. 33
32
31
30
25
34
FG018634
Figure 15
25
F0005216
Figure 16
26
FG005214
Figure 17
9. Connect as tagged, fuel supply line (21, Figure 18) and fuel
return line (19) to fuel tank (1).
10. Install clamp (9, Figure 18) to hold fuel return line (19) to 1
tank (1).
19
21
FG005213
Figure 18
FG003872
Figure 19
FG005211
Figure 20
Fuel Transfer
Pump (Opt)
Edition 1
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.
Theory of Operation
Fuel
4
1 2
6 5 3
Fuel Tank
IN OUT
2-2 2-1
FG003881
Figure 1
Reference Reference
Description Description
Number Number
1 Motor 3 Inlet Hose
2 Pump 4 Outlet Hose
2-1 Pump Cover 5 Check Valve
2-2 Rotor and Vane 6 Strainer Cap
Hose
Switch FG001143
Figure 2
III
V
FG001145
Figure 4 WITHOUT TOGGLE SWITCH
FG000670
Figure 5 WITHOUT TOGGLE SWITCH
FG003883
Figure 6
REPLACEMENT OF REAR
COVER
Brush assembly and a thermal limiter are installed in the rear
cover. If you find any damage, replace them with new ones.
Remove the switch cover and screw (M5 x L95) from the rear
cover.
Remove cover.
At reassembly of rear cover, widen the space of the brush and
insert it to the armature. Then fit the hole of screw in the Figure 7
housing.
Be careful when installing the screw. The cover screw may be
attracted by the motor magnet.
REPLACEMENT OF ARMATURE
Rear Cover
Pump Side
You can replace only the armature in case motor was damaged Side
by a short circuit.
Remove the switch cover and rear cover, than remove the
armature from the housing.
Remove the pump cover and remove the rotor and vane.
Insert a new armature into the housing. Commutator
Swing Bearing
Edition 1
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
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.
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.
Reference
Description
Number
1 Outer Ring
2 Inner Ring
3 Tapered Pin
4 Plug
5 Ball
6 Retainer
7 Seal A
Figure 2
Disassembly
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
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 11
Swing
Reduction Gear
Edition 1
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.
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.
Parts List
Figure 1
WARNING
or maintenance
190-00695A
FG014348
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.
Figure 3
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 motor’s 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
Figure 6
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
Figure 11
12. Reach into the gear case and remove the roller bearing.
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 18
Figure 20
Figure 21
2. Put the pin assembly No.1 on the pin hole correctly and
insert it with a press.
Figure 22
Figure 23
Figure 24
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
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
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
Figure 37
Figure 38
Figure 39
Figure 40
Figure 42
Figure 43
Figure 44
Figure 45
Figure 46
Figure 47
Figure 49
Figure 50
CAUTION
Care should be taken not to have drive shaft drop to
floor when it is pressed out of case.
Figure 51
Figure 53
Figure 54
5. Put the lock plate on it, engage the bolt applied Loctite
#262 (M16x40, torque: 2,700 kgf•cm), and complete the
procedure by tying it with wire as shown in the figure
below.
Figure 55
Figure 57
Figure 58
Figure 59
Figure 61
Figure 62
Figure 63
Figure 64
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
Figure 68
Figure 69
Figure 70
Figure 72
Figure 73
Figure 74
Figure 76
Figure 77
5. Insert plugs in the PT3/8 and PT1/8 taps of the drain port.
Figure 78
Figure 80
FG000936
Figure 81
FG000937
Figure 82
FG000938
Figure 83
FG001353
Figure 84
Figure 85
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
Figure 91
Figure 92
4. Insert the sun gear No.1 in the middle of the carrier No.1.
Figure 93
Figure 95
FG000950
Figure 96
FG000954
Figure 98
Figure 99
Figure 101
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
Figure 104
Figure 105
Figure 106
Figure 107
Figure 109
Figure 110
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
FG000973
Figure 114
Figure 115
Figure 116
Figure 117
5. Remove the plug, engage the level pipe sealed with Teflon
tape, and check the oil level.
Figure 118
Figure 119
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
FG000980
Figure 123
FG000981
Figure 124
Figure 125
Track
Assembly
Edition 1
Track Assembly
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 6
Track Tension ....................................................... 7
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 ....................................... 21
Lower Roller ....................................................... 22
Parts List ....................................................................... 22
Lower Roller Removal ................................................... 23
Lower Roller Disassembly ............................................. 23
Lower Roller Reassembly ............................................. 24
Lower Roller Installation ................................................ 25
Upper Roller ....................................................... 26
Parts List ....................................................................... 26
Upper Roller Removal ................................................... 27
Upper Roller Disassembly ............................................. 27
Upper Roller Reassembly ............................................. 29
Track Spring and Track Adjusting Cylinder ........ 30
Parts List ....................................................................... 30
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.
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
Distance "A"
Terrain Type
DX300LC / DX300LCA DX340LC / DX340LCA /DX350LC
320 - 340 mm 330 - 360 mm
Normal "B"
(12.60 - 13.39 in) (13.0 - 14.17 in)
320 mm 330 mm
Minimum "C"
(12.60 in) (13.0 in)
340 - 370 mm 360 - 410 mm
Muddy, Sandy or Snowy "D"
(13.39 - 14.57 in) (14.17 - 16.14 in)
WARNING
The track adjusting mechanism is under very high-
pressure. NEVER release pressure too suddenly. The
grease cylinder valve should never be backed off more than
1 complete turn from the fully tightened down position.
Bleed off pressure slowly and keep your body away from
the valve at all times.
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.
8 10
7
2
9 11
1
3
6
4 5 FG003910
Figure 4
3 4
2
6
1
FG000508
Figure 5
4 3
2
6
1
5
FG000509
Figure 6
4
3 5
1
2
FG000510
Figure 7
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
4
section for procedure.
3
3. Move machine until master link (1, Figure 8) is positioned
1
at approximately 10 o'clock from top position on front idle
roller. 2
FG003911
Figure 9
90 ~ 110
FG000345
Figure 10
FG000345
Figure 11
FG003912
Figure 12
FG003982
Figure 13
Parts List
1 9
2 8
7
4
5
6 7
8
9
3
FG003913
Figure 14
Reference Reference
Description Description
Number Number
1 Idler Assembly 6 Pin
2 Idler 7 Floating Seal
3 Bearing 8 O-ring
4 Shaft 9 Plug
5 Bushing
FG003914
Figure 15
2. Separate the pin (6, Figure 16) from the bearing (3).
3
FG003915
Figure 16
FG001482
Figure 17
4. Detach the floating seal (7, Figure 18) from the idler (2)
3
and bearing (3).
7
2
3 FG001483
Figure 18
FG001484
Figure 19
6. Remove bushing (5, Figure 20) with the press and special
tool (10, ST-1909).
10
5 2
FG001485
Figure 20
8
FG001486
Figure 21
4. Install floating seal (7, Figure 22) inside the idler (2) and
3
bearing (3).
NOTE: Apply clean engine oil to the joint side of the 7
floating seal. Apply grease to the floating seal 2
O-ring.
3 FG001483
Figure 22
FG001488
Figure 23
Parts List
2 8
5 6
7
7
8
2 FG000483
Figure 24
FG001489
Figure 26
FG001490
Figure 27
2
7 6 FG001493
Figure 28
FG001491
Figure 29
3. Align collar (2, Figure 30) and axle (3) pin holes and pin (5)
the collar. 3 7 2
FG001492
Figure 30
4. Insert floating seals (6, Figure 31) into the roller (1) and
1
collar (2).
6
NOTE: Apply clean engine oil to the joint side of the
2
floating seal. Apply grease to the floating seal
O-ring.
5. Slide the axle inside the roller.
2
7 6 FG001493
Figure 31
6. Install the collar (2, Figure 32), O-ring (7), and pin (5) on
the remaining side. 5
2 FG001487
Figure 32
FG000345
Figure 33
Parts List
3
8
6
Track Frame
4
1
5
11
14
12
7
10
15
13
FG001141
Figure 34
FG000524
Figure 35
9
FG001494
Figure 36
13
FG001495
Figure 37
3. Separate the roller (1, Figure 38) from the axle (2).
2
1
FG001497
Figure 38
4. Separate the floating seal (6, Figure 39) from the roller.
1
5. Separate the O-ring (8) and thrust ring (3) from the axle.
6
8
3
FG003916
Figure 39
FG001502
Figure 40
FG003917
Figure 41
2. Insert floating seal (6, Figure 42) into the roller (1) and
1
bushing.
NOTE: Apply clean engine oil to the joint side of the
floating seal. Apply grease to the floating seal 2
O-ring.
6
3. Install the axle (2), O-ring (8) and thrust ring (3). 8
3
FG003916
Figure 42
9 FG001501
Figure 43
Parts List
9 11
8
7 3
10
1
12
13
14
2
FG003918
Figure 44
Reference Reference
Description Description
Number Number
1 Cylinder 8 Lock Plate
2 Piston Rod 9 Bolt
3 Yoke 10 Spring Pin
4 Spacer 11 Spring Washer
5 Shaft 12 Packing
6 Spring 13 Backup Ring
7 Lock Nut 14 Dust Seal
1Drive Coupling
(Main Pump)
Edition 1
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.
FG000656
Figure 1
FG000657
Figure 2
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
Hydraulic System
Troubleshooting,
Testing and
Adjustment
Edition 1
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.
7
6
5 7 6 5
6 7
13 17
12
16
6
7
5
9
20
15
4
3 5
20 7
6 10
5 11
7 6
14
18
19
1
8
5 TRAVEL MOTOR
2 7
6 10
5 11
7
6
18
19
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.
Boom Up Circuit
When you pull the boom control lever backward, the right side
pilot valve generates secondary boom up pilot pressure that is BOOM
CYLINDER
transmitted to the BOOM1 and BOOM2 spools of the control
valve simultaneously. When secondary pilot pressure reaches 7
- 9 kg/cm2 (100 - 130 psi), boom control valve spools open and BMD BM1 PILOT VALVE BM2
PUMP(L) PUMP(R)
ARS1560L
Figure 2
PUMP(L)
ARS1570L
Figure 3
Overload relief valves set at 360 kg/cm2 (5,112 psi) have been
installed at the AM 1 and AMD 1 ports on the right side of the
control valve to protect the circuit and system components from
possible damage caused by shocks and/or overload pressure.
Additional protection - to prevent cavitation of the cylinder - is
provided by a makeup valve and reservoir return circuit, which
ensures that the volume of oil going to the cylinder will not
exceed the volume of oil coming out.
to the AM1 and AM2 spools of the control valve simultaneously. REGENERATION VALVE
When secondary pilot pressure reaches 7 - 9 kg/cm2 (100 - 130 AM2 PILOT VALVE AMD1 AM1
psi), the arm control valve spools AM1 and AM2 open. Output
flow from both halves of the pump assembly is directed to the PL TL PR
arm cylinder.
When working in the arm crowd mode, under certain conditions, CONTROL
VALVE(L)
CONTROL
VALVE(R)
oil in the arm cylinder could suddenly be forced out by the weight
of the arm and bucket. Insufficient oil flow to the cylinder could PUMP(L) PUMP(R)
lead to cavitation in the cylinder and/or surging or irregular ARS1580L
movement. This is prevented by a regeneration valve attached
Figure 4
to the control valve which maintains the balance between oil
flowing into the cylinder and oil flowing out.
CONTROL CONTROL
VALVE(L) VALVE(R)
PUMP(L) PUMP(R)
ARS1590L
Figure 5
TL PL
CONTROL
VALVE(L)
PUMP(L)
ARS1600L
Figure 6
TL PL
CONTROL
VALVE(L)
PUMP(L)
ARS1770L
Figure 7
TL PR
CONTROL
VALVE(R)
PUMP(R) ARS1620L
Figure 8
pump is directed through the PR and SWL ports of the control SWD SW PILOT VALVE
valve to the swing motor.
TL PR
CONTROL
VALVE(R)
PUMP(R)
ARS1610L
Figure 9
PL TL PR
CONTROL CONTROL
VALVE(L) VALVE(R)
PUMP(L) PUMP(R)
ARS1630L
Figure 10
PL TL PR
CONTROL CONTROL
VALVE(L) VALVE(R)
PUMP(L) PUMP(R)
ARS1640L
Figure 11
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 1,850 rpm with no load.
• at 1,850 rpm stall load.
If engine rpm drops excessively with a load or fails to surpass
rated speed (1,750 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.
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.
WARNING
This procedure should be done with two people. To reduce
the chance of accident or unintended start-up, one person
should remain at the operator's control stand while checks
and adjustments are made.
IMPORTANT
Top off the hydraulic fluid reservoir if there is any
measurable loss of hydraulic oil during test gauge
and adapter fitting installation.
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.
WARNING
This procedure should be done with two people. To reduce
the chance of accident or unintended start-up, one person
should remain at the operator's control stand while checks
and adjustments are made.
IMPORTANT
Pressure adjustments and checks cannot be made if pilot
pressure is outside the specified range. Refer to the pilot
pump adjustment procedure if required, then proceed with
any necessary adjustments to main relief pressure settings.
WARNING
This procedure should be done with two people. To reduce
the chance of accident or unintended start-up, one person
should remain at the operator's control stand while checks
and adjustments are made.
IMPORTANT
Before starting this procedure or going onto make any
changes of adjustment settings:
• Verify engine output to the rated speed –
1,800 ±50 rpm.
• Permanently mark setscrew positions at the
current regulator control setting.
2
2
1
1 ASS0320L
Figure 12
Figure 14
The adjusting screw (1, Figure 12) affects the delivery rate (Q) of
the pump. Tightening the adjusting screw decreases the
maximum cut flow (as shown in Figure 15) while backing out the
screw increases cut flow delivery rate.
Balance both pumps for equal output.
Q
P
HDA3008L
Figure 15
Precautions/Initial Checks
1. Stop work. Release all weight or any type of load safely
before proceeding. Avoid risking injury or adding to damage.
2. Shut down engine and disengage control functions until
initial tests are ready to be made.
WARNING
Prevent possible injury and/or loss of operating
control. Stop work and park the excavator at the first
indication of:
1. Equipment breakdown.
2. Inadequate control response.
3. Erratic performance.
Stop the machine, put the boom and arm in the inoperative
(overnight park) position and begin by making the fastest,
simplest checks first:
• Check oil level.
• Check for overheating, oil leaks, external oil cooler
clogging or broken fan belt. Consult service record for
prior repair/service work.
• Drain some tank oil into a clean, clear container. Look
for metal shavings/grit, cloudiness/water or foam/air
bubbles in the oil.
NOTE: Dispose of drained fluids according to
local regulations.
• Check for wobble through the engine/pump flex
coupling. Run engine with the pump input hydraulic
power control nut turned to the lowest power to check
the engine.
• Investigate unusual operating noises or vibration.
Check for loose bolts, connections.
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.
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.
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.
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.
Accumulator
Edition 1
Accumulator SP000028
Page 1
MEMO
Accumulator SP000028
Page 2
Table of Contents
Accumulator
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 6
Specifications .................................................................. 8
Accumulator SP000028
Page 3
MEMO
Accumulator SP000028
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.
Accumulator SP000028
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
Accumulator SP000028
Page 6
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
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.
Accumulator SP000028
Page 7
Specifications
Model Serial Number System Charge Pressure Volume
10 kg/cm2 320 cc
DX140LC S/N 5001 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX180LC S/N 5001 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX225LC S/N 5001 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX255LC S/N 5001 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX300LC S/N 7440 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX300LCA S/N 5001 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX340LC S/N 5980 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX340LCA S/N 5001 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX350LC S/N 5980 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX420LC S/N 5327 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX480LC S/N 5221 and Up Pilot
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX520LC S/N 5117 and Up Pilot
(140 psi) (19.53 in3)
Accumulator SP000028
Page 8
SP000181
CENTER JOINT (SWIVEL)SP000181
1Center Joint
(Swivel)
Edition 1
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.
Figure 1
Reference Reference
Description Description
Number Number
1 Body 6 Wear Ring
2 Shaft 7 Sliper Seal
3 Cover 8 O-ring(1AP 120)
4 Spacer 9 O-ring(1BP 100)
5 Shim 10 O-ring(1BG 120)
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). COVER BOLT (M12)
FG018653
Figure 2
CAUTION
Care should be taken not to make a flaw on the surface
of the shaft when disassembling the body of the shaft
assembly.
FG018655
Figure 4
CAUTION
Care should be taken not to damage the inside of the
body because it is likely to be damaged when
disassembling the sliper seal. It may be disassembled
more easily with a driver whose tip is bent as shown in
the figure below. FG018656
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.
PF3/4 PLUG
PF3/8 PLUG
FG018657
Figure 6
CAUTION
The inside of the body should be air washed and rust-
proof treated after washing it, as its material is subject
to rust.
CAUTION
Apply active oil to every functional (moving) part before
assembly to reduce any assembly friction as much as
possible.
PF3/4 PLUG
PF3/8 PLUG
FG018657
Figure 7
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.
1BG120 O-RING
CAUTION FG018656
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.
FG018659
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
FG018660
Figure 10
CAUTION
After the completion of the assembly, a start-up and a FG018661
rotation torque tests should be performed for the Figure 11
sliper seal to seat in its place properly.
Cylinders
Edition 1
Cylinders SP000030
Page 1
MEMO
Cylinders SP000030
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
Cylinders SP000030
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.
Cylinders SP000030
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
F1 = P x πD2
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 π(D2)
4
Q2 = S x π(D2-R 2)
4
Q1 > Q 2 FG001459
Figure 3
Cylinders SP000030
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
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
Cylinders SP000030
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 øA øB 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)
DX300LC / 147.0 mm 107.0 mm 12.0 mm 5.0 mm
ARM S/ARM
DX300LCA (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)
DX340LC /
147.0 mm 107.0 mm 12.0 mm 5.0 mm
DX340LCA / ARM OPT ARM
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
DX350LC
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)
Cylinders SP000030
Page 11
Piston Jig
( )
15
2-∅"B"
2)
F/
∅8 Through Hole
R(
"
"D
∅
"A"
∅"
C"
35
R(R15~20)
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) øB øC øD 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)
DX300LC / 120.0 mm 13.0 mm 85.0 mm 150.0 mm
ARM S/ARM
DX300LCA (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)
DX340LC /
130.0 mm 13.0 mm 93.0 mm 165.0 mm
DX340LCA / ARM OPT ARM
(5.12 in) (0.513 in) (3.66 in) (6.50 in)
DX350LC
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)
Cylinders SP000030
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 øA-0.05 øB ( ±0.1) E F+0.05 Part
-0.15 0 (CYLINDER)
90.0 mm 105.0 mm 40.0 mm 7.0 mm
BOOM
(3.54 in) (4.13 in) (1.58 in) (0.28 in)
DX300LC / 90.0 mm 105.0 mm 40.0 mm 6.5 mm
ARM S/ARM
DX300LCA (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)
DX340LC /
100.0 mm 115.0 mm 45.0 mm 7.5 mm
DX340LCA / ARM OPT ARM
(3.94 in) (4.53 in) (1.77 in) (0.30 in)
DX350LC
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)
Cylinders SP000030
Page 15
Dust Wiper Jig
. 5
C1
3-
R0.2
1
DIA. (B+40)
DIA. (A-20)
DIA. A
DIA. B
15 C D
ARS4760L
Figure 9
Material: SM45C which is done thermal refining <QT> Hrc 22 - 28
Undefined Chamfer C/R = 0.5 Max.
Cylinders SP000030
Page 16
MODEL CYLINDER øA-0.2
-0.3 øB -0.2
-0.3 C 0-0.1 D MODEL (CYLINDER)
95.0 mm 109.0 mm 6.0 mm 7.0 mm
BOOM
(3.74 in) (4.29 in) (0.24 in) (2.28 in)
DX300LC / 105.0 mm 121.0 mm 6.0 mm 7.0 mm
ARM S/ARM
DX300LCA (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)
DX340LC /
115.0 mm 131.0 mm 6.0 mm 7.0 mm
DX340LCA / ARM OPT ARM
(4.53 in) (5.16 in) (0.24 in) (2.28 in)
DX350LC
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)
Cylinders SP000030
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 øA+0.2
+0.1 B+0.2
+0.1 MODEL (CYLINDER)
140.0 mm 28.5 mm
BOOM
(5.51 in) (1.12 in)
DX300LC / 150.0 mm 28.5 mm
ARM S/ARM
DX300LCA (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)
DX340LC /
170.0 mm 34.5 mm
DX340LCA / ARM OPT ARM
(6.69 in) (1.36 in)
DX350LC
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)
Cylinders SP000030
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 øA+0.2
+0.1 MODEL (CYLINDER)
140.0 mm
BOOM
(5.51 in)
DX300LC / 150.0 mm
ARM S/ARM
DX300LCA (5.91 in)
140.0 mm
BUCKET S/BUCKET
(5.51 in)
150.0 mm
BOOM OPT BOOM
(5.91 in)
DX340LC /
170.0 mm
DX340LCA / ARM OPT ARM
(6.69 in)
DX350LC
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)
Cylinders SP000030
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.
Figure 12
Figure 13
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
Figure 16
Figure 17
Figure 18
Cylinders SP000030
Page 23
8. Remove set screw using socket wrench.
HAOF340L
Figure 19
Figure 20
Figure 21
11. Use a plastic hammer to evenly pull off rod cover (9) from
end of piston rod. Be careful not to damage rod bushing (6)
and dust wiper, U-packing and other seals.
Figure 22
Cylinders SP000030
Page 24
12. Use a dull, rounded tip tool to pry off O-ring (11) and
backup ring (12).
HAOF37OL
Figure 23
Figure 24
14. Remove O-ring (20) and backup ring (21) from cylinder
head.
HAOF38OS
Figure 25
HAOF39OL
Figure 26
Cylinders SP000030
Page 25
16. Disassemble retaining ring (3) and dust wiper (2). Separate
retaining ring (8) and rod bushing (6).
Figure 27
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.
Figure 29
Figure 30
Cylinders SP000030
Page 27
3. Prelubricate O-rings and seals before reassembly (Figure
31).
Figure 31
Figure 32
Figure 33
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
Figure 37
Figure 38
Cylinders SP000030
Page 29
Cylinders SP000030
Page 30
SP000261
SWING MOTOR SP000261
Swing Motor
Edition 1
Swing Motor
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 6
Theory of Operation ........................................................ 6
Makeup Check Valve ...................................................... 9
Operation of Time Delay Valve ....................................... 9
Operation of Swing Reactionless Valve .......................... 9
Parts List ....................................................................... 10
Specifications ................................................................ 12
Torques ......................................................................... 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)......................................................... 22
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
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.
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 1
Y Cylinder A Piston
W1 W1
R1 N1
f1 P
F1
O
Drive Shaft
Y
High pressure Low pressure
FG005170
Figure 2
Figure 3
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 8
Torques
No. Tools Measures B Torque
1700 - 1900 kg•cm
30 Relief Valve M33 36 mm
(123 - 137 ft lb)
2,090 kg•cm
33 Plug PT 1/4 6 mm
(150 ft lb)
691 kg•cm
32 Wrench Bolt PF 1/4 5 mm
(50 ft lb)
2,090 kg•cm
24 Wrench Bolt M14 12 mm
(150 ft lb)
2,090 kg•cm
25 Wrench Bolt M14 12 mm
(150 ft lb)
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 Ring (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
General Precautions
1. Observe any abnormalities and any possible causes that
have noting to do with the motor before starting work.
2. Make sure that no foreign substance is involved when
disassembling the machine, which is the most frequent
cause of its wear.
3. Treat carefully and pay attention to avoid any damage
against it that is machined precisely.
Troubleshooting
Problem Possible Cause Remedy
Abnormal operation of driving devices.
Motor pressure does not Oil bypassing in relief valve (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.
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.
FG000682
Figure 10
Figure 11
Figure 12
FG000687
Figure 13
FG000688
Figure 14
FG000689
Figure 15
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
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
FG000699
Figure 23
FG000701
Figure 25
Figure 26
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
FG000709
Figure 30
FG000710
Figure 31
FG000711
Figure 32
FG000712
Figure 33
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.
FG000715
Figure 35
FG000716
Figure 36
FG000717
Figure 37
FG000719
Figure 38
Figure 39
FG000717
Figure 40
Figure 41
5. Secure shaft with snap ring (4) using snap ring pliers.
FG000722
Figure 42
Figure 43
FG000724
Figure 44
Figure 45
FG000726
Figure 46
FG000727
Figure 47
FG000728
Figure 48
FG000729
Figure 49
FG000759
Figure 50
FG000730
Figure 51
FG000731
Figure 52
FG000696
Figure 53
FG000732
Figure 54
Figure 55
FG000704
Figure 57
FG000687
Figure 58
FG000736
Figure 59
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
FG000745
Figure 65
FG000711
Figure 66
FG000710
Figure 67
FG000746
Figure 68
FG000706
Figure 69
Figure 70
6. Coat valve plate (20) with grease and attach it to rear cover
(23).
FG000701
Figure 71
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
FG000754
Figure 76
FG005165
Figure 77
FG005166
Figure 78
FG005169
Figure 79
Figure 80
Travel Motor
Edition 1
Travel Motor
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 6
Theory of Operation ........................................................ 7
Parts List ....................................................................... 16
Specifications ................................................................ 19
Special Tools and Materials ............................... 20
Hydraulic Motor Part...................................................... 20
Reduction Gear Part...................................................... 21
Tightening Torque Chart ............................................... 22
Troubleshooting, Testing and Adjustment .......... 23
General Precautions...................................................... 23
Troubleshooting............................................................. 23
Disassembly ....................................................... 27
General Caution Matters ............................................... 27
Reduction Gear Part...................................................... 27
Hydraulic Motor Part...................................................... 33
Cleaning and Inspection (Wear Limits and
Tolerances)......................................................... 38
Maintenance Standard .................................................. 38
Reassembly ........................................................ 41
General Caution Matters ............................................... 41
Hydraulic Motor Part...................................................... 41
Checkup after Assembly ............................................... 57
Performance Test.......................................................... 57
Installation .......................................................... 59
Check ............................................................................ 59
Piping ............................................................................ 59
Gear Oil ......................................................................... 59
Oil Filling........................................................................ 60
General Caution Matters ............................................... 60
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.
qmax (q1)
qmin (q2)
Counter balance valve part Relief valve part Swash tilting part Brake part Rotary part 3rd 2nd 1st
Hydraulic Motor
1. Generation of rotational force.
Y Cylinder A Piston
W1 W1
R1 N1
f1 P
F1
O
Drive Shaft
Y
High pressure Low pressure
ARS4530L
Figure 2
A Port B Port
Poppet A
Chamber A
Seat A
AUS0550L
Figure 3
AUS0570L
Figure 4
CAUTION
If hydraulic motor does not rotate even after brake is
released, pump or other part is suspected of malfunction
and thus it is difficult to generate working pressure. At this
time, if you haul system with hydraulic motor not
disassembled, connect a short hose, etc. between pressure
measurement ports Am and Bm to maintain a low hauling
speed.
i = (-----------------------------------------------------------------------------------------------
Zs1 + Zr1 ) ( Zs2 + Zr2 ) ( Zs3 + Zr3 ) – 1
Zs1 × Zs2 × Zs3
Hydraulic Motor
Figure 9
Figure 10
Specifications
Travel Motor Specification
195 cc/rev
Motor displacement
(11.90 in3/rev)
Reduction ratio 63.84
General Precautions
1. If a defect is identified, check to see if same problem has
ever occurred before.
2. When taking corrective action, handle each part carefully.
Use care not to cause possible damage or rust to/on
sliding parts, gear surfaces, bearings, and pins.
Troubleshooting
Refer to following tables.
Page 24
Check Item Cause Remedies
Travel Motor
A. Travel motor does not rotate
Delivery pressure rises Yes
Overloading Eliminate the reason
of overload
No
No
Relase of brake Brake ON Refer to “B”
Yes
Hydraulic motor failed Replace Motor
Matal power detected
from the drain. No Replace the
Gear damaged
reduction gear
No Replace hydraulic
Hydraulic motor damaged motor
AUS0640L
SP000253
Troubleshooting
Check Item Cause Remedies
B. Brake is not
Travel Motor
released No Replace the
Brake piston moves lightly Brake piston seized
brake piston casing
Yes
Yes
Refer to “A” #1
Yes
Yes
Yes
Damage to spring Replace spring
Yes
AUS0640L
Page 25
SP000253
Troubleshooting
Page 26
Check Item Cause Remedies
Travel Motor
D. Oil leakage
Tighten to the
Loose bolt
specified torque
Oil leaks out assembled surface
O-ring damaged or poorly assembled Replace and
reassemble O-ring
Poor roughness and flatness of Replace any
assembled surface unstable part
AUS0660L
SP000253
DISASSEMBLY
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 19
Figure 20
Figure 21
11. Remove snap ring (037), and No. 3 pin (017) from shaft
casing (272) on motor side.
Figure 22
Figure 23
Figure 24
13. Remove set screw (054) from nut ring (047). Remove nut
ring (047) from shaft casing (272).
Figure 25
Figure 26
Figure 27
Figure 28
16. Remove floating seal (034) from shaft casing (272). Do not
damage it.
NOTE: Be careful not to damage O-ring surface and
seat.
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
Figure 41
Figure 42
Figure 43
Figure 44
Figure 45
Figure 46
Figure 47
Figure 48
Figure 49
Maintenance Standard
Change parts with standard of following table. If parts have
damages of external appearance, change without following
table.
Recommend
Standard
Parts name and inspection item ed value of Remedy
dimension
replacement
Clearance (D-d) between piston and
0.52 mm 0.077 mm
cylinder bore
Replace
Clearance between piston and shoe (δ) 0.1 mm 0.3 mm
Shoe thickness 5.5 mm 5.3 mm
Height (H-h) of spherical bushing and
23.8 mm 23.3 mm Replace with set
retainer place assembly
Free length of cylinder spring 40.9 mm 40.3 mm Replace
Drive spline 43.91 mm 43.31 mm Even if one each of
Over pin diameter (4.5) recommended value of
of drive shaft Cylinder spline 49.06 mm 48.46 mm replacement is not
reached, replace.
Over pin diameter (4.5) of spline inside of
35.25 mm 35.75 mm
cylinder and spherical bushing
Thickness of separate plate 1.5 mm 1.3 m
Thickness of friction plate 3.9 mm 3.7 mm
Free length of brake spring 42.4 mm 41.4 mm Replace
Base tangent length of cylinder outside
50.02 mm 49.42 mm
(7 each)
Over pin diameter (4.5) of inside gear of
152.97 mm 153.57 mm
friction plate
Swash plate/
0.4-Z 3-Z Lap each
Roughness of sliding shoe
surface Cylinder block/
0.4-Z 3-Z Joint lapping
Valve plate
If there are flaking on
Roller bearing/needle bearing
sliding surface, replace.
When disassembling,
O-ring/Oil seal
replace as a rule.
If there are crushing
Kinds of bolt
parts, replace.
Figure 50
2. Thickness of shoe: t
Figure 51
Figure 52
Figure 53
Figure 54
Figure 55
Figure 56
Figure 57
Figure 58
Figure 59
Figure 60
Figure 61
Figure 62
Figure 63
Figure 64
Figure 65
Figure 66
Figure 67
Figure 68
Figure 69
Figure 70
Figure 71
Figure 73
Figure 74
Figure 75
Figure 76
Figure 77
Figure 78
Figure 79
Figure 80
Figure 81
15. Loosen bolts for releasing brake and then assemble plug
(564).
NOTE: Tightening torque for plug (564): 220 kgf•cm.
Figure 82
Figure 83
Figure 84
Figure 85
Figure 86
Figure 87
6. With bearing inserted, insert nut ring (047) with shim (035)
into shaft casing. Use assembly jig to tighten it to specified
torque.
NOTE: Tighten nut ring to shaft casing to maximum
torque (5000 kgf•cm) and then disassemble it
and reassemble it again to specified torque.
Specified torque: 3300 kgf•cm
Figure 88
Figure 89
Figure 90
Figure 91
Figure 92
10. Insert No. 3 pin (017) into shaft casing. Install snap ring
(037).
Figure 93
Figure 94
Figure 95
12. Install socket bolts (029) to secure housing (002) and ring
gear (001) together.
NOTE: Tightening torque is 3000 kgf•cm
NOTE: Use LOCTITE: #636 on bolt threads.
Figure 96
Figure 97
Figure 98
Figure 99
Figure 100
Figure 101
Figure 102
Figure 103
Figure 104
Figure 105
Figure 106
Figure 107
Figure 108
Figure 109
Figure 110
Figure 111
22. Install new O-ring (081) on ring gear (001). Place side
cover (004) onto ring gear, then tighten socket bolts (030)
to specified torque.
NOTE: The specified torque is 350 kgf•cm. When
reassembling, use a new O-ring.
Figure 112
Figure 113
Performance Test
Be sure to add a sufficient amount of working oil into motor case
before carrying out performance test. Be sure to carry out
performance test below after finishing servicing of TM motor.
RPM: 20 rpm
Check
Check each item before assembling and take proper action if
there is anything to be corrected.
Piping
1. Turning direction is indicated in outside dimension
drawing. Be careful of piping direction.
• Turning direction
Gear Oil
Kind of Oil
Be sure to use gear oil of GL-4 grade or higher by API
classification equivalent to SAE #90. Never mix with other kind
of oil.
Oil Filling
Position check port (PF 1/2) vertically (See external dimension
diagram.) and add oil until oil it is present at level port.
(approximately 5.5 liter)
Main Pump
Edition 1
Main Pump
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
Sectional 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 ............................. 17
Control Module ................................................... 20
Control Module LR ........................................................ 20
Control Module H .......................................................... 21
Removing the Controller ..................................... 22
Valve Plate with Valves ...................................... 24
Remove the Rotary Groups ................................ 25
Remove the Intermediate Wheel ........................ 28
Remove Auxiliary Drive ...................................... 30
Inspection ........................................................... 33
Re-fitting the Rotary Group................................. 38
Pump Assembly.................................................. 40
Hydraulic Component - Measurement "D".......... 43
Measuring Device - Hydraulic Component 452 269 ...... 43
Mounting Position .......................................................... 44
Measuring Procedure .................................................... 46
Installation of Control Housing............................ 47
Assembly of Intermediate Wheel ........................ 50
Installation of Gear Pump ................................... 51
Installation of Cover / Auxiliary Drive .................. 52
Assembly Guidelines for Tightening Torques ..... 53
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.
A8VO200LA1KH1/63
ASS0010L
Figure 1
ASS1140L
Figure 3
ASS0030L
Figure 4
ASS0040L
Figure 5
ASS0050L
Figure 6
ASS0060L
Figure 7
ASS0070L
Figure 8
ASS0080L
Figure 9
ASS0090L
Figure 10
ASS0100L
Figure 11
ASS0110L
Figure 12
ASS0120L
Figure 13
ASS0130L
Figure 14
ASS0140L
Figure 15
ASS0150L
Figure 16
ASS0160L
Figure 17
ASS0170L
Figure 18
ASS0180L
Figure 19
ASS0190L
Figure 20
ASS0200L
Figure 21
ASS0210L
Figure 22
ASS0220L
Figure 23
ASS0230L
Figure 24
ASS0240L
Figure 25
Figure 26 ASS0250L
1 ASS0260L
Figure 27
ASS0270L
Figure 28
ASS0280L
Figure 29
Figure 30 ASS0290L
Figure 31 ASS0300L
Figure 32 ASS0310L
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)
X
ASS0330L
Figure 34
Control Module LR
ASS0340L
Figure 35
ASS0350L
Figure 36
ASS0360L
Figure 37
ASS0370L
Figure 38
(1)
ASS0380L
Figure 39
1. Remove cover.
NOTE: Do not change the setting of adjustment screw
(1, Figure 39).
ASS0390L
Figure 40
ASS0400L
Figure 41
ASS0410L
Figure 42
ASS0420L
Figure 43
ASS0430L
Figure 44
ASS0440L
Figure 45
ASS0450L
Figure 46
ASS0460L
Figure 47
ASS0470L
Figure 48
ASS0480L
Figure 49
2
Rotary Group 2
Rotary Group 1
ASS0490L
Figure 50
2
1
ASS0500L
Figure 51
A Adjustment of measurement D
*
1. Holding device
Drive shaft 2
Drive shaft 1
1. Holding device
*
A
Adjustment of measurement D
ASS0520L
Figure 53
2. Install sleeve. I
NOTE: Press out bolt with a hydraulic press.
ASS0530L
Figure 54
ASS0540L
Figure 55
ASS0550L
Figure 56
ASS0560L
Figure 57
ASS0570L
Figure 58
ASS0580L
Figure 59
ASS0590L
Figure 60
ASS0600L
Figure 61
ASS0610L
Figure 62
ASS0620L
Figure 63
ASS0630L
Figure 64
ASS0640L
Figure 65
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
ASS0680L
Figure 69
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
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
2
1
1
ASS0760L
Figure 77
*
*
*
*
ASS0770L
Figure 78
ASS0780L
Figure 79
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
ASS0810L
Figure 82
ASS0820L
Figure 83
ASS0830L
Figure 84
ASS0840L
Figure 85
ASS0850L
Figure 86
ASS0860L
Figure 87
Stop
D
A
A
D
Stop
ASS0870L
Figure 88
Assembly Guideline
Retaining force:
After rotary group has been installed into housing, it has to be
pressed in until the end stop is reached. Allow housing to cool
down from its assembly temperature (approximately 80° C) to
room temperature.
ASS0880L
Figure 89
ASS0900L
Figure 90
ASS0890L
Figure 91
ASS0910L
Figure 92
ASS0920L
Figure 93
Figure 94
Figure 95
ASS0950L
Figure 96
ASS0960L
Figure 97
Figure 98
Figure 99
ASS0990L
Figure 100
* ASS1000L
Figure 101
ASS1010L
Figure 102
ASS1020L
Figure 103
Pressure Pressure
side side
Suction side
ASS1030L
Figure 104
ASS1040L
Figure 105
ASS1050L
Figure 106
2
ASS1060L
Figure 107
ASS1070L
Figure 108
ASS1080L
Figure 109
ASS1090L
Figure 110
ASS1100L
Figure 111
ASS1110L
Figure 112
G
Seal
ASS1120L
Figure 113
Gear Pump
Edition 1
Gear Pump
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
Disassembling Single Gear Pump (Opt)............... 6
Reassembling Single Gear Pump (Opt) ............... 9
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.
Figure 1
Figure 2
3. Coat the sharp edges of the drive shaft with adhesive tape
and smear a clean grease on the shaft end extension to
avoid any damaging lip of the shaft seal when removing
the mounting flange.
Figure 3
Figure 4
Figure 5
Figure 6
6. Remove the shaft seal taking care not to give any damage
on the surface of shaft hole.(only when it is needed to
replace shaft seal)
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
11. Check that the pump rotate freely when the drive shaft is
turned by hand. If not a pressure plate seal may be
pinched.
Figure 20
Main Control
Valve
Edition 1
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.
Theory of Operation
Neutral Passage
The oil supplied from the port (P1) enters into the tank passage
(Ta) through the orifice (Lc 1) of negative relief from the neutral
passage (L1) and returns to ports (T1, T2 and T3).
The oil supplied from the port (P2) passes the tank passage (Ta)
through orifice (Rc 1) of negative relief from the neutral passage
(R1) and returns to port (T1, T2 and T3).
The pressure of chambers (L2 and R2) flowing over the negative
relief, flows into pump from ports (ps1 and ps2), to control the
volume of pump P1 and P2.
In addition, when excessive oil flows excessive into the neutral
passage, the negative relief operates to prevent the abnormally
high-pressure on ports (ps1 and ps2).
ARM 1 ARM 2
[Section 5] [Section 9]
BOOM 2 BOOM 1
[Section 4] [Section 8]
SWING BUCKET
[Section 3] [Section 7]
TRAVEL
OPTION [Section 6]
[Section 2]
TRAVEL STRAIGHT
[Section 1] TRAVEL
[Section ST]
P1 Side P2 Side
FG001295
Figure 1
BOOM 2
[Section 4]
SWING
[Section 3]
OPTION
[Section 2] Z
TRAVEL
[Section 1]
SECTION "L-L"
"Z" Detail FG001296
Figure 2
ARM 2
[Section 9]
BOOM 1
[Section 8]
6
BUCKET
[Section 7]
TRAVEL
[Section 6]
STRAIGHT
TRAVEL
[Section ST]
Ta
3
2
Ta
SECTION "R-R"
FG001297
Figure 3
OPTION
[Section 2]
TRAVEL
[Section 6]
TRAVEL
[Section 1]
STRAIGHT
TRAVEL
[Section ST]
FG001298
Figure 4
OPTION
[Section 2]
Neutral Position
Switched Position
TRAVEL
[Section 6]
Neutral Position
TRAVEL
[Section 1]
Switched Position
STRAIGHT
TRAVEL
[Section ST]
FG001299
Figure 5
SWING
[Section 3]
Neutral Position
BUCKET
[Section 7]
FG001300
Figure 6
Switched Position
SWING
[Section 3]
Neutral Position
BUCKET
[Section 7]
FG001301
Figure 7
BOOM 2
[Section 4]
BOOM 1
[Section 8]
FG001302
Figure 8
BOOM 2
[Section 4]
BOOM 1
[Section 8]
FG001303
Figure 9
BOOM 2
[Section 4]
BOOM 1
[Section 8]
FG001304
Figure 10
ARM1
[Section 5]
ARM 2
[Section 9]
FG001305
Figure 11
ARM1
[Section 5]
ARM 2
[Section 9]
FG001306
Figure 12
ARM1
[Section 5]
i a b c
g h d e f
ARM1
[Section 5]
ARM2
[Section 9
FG001308
Figure 14
Normal Position
DR2 Passage
FG001309
Figure 15
FG000631
Figure 16
TRAVEL
[Section 1]
2
1 STRAIGHT
TRAVEL
[Section ST]
FG001310
Figure 17
SWING
[Section 3]
Neutral Position
BUCKET
[Section 7]
FG001311
Figure 18
SWING
[Section 3]
Neutral Position
BUCKET
[Section 7]
FG001312
Figure 19
S1 d c S2
DR
To Main Spool
FG001313
Figure 20
2. Oil passage cut off condition of the port (A5) and the spring
chamber. 1 a 4 b 3 2
A. If port pc1 is pressurized, piston (2) is moved and A5
spool (3) reacts.
B. Spool (3) activates poppet (4). pc1
C D
FG000639
Figure 23
"HP"
F
FG000640
Figure 24
"HP"
C D
FG000641
Figure 25
4. Pressure up operation
I
If pressure is applied to pilot port "PH," piston (H) moves to "LP"
the pressure setting position of plug (I) so that the force of
spring increases, thus increasing pressure in the neutral oil
passage (HP).
"HP"
H
FG000642
Figure 26
"HP"
FG000645
Figure 28
"HP"
FG000646
Figure 29
"HP"
F
FG000647
Figure 30
FG000648
Figure 31
2. Operation of relief
Ta Poppet
If excessive oil flows into passage (L2 (R2)), pressure
generated at passage (L2 (R2)) by orifice (Lc1 (Rc1)) goes
to back chamber of poppet, and poppet operates by the Lc1 [Rc1]
difference of pressurized area between passage and back
chamber.
By operation of this poppet, oil flows from passage through L2 [R2]
plug and drill hole to tank passage (Ta). By this action, ps1
generation of excessive pressure in low-pressure relief [ps2] L1
[R1]
signal port is prevented. FG001320
Figure 33
72
57 72
33
32
32
33
72
81
71 69
77
69
81 72
92
77
93
69
72
89
88
75 69
89
60
75 88 72 72
62
61
68
VIEW A
FG003962
Figure 34
74
7
91
62 70
70
63 A
16
ARM 1
15
72 14
BOOM 2
7
SWING
74 12
8 OPTION 74
7
TRAVEL
4
17
3
2
7 5
12
74
13 105
1 B
ARM 2
5 BOOM 1
BUCKET
6
65 TRAVEL
66 66
STRAIGHT
TRAVEL
72
65
66
50 65
65
65
65
VIEW A SECTION B
FG003963
Figure 35
78
101 49
48
47
46
36
94A 37
75
97
100
95 103
104
102 99
94 98
96 31
30
31
27
26
25
24
34
35
36
37 24A
75
36 42
94A
38
44
45 39
101 40
36 41
43
67
51 34
92 73 35
35 54 76
36 55
53
37 VIEW A
52
75 75
FG003964
Figure 36
Specifications
Rated flux: 270 L/min
However, 50L/min. in neutral
Rated pressure: 34.3MPa
Permitted pressure: Max. pressure of 1.5MPa or less
Used pressure of 0.5MPa or less
Permitted use of oil temperature: Normally -20 - 80°C
Highest 100°C
(Use of the rubber for thread.)
Troubleshooting
Adjustment of Valves
CAUTION
If pressure of main relief valve is higher than the specified
pressure for it, change main relief valve assembly setting
without adjusting overload relief valve.
CAUTION
When disassembling assembly, when pressure is not
fully released, or bucket is not lowered to ground, is
very dangerous. A poppet in an antidrift valve may
spring out and drop the bucket at the same time.
Always lower bucket to ground and fully release
pressure before disassembling.
CAUTION
When removing spool, be careful not to damage it.
Attach label to each spool in order to install it in the
correct position when reassembling.
5. Remove socket head bolt (74, two places per each section,
width across flats: 8 mm) and cap (12, ten places).
6. Remove O-ring (7, one place per each section) from valve
housing (1 and 13).
7. Disassembly of spool.
70~100
Work with spool gripped in vise with wood (see Figure
37) so as not to scratch outside diameter of spool.
Because Loctite is applied to threaded portion of
spool end, heat outside surface of spool with
industrial drier to release Loctite.
Heat spool until spool end is easily loosened, and FG001316
remove immediately after heating it to 200° - 250°C
Figure 37
(392° - 482°F).°
If it is over heated, change spring to new one.
CAUTION
Work with spool gripped in vise with wood (see Figure
37), so as not to scratch outside diameter of spool.
Because Loctite is applied to threaded portion of
spool end, heat outside surface of spool with
industrial drier to release Loctite.
Heat spool until spool end is easily loosened, and
remove immediately after heating it to 200° - 250° C
(392° - 482°F).
If it is over heated, replace spring with a new one.
CAUTION
When removing a plug, when pressure is not fully released,
or bucket is not lowered to ground, is very dangerous. A
part in the valve may spring out and drop the bucket at the
same time. Always lower bucket to ground and fully release
pressure before disassembling.
CAUTION
Removing a plug, when pressure is not fully released, or
bucket is not lowered to ground, is very dangerous. A part
in the valve may spring out and drop the bucket at the same
time. Always lower bucket to ground and fully release
pressure before disassembling.
CAUTION
Be careful, there is not a poppet and spring in travel
straight valve section (Section H-H).
CAUTION
Removing antidrift valve seat, when pressure is not fully
released, or bucket is not lowered to ground, is very
dangerous. A part in the valve may spring out and drop the
bucket at the same time. Always lower bucket to ground
and fully release pressure before disassembling.
CAUTION
Removing inner parts of antidrift valve, when pressure
is not fully released, or bucket is not lowered to
ground, is very dangerous. A part in the valve may
spring out and drop the bucket at the same time.
Always lower bucket to ground and fully release
pressure before disassembling.
Slowly loosen plug assembly (67-14) and plug (67-3),
check if there is a resistance by remaining pressure
and remove.
CAUTION
Removing relief valve, when pressure is not fully released,
or bucket is not lowered to ground, is very dangerous. A
part in the valve may spring out and drop the bucket at the
same time. Always lower bucket to ground and fully release
pressure before disassembling.
Do not loosen adjusting plug for pressure setting or lock
nut.
Adjusting plug for pressure setting is dangerous because
pressure setting will be changed which may result in a
dangerous situation.
CAUTION
Do not disassemble combined bolt (77) if it is
unnecessary.
If it is necessary to disassemble it, work by placing it
horizontally on a work bench.
Prepare spare O-ring (65 and 66).
A
Piston JIS O-ring Type
Figure 38
Width across flat 31.75 Width across flat 17 Width across flat 6
(Cap) (Lock Nut) (Adjuster)
FG001318
Figure 39
CAUTION
When disassembling adjuster kit, be careful not to let
parts spring out or lose poppet because of spring
force.
2 D 1
4 2
"O-ring" P/N: 95113-02100 "O-ring" P/N: 21001-00213
FG001321
Figure 40
1. This unit has press fit portion (D) and it should be replaced
as a complete assembly.
Cleaning
Clean all parts thoroughly using a suitable cleaning fluid and dry
them with moisture free compressed air. Put them on a clean
paper or a vinyl for inspection.
Inspection
Inspect all parts for scratches, notches and other defects.
1. Inspect load check seat surface of valve housing for
scratches, scores, dirt, notches and corrosion. Remove
small scratches with oilstone.
2. Inspect exterior surface of spool for scratches and notches.
Remove small scratches with oilstone.
3. Sliding parts should be moved lightly and foreign materials
should be removed in all grooves and passages.
4. Replace any springs that are damaged, heavy deformed or
worn.
5. If relief valve malfunction, inspect it using relief valve
maintenance procedure.
6. Replace all O-rings and backup rings with new.
7. After disassembling cap or plug, check whether there are
paint chips around body hole or plug. If paint chips
penetrate into valve, they can cause malfunction or valve
to leak.
Caution on Assembly
CAUTION
When working with Loctite, work in a place that is well
ventilated.
CAUTION
Check number of each part, installation position and tools
needed before reassembling.
CAUTION
Be careful not to get Loctite into spool by over
applying it.
Be careful that spool operation does become
deteriorated by over torquing spool end.
When reassembling it and A56, be careful because
there are two different types of springs.
CAUTION
Be careful not to get Loctite into spool by over
applying it.
Be careful that spool operation does become
deteriorated by over torquing spool end.
CAUTION
Be careful of installation position of O-ring and backup
ring.
If they are reversed, the O-ring will be damaged and
drift speed of actuator can be increased.
CAUTION
It Is better to apply grease to seat surface when
installing spring and spring seat onto seat of poppet.
CAUTION
When reassembling safety valve, securely tighten plug that
is installed in body.
Do not loosen adjusting plug for pressure setting or lock
nut.
Adjusting plug for pressure setting is dangerous because
pressure setting will be changed which may result in a
dangerous situation.
CAUTION
Be careful of installation position of O-ring and backup
ring.
If they are reversed, the O-ring will be damaged and an
oil leak can occur.
CAUTION
Be careful of installation position of O-ring and backup
ring.
If they are reversed, the O-ring will be damaged and an
oil leak can occur.
Check installing of O-ring (40-4) on spacer assembly
and be careful of installation direction.
CAUTION
After inserting spool, check to see if it slides easily.
CAUTION
Align spool with hole and insert it slowly.
After inserting spool, check to see if it slides easily.
If spool is inserted when it is in a poor operating
condition with a scratch, it can cause a malfunction of
the spool.
CAUTION
When tightening plug to cap, be careful not to over
tighten. If it is over tighten, threads of cap can be
damaged.
A
Piston JIS O-ring Type
Figure 41
Width across flat 31.75 Width across flat 17 Width across flat 6
(Cap) (Lock Nut) (Adjuster)
FG001318
Figure 42
CAUTION
In the event of disassembling the adjustment kit, be
careful for popping out of parts by the spring or the
loss of the poppet.
2 D 1
4 2
"O-ring" P/N: 95113-02100 "O-ring" P/N: 21001-00213
FG001321
Figure 43
CAUTION
The sources of all tightening torque is coating with the
operation oil.
START-UP PROCEDURES
1. Before operating machine, make sure that oil passages
and hydraulic oil are clean.
2. Hydraulic oil of which annealing point is 82° - 113° C (180° -
235°F) should be used in the hydraulic system.
3. Relief valve pressure should not be raised above specified
pressure setting.
4. The difference between main relief valve setting pressure
and overload relief valve setting pressure should not be
over 2.0 MPa [20.39 kg/cm2 (290 psi)].
5. Before operating machine, the hydraulic system should be
fully warmed up. If machine is operated with cold hydraulic
oil and valve, be careful of the following, to prevent spool
sticking due to heat shock.
NOTE: Do not operate main relief valve or overload
relief valve suddenly and continuously. Cycle oil
through all actuators and warmed up cold
hydraulic oil in the lines and components
uniformly.
NOTE: Slight or compound work should not be
suddenly operated at cold weather because
heat is developed partly at all the orifices.
Remote Control
Valve (Work Lever
/ Joystick)
Edition 1
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.
Theory of Operation
Structure
The remote control valve contains four push rods, spring
holders, spools and return springs, which are in the valve
casing. The valve works as a pressure reduction valve.
The housing has six ports, which include input port P, tank port
T, and four secondary pressure ports.
The electric horn button is installed in the valve handle.
Gear pump pressure is used for operating control spools.
Function
1. Neutral Position
When the lever is in neutral mode, the spool is pushed
upward by return spring. The force of balancing spring,
which determines the secondary discharge pressure, is not
transmitted to the spool. The input port is closed and the
pressure of the output port is the same as the pressure of
the tank port T.
2. Control Switch
Pressing of the push rod starts to press the balance spring,
whose force is transferred to the spool to connect the P
and T ports, transferring the pilot pressure. Output
pressure acts on the bottom of the spool and press the
spool upwards until it is balanced with the force of the
balance spring.
In short, the second pressure (output pressure) changes in
proportion to the pressing force of the balance spring.
28
24
18
25A
16 23
17
36
12 18
22 16
32 11 17
25 15 35
8 20 12
14
11
13 10
34 8
5 7
21
30
6
4 33
5
19
27 9
4
26 1
9
3 4
2 1
29
37 : 24 ~ 28
3
Figure 1 FG003938
Performance
PRESSURE (kgf/cm )
(20)
TORQUE (kgf.cm)
TORQUE (kgf.cm)
2
Operating Torque
15.9 3 15.4 3
5.5 2 5.5 2
Secondary Pressure
Secondary Pressure
(6.2) (5)
FG003944
Figure 2
Torques
No. Tool Standard Remark
500 kg•cm
3 Plug PF 3/8
(36 ft lb)
1,660 kg•cm
19 Swash Plate 27 mm
(120 ft lb)
1,660 kg•cm
20 Hex Nut 22 mm
(120 ft lb)
1,660 kg•cm
22 Nut 22 mm
(120 ft lb)
FG000804
Figure 3
FG000805
Figure 4
3. Remove hex nut (23) and swash plate (22) from case.
FG000806
Figure 5
FG000807
Figure 6
FG000808
Figure 7
FG000809
Figure 8
FG000810
Figure 9
FG000811
Figure 10
FG000812
Figure 11
FG000813
Figure 12
FG000814
Figure 13
FG000815
Figure 14
FG000817
Figure 16
REASSEMBLY
1. Install four plugs (2) into case (1).
FG000815
Figure 17
FG000817
Figure 18
FG000814
Figure 19
FG000818
Figure 21
FG000819
Figure 22
FG000812
Figure 23
FG000820
Figure 24
5. Install spool kit assembly into case (1). (The same way is
used for four parts.)
FG000821
Figure 25
6. Assemble plug kit insert rod seal (18), O-ring (17), and
push rod (2) into plug (16) in proper order.
FG000822
Figure 26
FG000810
Figure 27
FG000809
Figure 28
FG000811
Figure 29
FG000823
Figure 30
FG000808
Figure 31
FG000807
Figure 32
10. Install wash plate (22) and hex nut (23) into case (1).
FG000806
Figure 33
FG000824
Figure 34
12. Install boot (20) and bushing (29) into case (1).
FG000825
Figure 35
FG000805
Figure 36
14. Put lead wire in bushing (29), tie it, and arrange boot.
FG000826
Figure 37
FG000827
Figure 38
FG001097
Figure 39
FG000828
Figure 40
FG000829
Figure 41
HAOB290L
Figure 42
ARO0470L
Figure 43
Travel Control
Valve (With
Damper)
Edition 1
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.
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
40 160
SECONDARY PRESSURE (kg/cm2)
112.6
25 1.5
Operating Torque 91.8
46.4
7.5 1
Secondary Pressure
HB4M033L-1
Figure 3
HB4M032L-1
Figure 4
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
Specifications
Travel Control Valve Specification
Pilot Control
Type
(With Damper)
Torques
Part Reference
Bolt Size Tool Tightening Torque
Number
88 kg•cm
26 M6 5 mm L-Wrench
(6 ft lb)
100 kg•cm
30 M8 4 mm L-Wrench
(7 ft lb)
440 kg•cm
32 M10 17 mm Spanner
(32 ft lb)
440 kg•cm
37 M10 8 mm L-Wrench
(32 ft lb)
WARNING
or maintenance
190-00695A
FG014348
If engine must be running while performing Figure 6
maintenance, always use extreme caution. Always
have one person in the cab at all times. Never leave the
cab with engine running.
FG003016
Figure 7
ARS1870P
Figure 8
FG000985
Figure 9
3. Remove cam shaft (29) and cover (25) from cam (27).
FG000986
Figure 10
4. Remove hex nut (32) and swash plate (31) from cam.
FG000987
Figure 11
FG000988
Figure 12
FG000989
Figure 13
FG000990
Figure 14
FG000991
Figure 15
FG000992
Figure 16
FG000993
Figure 17
FG000994
Figure 18
FG000995
Figure 19
FG000996
Figure 20
FG000997
Figure 21
FG000998
Figure 22
FG000996
Figure 23
FG000997
Figure 24
FG000998
Figure 25
FG000995
Figure 26
FG000999
Figure 27
FG001000
Figure 28
FG000994
Figure 29
FG000992
Figure 30
FG000991
Figure 32
7. Assemble rod seal (23), dust seal (24), and O-ring (22) into
plug (21).
FG001001
Figure 33
FG001002
Figure 34
FG001003
Figure 35
FG001004
Figure 36
FG001005
Figure 37
10. Install push rod assembly into each body (1 and 2).
FG000990
Figure 38
FG001006
Figure 39
12. Assemble cover (28) onto each body (1 and 2) and install
hex socket head bolt (26) using torque wrench.
FG001007
Figure 40
FG000989
Figure 41
13. Install set screws (31) and hex nut (32) into cam (27) and
tighten it.
FG000987
Figure 42
FG000986
Figure 43
15. Install set screw (30) in cam (27) and tighten it using torque
wrench.
FG000985
Figure 44
FG001009
Figure 45
ARS2250P
Figure 46
FG003016
Figure 47
2. Install pedal brackets (3) and levers (4, Figure 48) on pedal
valve and install four bolts and washers (2).
3. Install rubber boots (1, Figure 48). 1
3
3
2
2
ARS2951L
Figure 48
FG003016
Figure 49
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
1Solenoid Valve
Assembly
Edition 1
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.
Parts List
Figure 1, shows components used in the 5-solenoid valve.
4
5
1
Reference
Description Sizes Quantity Remarks
Number
1 Block Body 79x82x272.5 1 1-A0098-07-0
2 Solenoid Valve QF-S3A-0421 5 C1, C2, C3, C4, C5
2-1 Coil VDL24VDC 5 C1, C2, C3, C4, C5
3 Check Valve FD-DCP-0-A 1 C6
4 Plug PF 1/4" 3 P3, P4, H0
5 Plug PT 1/8" 6
Reference
Function Operations Remarks
Number
Provides pressurized oil coming from the pilot pump for
C1 Pilot Cut-off the pilot pressure supply solenoid valve to operate
each work system.
Breaker Pressure Sup- Supplies pilot pressure for the pedal valve assembly
C2
ply and shuttle valve.
Sets low and high travel speed. Shifts speed between
C3 High/Low Travel Speed both depending on the state of the solenoid valve or a
signal detected in the e-EPOS controller.
Main Pressure (Power Temporally increases the pressure setting of the main
C4
Boost) Increase relief valve, to increase the excavation power.
Supplies pilot pressure to shear valve that controls the
Breaker/Shear Mode
C5 front option attachment so it is ready to work in the
Selection
breaker mode.
4
5
1
Reference
Description Sizes Torques (kg•cm) Tools
Number
200 ± 25 kg•cm
2 Solenoid Valve UNF7/8 - 14" Hex torque wrench/1," socket
(170 ± 20 in lb)
60 ± 2 kg•cm
2-1 Coil Locknut UNF1/2 - 20" Hex torque wrench/19 mm, socket
(50 ± 2 in lb)
400 ± 2 kg•cm
3 Check Valve UNF7/8 - 14" Hex torque wrench/1," socket
(350 ± 2 in lb)
250 ± 25 kg•cm
4 PT 1/4" Plug UNF1/4 - 19" Hex torque wrench/19 mm, socket
(220 ± 20 in lb)
280 kg•cm Hex torque wrench/5 mm, wrench
5 PT 1/8" Plug Bolt UNF1/8 - 28"
(240 in lb) socket
CAUTION
Take care not to damage the valve tube and
retainer when removing the coil locknut.
If the valve tube and retainer is damaged (bent or
deformed), the solenoid valve may not operate.
CAUTION
Excessive torque may damage the solenoid
valve.
Figure 3
Parts List
Figure 4, shows components used in the 2-solenoid valve.
2-2
FG013249
Figure 4
Reference
Description Size Quantity Remarks
Number
1 Block Body 57x73x105 1 1-A1097-07-0
2 Solenoid Valve QF-S3A-0421 2 C1, C2
2-2
FG013249
Figure 5
Reference Torques
Description Sizes Tools
Number (kg•cm)
200 ±25 kg•cm
2 Solenoid Valve UNF7/8-14" Torque wrench/1" hex. socket
(170 ±20 in lb)
200 ±25 kg•cm
2-1 Coil Locknut UNF1/2-20" Torque wrench/ 19 mm hex. socket
(170 ±20 in lb)
CAUTION
Take care not to damage the valve tube and
retainer when removing the coil locknut.
If the valve tube and retainer is damaged (bent or
deformed), the solenoid valve may not operate.
CAUTION
Excessive torque may damage the solenoid
valve.
Coil Nut
Coil
Cap Housing
Tube &
Retainer
Case
FG007535
Figure 6
Troubleshooting Guide
Symptoms Causes How to Check Solutions
Foreign substance, Disassemble the solenoid valve and check if there is Remove con-
dirt and dust in sole- any contamination such as a foreign substance and taminant, wash,
noid valve. sludge between the case and the spool. and assemble
components.
Tube or retainer of Disassemble the solenoid valve and check if there is Replace sole-
solenoid valve dam- any deformation (bending or reduction) in the tube noid valve.
aged. or the retainer.
Solenoid
Coil broken, short, or Disassemble the solenoid valve and check the coil Replace coil.
valve will
burned. resistance.
not func-
Spec: 26.7Ω @ 20°C
tion prop-
Disconnection: ∞
erly
Short: Low or excessive resistance
Disassemble the solenoid valve and check the out-
side of the coil to see if its casing is burned and
melted.
Connector terminal Check if the cap housing (where coil lead is Replace hous-
ground defect. attached) and the housing (across its length) are ing or terminal.
grounded properly.
1Breaker EPPR
Valve (Opt)
Edition 1
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.
Figure 7
Reference Reference
Description Description
Number Number
1 Solenoid 5 Pin
2 Valve casing 6 Spring
3 Sleeve 7 O-ring
4 Spool 8 O-ring
Maintenance
Used Torques
Bolt Sizes Names
(kgf.cm)
M 35 Hex bolt 450 ± 50
M 10 Hex bolt 200 ± 20
NPTF 1/16 Plug 90
FG003690
Figure 8
FG003691
Figure 9
FG003692
Figure 10
FG003693
Figure 11
FG003694
Figure 12
FG003695
Figure 13
FG003696
Figure 14
FG003697
Figure 15
FG003698
Figure 16
3Hydraulic
Schematic
DX300LC/
DX300LCA/
DX340LCA
Edition 1
Hydraulic Schematic
DX300LC/DX300LCA/DX340LCA
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
DX300LC/DX300LCA/DX340LCA ........................ 7
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.
B FORWARD
A FORWARD
250kg/cm 2
2
Au
PG ONE/TWO-WAY 24 26 27 28 29 30 25
330kg/cm Dr 1. PUMP
330kg/cm2 23. LOCK VALVE
P
ROTATING ; JOYSTICK SWITCH 31 32 33 34 46 24. PROPORTIONAL VALVE 2. PILOT FILTER
q2 min.
q2 min.
25. HIGH PRESS. RETURN FILTER 3. SOLENOID VALVE (CUT OFF)
330kg/cm 2 QUICK COUPLER 36 26. ONE/TWO-WAY SELECT V/V 1 4. ACCUMULATOR
BACKWARD B
330kg/cm2
BACKWARD A
q1
q1
max.
max.
27. ONE/TWO-WAY SELECT V/V 2 3 5. SOLENOID VALVE (PACKAGE)
GB GA PATTERN CHANGE VALVE (ISO BHL) 1 40 28. STOP VALVE 6. JOYSTICK VALVE(L)
1 2 Pi Dr 4 3 T 275kg/cm 2 O 29. OPT. PEDAL VALVE 1 7. JOYSTICK VALVE(R)
14 35 41 42 43 44 45
ARTI. BOOM 4 P 30. SHUTTLE VALVE for OPT. 8. PEDAL VALVE
Dr Dr
Bm Bm
B RIGHT Mu LEFT A
T 31. PTO 9. SHUTTLE VALVE
15 TRAVEL MOTOR (L) 16 TRAVEL MOTOR (R) 15 32. ADDITIONAL GEAR PUMP S 10. CONTROL VALVE
33. SOL. V/V for ROTATING T 11. BOOM CYLINDER
34. ROTATING VALVE D 12. ARM CYLINDER
35. OPT. PEDAL VALVE 2 13. BUCKET CYLINDER
4 36. QUICK CLAMP VALVE 14. SWING DEVICE
ARTIC. BOOM 41 39. SOL. VLAVE E3C 15. TRAVEL DEVICE
1 40. PATTERN CHANGE VALVE
Pb9 Pb5 16. CENTER JOINT
4 41. ARTI. BOOM CYLINDER
17. RESTRICTION VALVE
pa9
A 4 42. OPT. SHUTTLE VALVE
P C2
4 43. ARTI. BOOM LOCK V/V
18. RESTRICTION VALVE
DR2 DR3 DR4 V2 T Pi E
43 4 4 44. ARTI. VALVE
19. OIL COOLER
E
V2 T PI T C1
4 45. SOL. V/V for ARTI 20. FULL FLOW FILTER
DR1
11 11 10 23 12
pa5
4 46. OPT. PEDAL VALVE 3 21. AIR BREATHER
Pi1 of Pump C2 4 45 44 4 22. HYDRAULIC TANK
Pi2 of Pump ps2 ps1 OPT. PEDAL V/V #2
T2 T1 T3
Pi1 E A
A1 B1 370
370
C2 C2 pc1 B
A2 B2
E E Pb
A5 Pa
4 42
a T P
A B
Pi1 Pi1 pb9 ARM2 ARM1 B5
Valve;control from #10 P3 2 2 4 2
T T
V2 V2 pb5
pa9 360k@20L
1 1 3 1
23 23 P
from #32
pc2
pa5
80kg/cm 2
34
A8 4
pc3
8
B8
B4 T P
46 T P
35 T P T P
29
T
13 pb8 BOOM1 BOOM2 pb4
100kg/cm 2
pa4 b
360k@20L
pa8 B3
B7 360k@20L
A7
BKT SWING A3
L OPT. PEDAL 3 OPT. PEDAL 2
L.TRAVEL R.TRAVEL
OPT. PEDAL 1
pb3 2 1 2 1 2 1 4 3 2 1
pb7 CW CCW UP DOWN FORWARD FORWARD
pa3 L.H BACKWARD BACKWARD
pa7 220kg/cm 2
pi4 A pb6 pa6 pb1 pa1
Pi B2
A2
B6
OPT T
pb2
27
A6
TR(L) 250k@20L P4 X
pb6 28 A B
pa2 L
T
B1 C
pa6 A
B
TR(R) A1 R.H
pb1 33
26
pa1
6 7
X P1 T P T P
MAIN
2
RELIEF from JOYSTICK(L) SWITCH
2 2
350Kg/cm @136L/min
VALVE(LEFT) 330Kg/cm2@156L/min VALVE(RIGHT) 1 3 1 3
25
P2 P3 pr PH PA PP PT P1 4 4
SWING ARM BOOM BUCKET
PH of Sol. v/v
19k 1 3 2 4 2 4 1 3
SWING MOTOR SH 19k LEFT DUMP DOWN CROWD
RIGHT CROWD UP DUMP
1 40
A1 C1
B1 D1
17 19
ISO BHL
A2 C2 D2
B2
Pcr=2.5k 24
A1 A2 A3 A4 A5 A6 A7 A8 30
18 Pcr=1.0k
ps1 9 A9 A10
1 4 B1 S1 B2 B3 B5 B6 B7 B8 B9 S2 B10
Pi1
Hammer Operating
21 A1 A2 PH
B4
Hammer/Shear
Psv a4 3 pa3 pb3 pb5 pb8 pa7 pa8 pb7 pb2
Safety Cut-off
from PRESS. SWITCH ON #30 pa2
Pressure up
high speed
pa5
500k 500k 5
Travel
Select
a1 a2 pc1 pc2 Pi
20 (FRONT) SENSOR SENSOR (REAR) ACC P2 HO TR2 PH BS
1
10u T
_
1.5k+0.2k A
LH-HI
(CLOSE) B RH-HI (OPEN)
22
177u Pi1 Pi2
ps1 ps2 P1
T
2
P0 P3 P4
ENGINE 40k 3
B1 39
a3
FG014415
Figure 1
Electrical
System
Edition 1
Electrical System
Safety Precautions ............................................... 6
Applicable Models ................................................ 6
Introduction ........................................................... 7
Electrical Supply System ...................................... 8
Engine Starting Circuit ........................................ 10
Engine Preheating System ................................. 14
Engine Stop ........................................................ 15
Charging System ................................................ 16
Monitoring System .............................................. 17
Operation ............................................................ 22
Warning and Indicator Lights .............................. 24
Initial Operation .................................................. 27
Mode Selector Switch ......................................... 27
Graphic Information Area Display....................... 28
Main Menu .......................................................... 30
Special Menu ...................................................... 34
Electronic Hydraulic Control System (e-EPOS).. 50
Power Mode Control ........................................... 52
Power Mode Control - Circuit Diagram ............... 57
Work Mode Control............................................. 58
Work Mode Control - Circuit Diagram................. 59
Engine Control System ....................................... 60
Engine Control Dial............................................. 61
Engine Control Motor.......................................... 62
Engine Control Circuit Diagram .......................... 63
Automatic Deceleration Control
(Auto Idle Control) .............................................. 64
Engine Overheat Protection System .................. 65
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.
Symbol Color
W White
G Green
Or Orange
B Black
L Blue
Lg Light green
R Red
Gr Gray
P Pink
Y Yellow
Br Brown
V Violet
6 3
8
4 2
B A
BR
E
- + - +
12V 150AH 12V 150AH
R(I) B(B+) P(R)
STARTER SWITCH CONNECTION
1
PST TML B BR R1 R2 C ACC
OFF SG
PREHEAT 7
ON
R
START F
E
FG021881
Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode
Start Operation
When the starter switch is turned to the "START" position, the
"S" and "E" terminals of the starter controller (7) are connected.
At this time the contacts in the starter relay (8) are closed by the
current flow from the battery (1) →fusible link (3) →fuse box (6) →
"B" terminal of starter switch (5) →"C" terminal of starter switch
(5) → "30" terminal of starter relay (12) - "87a" terminal → "C"
terminal of starter relay (8) - "D" terminal →"S" terminal of starter
controller (7) - "E" terminal →ground.
When the contact point "B" and "PP" of starter relay (8) are
connected, the pinion gear of the starter (9) is pushed forward
and makes contact with the ring gear of the flywheel and the
internal contacts of the starter are connected. The current flows
from the battery (1) →"A" terminal of the battery relay (2) →"B"
terminal of the battery relay (2, Figure 3) →"B" terminal of the
starter (9). The starter motor is rotated and the engine is started.
If the instrument panel has the password function activated,
input number should match the set number, otherwise the start
circuit closes and the engine does not start.
NOTE: If the security system is "LOCKED," a four-digit
password will be required to start the engine. If the
system is "UNLOCKED," no password will be
required and this display screen will not appear.
ENTER
In the event the security system is locked, current PASSWORD
flows from battery (1) →fusible link (3) →fuse box (6)
→ "B" terminal of starter switch (5) → "ACC" terminal
of starter switch (5) → "86" terminal of starter relay
(12) →"85" terminal of starter relay (12) →"CN1-15"
terminal of e-EPOS (13) →ground. This current flow
causes the coil in starter relay (12) to be activated, FG013717
opening contacts at "87a" terminal. This prevents Figure 2
starter relay (8) from functioning.
85 86 ACC
C
B 5
R2 BR
12 R1
3
CN1-15
6
4
B A
CN2-1
BR
13 E
11
STARTER SWITCH CONNECTION
R(I) B(B+) P(R) 2
PREHEAT 10 - + - +
ON R
F 1
START E
FG021882
Figure 3 STARTER CIRCUIT (1) - WHILE STARTING
Reference Reference
Description Description
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
3 Fusible Link 10 Alternator
4 Circuit Breaker 11 Diode
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 e-EPOS Controller
7 Starter Controller
7 8 9
N S D PP C
P C B B
B E
A
87a
30
87
85 86 ACC
C
B 5
R2 BR
12 R1
3
CN1-15
6
4
B A
CN2-1
BR
13 E
11
STARTER SWITCH CONNECTION
R(I) B(B+) P(R) 2
PST TML B BR R1 R2 C ACC
OFF SG
PREHEAT 10 - + - +
ON R
F 1
START E
FG021883
Figure 4 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START
Reference Reference
Description Description
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
3 Fusible Link 10 Alternator
4 Circuit Breaker 11 Diode
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 e-EPOS Controller
7 Starter Controller
9 4
CN6-1,2 2
ACC C B A
PREHEAT CN7-4,5,6
L5 B 5
R2 BR
R1 BR E
10
CN4-4,5,6
CN2-13
CN2-1
- + - +
11 1
C B
- STARTER SWITCH CONNECTION
200A
Reference Reference
Description Description
Number Number
1 Battery 7 Preheat Relay
2 Battery Relay 8 Air Heater
3 Fusible Link 9 Preheat Indicator Light
4 Circuit Breaker 10 Diode
5 Starter Switch 11 e-EPOS Controller
6 Fuse Box
8
9
6
3
ACC C
B 5
R2
BR
4 2
R1 B A
BR
E
7
- + - +
1 FG002089
Figure 6 ENGINE STOP CIRCUIT
Reference Reference
Description Description
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 7 Diode
3 Fusible Link 8 Injector Solenoid
4 Circuit Breaker 9 Engine Stop Motor
5 Starter Switch
ACC C
B
R2
5
BR
0.5G
R1
6
3
8
4 2
B A
BR
E
- + - +
R(I) B(B+) P(R) 12V 150AH 12V 150AH
STARTER SWITCH CONNECTION
1
PST TML B BR R1 R2 C ACC
OFF SG
PREHEAT 7
ON
R
START F
E
FG021885
Figure 7 CHARGING CIRCUIT
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode
+
2
-
5 7
1
8
4 R
3
E
E F
C H C H
10
6
1 2 3 4 5
6 7 8 9 0
11
14
12
13 FG021889
Figure 8
Reference Reference
Description Description
Number Number
1 Instrument Panel 9 Pump Discharge Pressure Sensor
2 Battery 10 Hydraulic Oil Temperature Sensor
3 Light Switch 11 Fuel Sensor
4 Return Filter Switch 12 Air Cleaner Indicator
5 Pilot Filter Switch Engine Coolant Temperature
13
6 e-EPOS Controller Sensor
7 Alternator 14 Engine Oil Pressure Switch
8 Warning Buzzer
7 8 9 10 11 12 5
6 1
1 CHECK
E
< CONNECTOR AND TERMINAL NO.>
F 4
16
C H C H 18
AMP 040 28P
14 20 6 5 4 3 2 1 8 7 6 5 4 3 2 1
22 12 11 10 9 8 7 16 15 14 13 12 11 10 9
13 (CN7) (CN6)
1 2 3 4 5
23
6 7 8 9 0
15
17 19 21 FG013521
Figure 9
When the engine starter switch is turned to the "I" (ON) position,
all gauge bands, switch/button indicator lights and warning lights
will turn "ON" and the alarm buzzer will sound about two
seconds.
During this functional check, a LOGO will appear on the multi
function gauge in the graphic information area.
19
CN6-1
3
CN6-3
CN6-2 +
CN6-12 -
CN6-11
2
17
4
R2 B 16 B
CN6-9
CN6-10 BR
14 E
CN2-1 A
18
+ CN5-7 15
CN3-1
5 SIG
CN3-2
9
LCD DISPLAY PANEL -
WATER TEMPERATURE CN2-17
FUEL LEVEL + 10
CN3-3
6 SIG CN2-18
GRAPHIC DISPLAY CN3-4
- 11
CN7-4 CN5-3
CN4-4
CN7-5
12
CN4-12 CAN A
CN7-6 CN4-6
CN3-7
GND
CN3-8 8
CN4-3
CN4-2 RxD
CN4-1 TxD CN3-9
CN3-10 7
1
2 CN5-13
3 CN5-14 21
4 20
5 CN5-15
6 CN5-16 22
14
CN5-5
R(I) CN2-14 23
13 FG021890
Figure 10
Instruments
Sensor Specification
Function Display
Input Terminal Input Specification
Blue
41°C (106°F) →1,372 ohms
61°C (142°F) → 855 ohms
Blue
Blue
40°C (104°F) → 1,397 ohms
50°C (122°F) → 1,139 ohms
N = 129 f / 60
CN5-15
Tachometer E/G SPEED 1800 RPM
CN5-16
N = Engine speed (rpm)
f = Frequency of engine
speed sensor (Hz)
FG021879
FG000050
Main pump
discharge CN3-1
pressure
FRONT PUMP 320 BAR
CN3-2
(front pump)
V = 0.00816 x P + 1.0
FG000051
V: Sensor output voltage (V)
P: Displayed pressure (Bar)
Main pump
discharge CN3-3
pressure
REAR PUMP 313 BAR
CN3-4
(rear pump)
FG000052
It lights in case of no
charge [voltage of
Normally, it lights
CN2 - 14 "R(I)" terminal is below
when starting engine
Charge 12 ±1V] or overcharge
CN1 - 8(9) and is out after
[voltage of "R(I)"
engine starts.
terminal is above
HAOA610L 33(V)].
It lights during
CN2 - 13 preheating and turns
Preheating "OFF" after completion
CN1 - 8(9) of preheating.
(After 20 sec preheating)
HB4O2003
Input
Description Symbol Operation Remarks
Terminal
FG000056
FG000057
FG000053
FG000554
FG001470
FG001471
INITIAL OPERATION
Item Input (Terminal) Output (Operation and initial setting mode)
Initial When "CN6-1,2" is applied • LCD, all of LED and warning lights are turned
Operation battery voltage (starter switch "ON" and turned "OFF" after about 2 seconds.
shifts from "OFF" to "ON"
• Warning buzzer is activated and turned "OFF"
after about 2 seconds.
• Power mode: Standard mode.
• Auto Idle: High Output (Activation).
• Display: Indicating coolant temperature, Fuel
level, Hydraulic oil temperature, Engine speed.
• Clock: Current time display.
e-EPOS Output
Operation Mode Electromagnetic Proportional Pressure
Swing Priority 7-Segment
Reducing Valve (E.P.P.R Valve)
Solenoid Valve Display
Current (mA)
No-load: 150 ± 20mA
Power Mode Load: Variable output - 9x
(Max. current: 400 ± 20mA)
No-load: 300 ± 20mA
Power
Standard Mode Load: Variable output - 7x
Mode
(Max. current: 600 ± 60mA)
No-load: 400 ± 20mA
Economy Mode Load: Variable output - 5x
(Max. current: 600 ± 60mA)
Overview
Many kinds of condition of machine are displayed on the letter
information display department. The information display
department is divided into two menus. One is main menu for
user and the other is special menu for specialist. These menus
can be moved from normal display mode by the combination of
selector buttons.
E F
C H C H 1
5
1 2 3 4 5
6 7 8 9 0
2 3 FG013562
Figure 11
l
operator.
3. Filter / Oil Info
Refer to the "Operation and Maintenance Manual" for details.
4. Adjust Display
5. Set Password
: UP : DOWN : SELECT
FG013563
Figure 12
Language
MAIN MENU
Put the cursor on Language in the main menu and put the Enter
Button ( , 3 on Figure 11) and the language select view
L 1. Language
l
2. Set Clock
l
appears.
The default language is Korean, but it will memorize and use the
3. Filter / Oil Info
newly set language. 4. Adjust Display
Use the Up Arrow Button ( , 1 on Figure 11) or Down Arrow
5. Set Password
Button ( , 2 on Figure 11) to move cursor to a language to be : UP : DOWN : SELECT
selected on the Language Select display and press the Enter FG013563
Button ( , 3 on Figure 11) and the selected language is Figure 13
indicated in the right bottom of the screen.
At this point pressing the Enter Button ( , 3 on Figure 11) or
the Escape Button (ESC, 4 on Figure 11) more than 1 second L Languag
brings the main menu with changed language and then pressing
the ESC button again shows the default view. 1. Korean
Without pressing a button more than 20 seconds, the default 2. English
view appears.
: UP : DOWN : SET
FG013564
Figure 14
l
Menu after putting cursor on Set Clock brings Set Clock display.
3. Filter / Oil Info
Without pressing a button more than 20 seconds, the default 4. Adjust Display
view appears.
5. Set Password
Please refer to the Operation Manual for detailed information on
Time Setting. : UP : DOWN : SELECT
FG013565
Figure 15
SET CLOCK
02:30:30
2003 11/04
: UP : DOWN : SELECT
FG013566
Figure 16
Filter/Oil Info
MAIN MENU
This mode displays total operating hours of filters and oils.
L 1. Language
After changing the filter and oil, reset the operating hour and l
2. Set Clock
l
then the operating hours until the next service interval can be
easily checked. 3. Filter / Oil Info
4. Adjust Display
5. Set Password
: UP : DOWN : SELECT
FG013567
Figure 17
Filter/Oil Information
R
1. Fuel Filter
Hrs : 0045Hrs 42m
: UP : DOWN : SELECT
FG013568
Figure 18
1. Fuel Filter 2. Air Cleaner 3. Engine Oil Filter 4. Hyd. Oil Filter
Adjust Display
MAIN MENU
Pressing the Enter Button ( , 3 on Figure 11) in the main
menu after putting cursor on Adjust Display brings Adjust
L 1. Language
l
2. Set Clock
l
Display.
Screen brightness can be adjusted using the Up Arrow Button
3. Filter / Oil Info
( , 1 on Figure 11) or the Down Arrow Button ( , 2 on Figure 4. Adjust Display
11). 5. Set Password
The default brightness is set to 50%. : UP : DOWN : SELECT
FG013569
Figure 20
1. Adjust Display
: UP : DOWN : SELECT
FG013835
Figure 21
l
Password Setting.
3. Filter / Oil Info
4. Adjust Display
5. Set Password
: UP : DOWN : SELECT
FG013571
Figure 22
Entering/Accessing Menus 4
When normal mode screen is displayed, if the enter button ( ,
3) and escape button (ESC, 4) are pressed simultaneously for
more than 3 seconds, normal mode screen (Figure 23) will be
changed to special menu screen (Figure 23).
3 FG013581
Figure 23
E F
C H C H
FG013591
Figure 24
Submenu Selections
: UP : DOWN
FG013594
Figure 28
Menu Select
DIGITAL INPUT STATE
1. Relift Press UP S/V :
2. High Speed S/V :
3. Reverse Fan S/V :
4. Starter Relay :
5. Afterheat Relay :
: UP : DOWN
FG013612
Figure 30
Failure Information
1. Entering Sub-menus: When a cursor is located in "Failure SPECIAL MENU
Info" of special menu screen press enter button ( , 3 on
1. Machine Information
Figure 23) and "Failure Info" screen is displayed.
2. Exiting Sub-menus: If escape button (ESC, 4 on Figure 23) 2. Failure Information
is pressed for more than 1 second, this information screen
will be returned to previous screen. 3. Operating Hours
: UP : DOWN : SELECT
FG013613
Figure 31
* Real-time Failure:
Current status of failure is displayed. FAILURE INFORMATION
* Failure Log:
Memorized record of past failure is displayed. 1. Realtime Fail
* Delete Fail Log: 2. Failure Log
This mode is used to delete all of the
memorized record of past failure.
3. Delete Fail Log
: UP : DOWN : SELECT
FG013614
Figure 32
: YES ESC : NO
FG013618
Figure 36
DELETED !!!
: YES ESC : NO
FG013619
Figure 37
: YES ESC : NO
FG013620
Figure 38
FMI 0 Above normal range (DATA VALID but ABOVE NORMAL OPERATIONAL RANGE)
FMI 1 Below normal range (DATA VALID but BELOW NORMAL OPERATIONAL RANGE)
FMI 2 Incorrect signal (DATA ERRATIC, INTERMITTENT OR INCORRECT)
FMI 3 Voltage above normal (VOLTAGE ABOVE NORMAL OR SHORTED TO HIGH SOURCE)
FMI 4 Voltage below normal (VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE)
FMI 5 Current below normal (CURRENT BELOW NORMAL OR OPEN CIRCUIT)
FMI 6 Current above normal (CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT)
FMI 8 Abnormal signal (ABNORMAL FREQUENCY OR PULSE WIDTH OR PERIOD)
FMI 11 Failure mode not identifiable (ROOT CAUSE NOT KNOWN - Malfunction)
FMI 31 NOT AVAILABLE OR CONDITION EXISTS
OPERATING HOURS
Operating Hours
Reset Hours
: UP : DOWN : SELECT
FG013622
Figure 40
1. Power Mode 2. Economy Mode 3. Auto Idle 4. Travel Speed 1st, 2nd
OPERATING HOURS
6. Coolant Temp. [ c]
40 : 00140 Hr
41-60 : 00054 Hr
61-85 : 00087 Hr
96-105 : 00001 Hr
105 : 00000 Hr
: UP : DOWN
FG013624
Figure 43
: UP : DOWN : SELECT
FG013625
Figure 44
: YES ESC : NO
FG013627
Figure 46
DELETED !!!
: YES ESC : NO
FG013628
Figure 47
X PASSWORD ERR!!!
: YES ESC : NO
FG013629
Figure 48
7 11
12
3 8
(Wheel)
P 14
13
4 5
N
17 10
P M
(Pump control signal)
(Potentiometer signal)
(Throttle signal)
(Throttle command)
(Switch signal)
(Coolant water temp. signal)
(Mode select signal) 1
(Auto idle signal)
(Machine information) E F
C H C H
18
UP
WER
PO 1 2 3 4 5
6 7 8 9 0
21 (Sensor) 19
FG021891
Figure 49
6 6
P
4 5
9
17
10
1 2 3 4 5
6 7 8 9 0
3
15
16
FG021892
Figure 50
Reference Reference
Description Description
Number Number
Instrument Panel 9 Engine Speed Sensor
1
(Power Mode Selector Button) Electromagnetic Proportional
10
2 e-EPOS Controller Pressure Reducing Valve
3 Engine 15 Engine Throttle Controller
4 Main Pump 16 Engine Control Dial
5 Aux Pump 17 Engine Control Motor
6 Control Valve
1. Power Mode
This mode should be selected for high speed work. In this
mode the engine output is most efficiently utilized due to
the discharged oil volume being controlled based on the
equivalent horsepower curve at various loaded pressures.
The e-EPOS controller compares the target engine speed
with the actual engine speed and controls the signal to the
E.P.P.R. (Electromagnetic Proportional Pressure POWER
Reducing) valve which in turn varies the pump output
quantity.
If the load increases, the engine speed will fall below the
rated speed. When this occurs, the controller senses this FG015516
decrease and immediately reduces the pump discharge Figure 51
volume to maintain the engine speed at the rated level.
On the other hand, if the load is decreased the controller
increases the discharge volume of the pump to maintain
the engine speed at the rated level.
By repeating these control operations, the engine speed is
maintained at the rated speed so that maximum power can
be generated.
In Power Mode, the e-EPOS controller receives engine
speed signals from the engine control dial and converts it
to an operating signal current and is then transferred to the
pump's E.P.P.R valve. At this time the E.P.P.R. valve
converts the electric signal to the corresponding control
pressure and sends it to the two pumps, adjusting the
pump discharge volume to the desired level.
A C
B D FG000580
Figure 52
Reference Reference
Description Description
Number Number
A Engine Horsepower (hp) C Pump Discharge Volume (lpm)
B Engine Speed (rpm) D Pump Discharge Pressure (kg/cm2)
A C
B D FG000581
Figure 53
Reference Reference
Description Description
Number Number
A Engine Horsepower (hp) C Pump Discharge Volume (lpm)
B Engine Speed (rpm) D Pump Discharge Pressure (kg/cm 2)
3. Economy Mode
Economy mode is used for light load work. When this
mode is selected, it will reduce noise and fuel consumption
in comparison with standard mode. The current to the
E.P.P.R. valve is shut off and pump discharge volume is
controlled by pump regulator.
The e-EPOS controller compares the target engine speed
with the actual engine speed and controls the signal to the
E.P.P.R. valve which in turn varies the pump output
quantity and it is the same method with power volume.
FG013671
Figure 54
B D FG021897
Figure 55
Reference Reference
Description Description
Number Number
A Engine Horsepower (hp) C Pump Discharge Volume (lpm)
B Engine Speed (rpm) D Pump Discharge Pressure (kg/cm2)
1
15A
CN6-1
CN6-2
26
CN6-9
2 26 15A 26 10A 26 10A
25
CN6-10
CN1-1
CN7-4 CN4-4 CN1-2
CN7-5 CN4-5 CAN
CN7-6 CN4-6
CN5-15
CN1-8
30 CN5-16 24
29 CN1-9
15 CN1-3 II
10 CN1-4 A/I
23
14 CN1-5 W/M
17 CN1-6 O/H 22
12 CN1-10 1 10
5
P/V-(A)
4 P4 2
(+)
CN1-21 3
M 6
(-) 5 P5 4
(+) 8 P3 RETRACT
P2
7 16
1
(-)
6 P1 CW LOW
SIG CN3-16 2
CN3-13 GND CN3-17 3
CN3-14 HIGH
1
+(5V)
2
SIG
3
GND
9
AMP 070 16P AMP 040 12P AMP 040 20P AMP 070 18P AMP MIC 21P
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
Reference Reference
Description Description
Number Number
1 Instrument Panel 23 Aux Mode Resistor
2 e-EPOS Controller 24 Battery
E.P.P.R. Valve (Electromagnetic 25 Battery Relay
10
Proportional Pressure Reducing) 26 Fuse
16 Engine Control Dial 29 Engine Throttle Controller
22 Aux Mode Switch 30 Engine Speed Sensor
6 6
3 12
P
4 5
17
1 2 3 4 5
6 7 8 9 0
15
16
FG021893
Figure 57
Reference Reference
Description Description
Number Number
Instrument Panel (Trenching 6 Control Valve
1
Mode Selector Switch) 12 Solenoid Valve
2 e-EPOS Controller 15 Engine Throttle Controller
3 Engine 16 Engine Control Dial
4 Main Pump 17 Engine Control Motor
5 Aux Pump
04@
BM5,0
BM5,1
26
4 26 04@
BM5,8 25
BM5,0/
BM0,0
BM6,3 BM3,3 BM0,1
BM6,4 BM3,4 B@M
BM6,5 BM3,5
24
12
'B4(
BM0,02
BM0,7
BM0,8
01 00 0/ 8 7 6 1/ 08 07 06 05 04 03 02 01 00 07 06 05 04 03 02 01 00 0/ 8 10 1/ 08 07 06 05 04 03 02 01 00
05 04 03 02 01 00 0/ 8
'BM1( 'BM0(
'BM4( 'BM3( 'BM2(
@LO/3/17O
5 4 3 2 1 0 7 6 5 4 3 2 1 0
01 00 0/ 8 7 6 05 04 03 02 01 00 0/ 8
'BM6( 'BM5(
FG000583
Figure 58
Reference Reference
Description Description
Number Number
1 Instrument Panel 24 Battery
2 e-EPOS Controller 25 Battery Relay
12 Solenoid Valve (Swing Priority) 26 Fuse
(Feedback Signal)
16
P 2
3
15 M
10A
BATT. RELAY
9
10 AUTO IDLE COMMAND
5 4
17
15 FG014301
Figure 59
Reference Reference
Description Description
Number Number
2 Engine Control Motor 15 Engine Throttle Controller
3 Engine 16 Engine Control Dial
CCW ( 10 ) ( 10 ) CW
MECHANICAL MECHANICAL
STOP STOP
(V)
5
4.0V
4
3 2.5V
2
2 1.0V
1
0 SETUP
1ST 2nd 7th 12th 13th
CCW CW
STOP STOP
FG000866
Figure 60
Reference Reference
Description Description
Number Number
Potentiometer
1 Knob 2
(Variable Resistor)
1 2 3
Circuit Diagram
P4
(GREEN)
(RETRACT) (GRAY) P1
ACCEL
(PINK) P2
P4(G) P5(Y) +
-
Vs
(5.0V)
(BLUE) P3 Vp
DECEL
(EXTEND)
FG014302
Figure 61
CN6-9
2 26 15A 26 10A
CN6-10
CN1-1 25
CN7-4 CN4-4 CN1-2
CN7-5 CN4-5 CAN
CN7-6 CN4-6
CN1-8 24
15 CN1-9
15 CN1-3 II
10 CN1-4 A/I
14 CN1-5 W/M
17 CN1-6 O/H
12
17 31
4 P4 Py
(+)
CN2-15
M
(-) 5 P5 Px
CN2-16
(+) 8 P3 RETRACT
7 P2 32 16
1
(-)
6 P1 CW LOW
SIG CN3-16 2
CN3-13 GND CN3-17 3
CN3-14 HIGH
1
+(5V)
2
SIG
3
GND
9
AMP 070 16P AMP 040 12P AMP 040 20P AMP 070 18P AMP MIC 21P
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
(CN7) (CN6)
FG002106
Figure 62
Reference Reference
Description Description
Number Number
1 Instrument Panel 24 Battery
2 e-EPOS Controller 25 Battery Relay
15 Engine Throttle Controller 26 Fuse
16 Engine Control Dial 31 Pressure Switch (Py)
17 Engine Control Motor 32 Pressure Switch (Px)
16 15
3
1
31
1 2 3 4 5
2 6 7 8 9 0
32
FG021894
Figure 63
Reference Reference
Description Description
Number Number
Instrument Panel 15 Engine Throttle Controller
1
(Auto Idle Switch) 16 Engine Control Dial
2 e-EPOS Controller 31 Pressure Switch
3 Engine 32 Pressure Switch
Engine
6 6
4 4
C H
E F
C H
33
1
6
2
7
3
8
4
9
5
0
10
15
2
FG021895
Figure 64
Reference Reference
Description Description
Number Number
1 Instrument Panel E.P.P.R. Valve
2 e-EPOS Controller 10 (Electromagnetic Proportional
Pressure Reducing Valve)
3 Main Pump
15 Engine Throttle Controller
4 Aux Pump
33 Warning Buzzer
6 Control Valve
Operation
6 6
Main Relief v/v
11
4 4
5
2
20
(Button Signal)
1
E F
C H C H
P
RU
WE
PO
18 FG021896
1 2 3 4 5
6 7 8 9 0
Figure 65
Reference Reference
Description Description
Number Number
1 Instrument Panel 11 Solenoid Valve (Boost)
2 e-EPOS Controller Breaker/Boost/Shear Selector
18
4 Main Pump Switch
5 Aux Pump Power Boost Switch
20
(Top of Right Work Lever)
6 Control Valve
1
15A
CN6-1
CN6-2
26
2 26 15A 26 20A
CN6-9 25
CN6-10
CN1-1 18
CN7-4 CN4-4 CN1-2
CN7-5 CN4-5 CAN
CN7-6 CN4-6 PST SHEAR PRESS BREAKER
TML 1 0 2
24
10
11
3
(C4) 14
CN1-11
13
6
CN2-2 (POWER MAX)
16
CN1-8 12
CN1-9
6 3
(Center)
(POWER MAX / BREAKER)
20
(CN2) (CN1)
FG000586
Figure 66
Reference Reference
Description Description
Number Number
1 Instrument Panel Power Boost Switch
20
2 e-EPOS Controller (Top of Right Work Lever)
11 Solenoid Valve (Pressure Up) 24 Battery
Breaker/Boost/Shear Selector 25 Battery Relay
18
Switch 26 Fuse
6 6
7
3
8 8
14
13
5
4 4
2
16
19
FG002110
Figure 67
Reference Reference
Description Description
Number Number
2 e-EPOS Controller 8 Pump Pressure Sensor
3 Engine 13 Solenoid Valve (High speed)
4 Main Pump 14 Travel Motor
5 Aux Pump 16 Engine Control Dial
6 Control Valve Selector Switch For Automatic
19
7 Pressure Switch (Py Port) Travel
26
15A
2 26 15A
26 15A
26 10A
CN1-8
CN1-9 CN1-1
+ CN1-2 25
8 SIG CN3-1
CN3-2
- 13
+
(C3) 24
CN1-12
CN3-3
9 SIG
CN3-4
15 -
19
0
15 CN1-3 3 2
CN2-4 I
10 CN1-4 II
14 CN1-5 0
I 5
17 CN1-6
CN2-5 6 II
12
7 8
4 P4
(+)
M
(-) 5 P5
(+) 8 P3 RETRACT
7 P2 16
(-)
6 P1 CW LOW
CN3-16 2
SIG
CN3-13 CN3-17
GND 3
CN3-14 HIGH
1
+(5V)
2
SIG
3
GND
9
AMP 070 16P AMP 040 12P AMP 040 20P AMP 070 18P AMP MIC 21P
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
AMP 040 28P
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
(CN7) (CN6)
FG002111
Figure 68
Reference Reference
Description Description
Number Number
2 e-EPOS Controller Selector Switch for Automatic
19
8 Pressure Sensor (Front Pump) Travel
9 Pressure Sensor (Rear Pump) 24 Battery
13 Solenoid Valve (High speed) 25 Battery Relay
15 Engine Throttle Controller 26 Fuse
16 Engine Control Dial
VR1
MOTOR
VR2 SIGNAL STATUS R G Y VOLTAGE
VR3
VR4
R G
Y
- ENGINE RPM SETTING -
RPM VR1
ENGINE THROTTLE CONTROLLER
RPM VR2
PART NO. K1003111
RPM VR3 SERIAL NO.
VR4
RPM WHEEL
TYPE
ONLY
FG002112
Figure 69
Reference Reference
Description Description
Number Number
1 VR1 (set auto deceleration speed) 3 Name plate
2 VR2 (set Power mode speed)
Figure 70
Reference Reference
Description Description
Number Number
1 Engine Fuel Control Lever 3 Engine Speed Adjusting Cable
2 Control Motor Cable Bracket 4 Engine Control Motor
WARNING
1. " ◎ "turn on brightly, "O" turn on, "X" turn off.
2. Measured terminal of motor voltage, 4(+), 5(-) terminal
of throttle controller.
3. Yellow LED is used to show the Power on.
4. In motor overload current cut off mode, remove the
cause of overload, and turn the start switch off and
then on normal work should resume.
e-EPOS Controller
The system operation status and malfunction codes can be
checked through the display on top of the e-EPOS controller box
the rear cover behind the operator's seat.
1 2
4 3
FG000588
Figure 71
Reference Reference
Description Description
Number Number
1 Upper Digit Power Monitor (Stays "ON" While
4
2 Lower Digit Power Is In Normal Range,)
Engine Speed Monitor LED
3 (Flash Interval Increases With
Engine Speed.)
1. Power Monitor
This LED is turned "OFF" when the input voltage to the
e-EPOS controller is below 18.5 ± 1 V or above 32.5 ± 1 V.
Stays "ON" while in normal range.
2. Engine Speed Monitor
This LED light flashes according to the engine speed. The
flashing interval is proportional to the engine speed.
3. Normal Operation Display Readout
Display Readout
Mode Selection Operation Status
Upper Digit Lower Digit
Normal Operation
Power Mode
Power Mode
HAOH340L HAOH370L
Normal Operation
Power Mode Standard Mode
Standard Mode
HAOH350L HAOH370L
Normal Operation
Economy Mode
Economy Mode
FG013637 HAOH370L
Outline
A
C
FG013857
Figure 72
Modes
FG000422
Figure 73
Donaldson.
FG000440
Figure 74
FG000441
Figure 75
FG000342
Figure 76
10 2
11
6
1
5
5
4
8
9
FG007144
Figure 77
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
0.5RW
FUSIBLE LINK
LAMP SWITCH
A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A CN11-4 0.85LW 47C
DIODE 4
1.25B CN11-1 99 - +
M
107B CN8-12 0.5LW CN10-1 107A 0.85B 0.85B
BLOWER
99 CN9-10 1.25B
20 19 18 17 16 15 14 13 12 11 10
4 3 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
Vent
Front
Outlet
Foot
DEF Outlet
Outlet
External Air
Internal Air
Evaporator Fan
Heater
Core
FG001359
Figure 79
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
Actuator
- Temp A/C
Control Relay Blower
Relay
Duct
Sensor
Air Flow
Control
Module
Actuator
Blower
-Wind Direction
Motor
Control
Water Temp
Sensor
Actuator
Evaporator - Internal/external
Air Exchanger
Internal
Internal Air Sensor
Air Filter FG007754
Figure 80
N P2
c
b
e
P2 P1
b c e
FG001361
Figure 81
N P2
P1
CN10-20 CN10-2
P2 P1
c e
FG001055
Figure 82
DRAIN
(CN10-1)
SOURCE GATE
(CN11-1) (CN10-6)
FG001056
Figure 83
30 86(+)
FG001057
Figure 84
Specifications
Rated voltage 24V L S1 (+)
Rated current 10A
B S2
(-)
FG001058
Figure 85
Figure 87
Figure 88
83.7
OUTPUT VOLTAGE(mV)
76.2
67.7
58.8
46.6
36.0
21.4
Control Panel
A/C OUTSIDE
AUTO A/C
AUTO MAX
TEMP
OFF
SEL MODE
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
Control Logic
Temp Control
FULL COOL FULL HOT
Actuator
Starter Switch ON
Code Description
E0 Normal
E1 Internal air temperature sensor short
E2 Internal air temperature sensor open
E3 Ambient air temperature sensor short
E4 Ambient air temperature sensor open
E5 Duct sensor short
E6 Duct sensor open
E7 Sun sensor short
E8 Sun sensor open
E9 Water temperature sensor short
E10 Water temperature sensor open
E11 D.P.S open
E12 Position error of wind direction actuator
E13 Position error of temperature control actuator
0.5 0.5
FG001067
Figure 93
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 95
HDA6074L
Figure 97
WARNING
Always wear protective glasses and gloves when handling
refrigerant. If refrigerant comes in contact with the skin or
eyes, immediately flush with clean, running water and
consult a physician.
Select a clean and well ventilated area to work.
The refrigerant container is under high-pressure and
should be stored below 40°C (104°F). Be careful not to drop
the container from a high location.
The contents are under high-pressure and should not be
used with compressed air or near an open flame.
UNION NUT
TORQUE WRENCH
CORRECT WRONG
WRONG
WRONG
CORRECT
O - RING POSITION
HDA6066L
Figure 98
RECOVER REFRIGERANT
RUN SYSTEM
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).
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 103
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.
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
WARNING
When charging refrigerant system with the engine
running:
• Always keep refrigerant supply container in
the upright position.
• Never open the high side pressure valve.
WARNING
• When outside temperature is low, warm the
refrigerant supply container with warm
water not exceeding 40°C (104°F). Do not
allow water to come in contact with the
charging adapter valve handle.
• When outside temperature is high, cool off
refrigerant supply container and condenser
to aid the refrigerant charging process.
Reference 4
Description HDA6073L
Number Figure 106
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.
Wiper Circuit
5 6 7
- 2 3 5 (Continuous mode) 3
+
M
8 (Intermittent 1 mode) 4
4 4
10 (Intermittent 2 mode) 5
5 6 11 (Washer mode) 6
1 7 8
12 - + 1
P
1
6 9 13 2
9 2 8
AMP MIC 13P
CN12 CN13 KET 8P
3
AMP MIC 13P 1
3 4 4 6
7 8 9 11 13 9 5
FG000589
Figure 107
Reference Reference
Description Description
Number Number
1 Battery 6 Wiper Controller
2 Battery Relay 7 Wiper Switch Panel
3 Fusible Link 8 Window Washer
4 Fuse Box 9 Wiper Cutoff Switch
5 Wiper Motor 10 Light Switch
Continuous operation
- Operation of wiper motor
Pressing the successive operation switch on the wiper switch
panel (7) changes the voltage of the "5" terminal of the wiper
controller (6) from HIGH (about 5.5 ± 0.5V) to LOW (0+0.5V) and
also current flows via the "3" terminal of the wiper controller (6) →
the "2" and "4" terminals of the wiper motor (5) →the "4" terminal of
the wiper controller (6) to run the wiper motor (5) continuously.
- Stop of wiper motor
Pressing again the successive operation switch on the wiper
switch panel (7) changes the voltage of the "5" terminal of the
wiper controller (6) from LOW (0+0.5V) to HIGH (about 5.5 ±0.5V).
As the "5" and "6" terminals of the wiper motor are connected still
that power is supplied to the "6" terminal of the wiper controller (6),
However, the controller (6) runs the wiper motor continuously
and then rotates the motor reversely by " letting current flow via
the "4" terminal of the wiper controller (6) → the "2" and "4"
terminals of the wiper motor (5) → the "3" terminal of he wiper
controller (6) when the "1" and "6" terminals of he wiper motor
(5) are connected and thus power voltage is supplied to the "7"
terminal of the wiper controller (6).
The Wiper motor (5) stops reverse revolution when the contact
of a cam switch connected to the "6" terminal of the wiper motor
(5) moves to an insulation area of the cam plate to disconnect
the "5" and "6" terminals of the wiper motor (5).
When the wiper motor (5) stops, arm and blade connected to it
move to the stop positions of the right pole in the cabin.
Intermittent operation
- Intermittent 1st (3-second)
Pressing once the Intermittent switch in the switch panel (7)
changes voltage of the "8" terminal in the wiper controller (6)
from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and current flows
through the "3" terminal in the wiper controller (6) →the "2" and
"4" terminals in the wiper motor (5) →the "4" terminal in the wiper
controller (6) to start the cycle that wiper stops 3 seconds after
every operation.
- Intermittent 2nd (6-second)
Pressing twice the Intermittent switch in the switch panel (7)
changes voltage of the "10" terminal in the wiper controller (6)
from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and current flows
through the "3" terminal in the wiper controller (6) →the "2" and
"4" terminals in the wiper motor (5) →the "4" terminal in the wiper
controller (6) to start the cycle that wiper stops 6 seconds after
every operation.
- Stopping the intermittent action
Pressing three times the Intermittent switch in the switch panel (7)
while the wiper is operating stops the action of the wiper motor.
NOTE: The wiper system does not work when the wiper
cutoff switch (9) is "ON."
7
13 87a
30
87
*15 85 86
*16
*9
87a
6
30 87a
*14 87
87
30
85 86
85 86
12
*8
87a
87
30 *5
0 0
86 3 2 2 3
II II
I 5 5 I
4
6 6
7 8 8 7
20A
10 30A
CN6-1 15A
CN6-2
CN6-9
11
L6 CN6-10 3
CN2-6
CN7-4 CN4-4
2
CN7-5 CN4-5 CAN
CN7-6 CN4-6 CN1-1
CN1-2
CN1-8
1
CN1-9
FG000590
Figure 108
Kind of Light
The lighting system is consists of headlights, work lights, cabin
lights (optional), relays and switches.
Operation
Connected Terminal
Switch Position Activated Relay Lit Light
of switch
1 "2-3" Terminal - Illumination Light of Switch
"2-3" Terminal - Illumination Light of Switch
Light Switch Headlight Relay Headlight (2 Ea.)
2
"5-6" Terminal Work Light (2 Ea.)
Work Relay
Symbol Light of Work Light
Front Cabin Light (2 Ea.) or
1 "2-3" Terminal Front Cabin Light Relay
Front Cabin Light (4 Ea.)
Cabin Light Front Cabin Light (2 Ea.) or
"2-3" Terminal Front Cabin Light Relay
Switch Front Cabin Light (4 Ea.)
2
Rear Cabin Light Relay / Rear Cabin Light (2 Ea.) and
"5-6" Terminal
Rear Work Light Relay Rear Work Light (1 Ea.)
10A 20A
4 1
5 CN1-1
7 O CN1-2
5 CN2-15
1 I
10 9
CN1-8
CN1-9
+
CN1-3
SIG
6 CN1-4
-
CN4
CN1 CN2 CN3
ARS1260L
Figure 109
Reference Reference
Description Description
Number Number
1 Battery 4 e-EPOS Controller
2 Battery Relay 5 OWD Selector Switch
3 Fuse Box 6 Pressure Sensor
ANTENNA
7 8 10
MODULE
2 15
3 Vcc(+5V) 9
11 3 16 (LH) (RH)
15A 1 MICOM
4 13
+ - + -
5 Vcc(+5V)
7
3 14
10A 1 DC/DC 17
CONVERTER 1 2 5 2
6 10
10A 87a 3
30 11
87 4
86 85
4
9 10 11 12 13 14 15 16 17 18
1 2 3 4
1 2 3 4 5 6 7 8
1
(Audio Control Panel) (STEREO)
FG000591
Figure 110
Reference Reference
Description Description
Number Number
1 Battery 7 Audio Control Panel
2 Battery Relay 8 Stereo
3 Fuse Box 9 Speaker
4 Fusible Link 10 Antenna Module
5 Converter 11 Light Switch
6 Stereo Relay
Connected Terminal of
Switch Measured values Operations
switch
PWR 4.36 ± 0.2V Stereo ON, OFF
1.24 ± 0.2V Volume up
"3-4"
0 + 0.2V Volume down
SCAN 2.49 ± 0.2V Frequency selection
1Electrical
Schematic
DX300LCA /
DX340LCA
Edition 1
Electrical Schematic
DX300LCA / DX340LCA
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
DX300LCA / DX340LCA....................................... 7
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.
+
129B 0.85RG 30 3RY TELESCOPIC BEACON M
1.25RG 0.85RG 129C 51B 8 (INT-1) 4 CONT. POWER
1.25RG 3RG 51A 87 33C
0.85LR 160A 0.5LY 160B
(RR) 0.85Or 156A 4 0.85LB 4 156B
0.85B 0.85B (RH) L 36B 0.85R 0.85G 37B 1 0 161A 10 (INT-2) 0.5LG 5 161B INT SEEK ANTENNA
1.25B 0.5B 85 86 0.5RG ROTATING 2 36A
0.85B 88B 3 I WASHER VOL.
(REAR) BEACON SWITCH 162A 11 (WASHER) 0.5L 6 162B
REAR WORKING LAMP 87a 0.85RG 129D 55C 0.5B 7 8 54L
+
30 125E 1.25RL (549-00101/K1002406D3) STOP RUN B 88H 0.85BR
(534-00085) 51C 0.5WR
1 WINDOW WASHER MODULE
00
CAR STEREO
1.25RG 87 (RL) 1.25RG ROTATING BEACON 124B M 157B 0.85WL 7 157A
129A 0.85B 1 0 LOWER WIPER SW (K1054553) (K1002641 ) (300654-00037)-RADIO
WORKING LAMP RELAY (534-00062) S 37A 0.85G 0.85G
(LH) 2 0.85RG - (549-00101/K1002406D5)
158B 5 0.85WB 6 158A 35C 12 0.85RB - + 0.85L 1 34E
0.5B 85 86 128B 0.5RG 1.25B 1.25B 00 (301202-00042) 33B 0.85Or 33A 3 (300637-00009)-MP3
127B 0.85RG CABIN LAMP I E 0.85B 0.85BR 0.85BR P SPEAKER
63C 6 35A 34C 2 121B 0.5WG 121A 15
(534-00085 )x2 0.85B 0.5B 7 8 0.5WR Vcc(+5V) (2541-9020 )x2
(FR) 0.85B 0.85WR 0.5RB 0.5L
LOWER WIPER MOTOR 3 123B 0.5W 123A 16 (LH) (RH)
52D (538-00012 )
WIPER MOTOR 35B 34D 54D MICOM
CABIN LAMP RELAY 2 HEAD LAMP 87a 54K 0.5WR 1
(538-00011) DIODE 5
127C 0.85RG (2544-9033 ) (534-00085) 30 1.25R 4 169A 169B 13
53B 34B 1 0.85L 0.85L 0.5BL
CABIN LAMP SWITCH 0.85RW 1.25RW 53A 87 + - + -
(FMR) 0.85B 130B 13 0.5RW 2 54C
(549-00103/K1002406D13 ) (RH) LAMP SWITCH (549-00103/K1002406D11) 0.5WR
0.85B 0.5B 85 86 0.5RG CN14 MOLEX 4P Vcc(+5V) 117B 118B 119B 120B
2B 0 125B 0 0.85B 0.85Lg 9 138A 99 2 0.85B 0.5B 8
87a 55B 2 52B 3 54I 117A 7 0.5GrR
(FRONT) 0.5WR 126A 3 I 2 0.5RL 0.85WR 54A 3 I 0.85R 138B AMP MIC 13P 0.5WR
30 125D 3RL 17
87 II 53C II WIPER CUT SW CN12 CN13 KET 8P 118A 0.5BY
127D 0.85RG 3RG 127A
(FML) 0 125C
0.85RW HEAD LAMP RELAY
0
00
FUEL PUMP (OPT) (549-00086 ) 19D 119A 2 0.5GrL
0.85B 85 86 126B (LH) (2544-9033 ) 0.85BR 0.85WR 5
0.5B 5 0.85B I 5 52C 0.5R
I 0.5RL 120A 10 0.5BW
0.5WR 0.5WR 14
0.5RG 128A 6 II 0.5RG 55A 6 II
FUEL PUMP 11 0.5B
127E 0.85RG 7 8 0.5WR 0.5B 7 8 54G 0.5WR
0.5B (401-00449)-DX220LC,DX300LC
CABIN LAMP RELAY 1 FUEL PUMP SW 0.85R 132A 2
(FL) 0.85B 54F (401-00527)-DX340LC DC/DC 99
00 (301202-00042) SEAT HEATER (OPT) 1.25R
(549-00093 )
12V POWER + 132B 3 CONVERTER
1 0.85LR 0.5BR 0.5BR 4 88C 0.85B
2B 3RL 1.25B 64B 1.25WL 64A 1 2 63B 1.25WR SOCKET 131B
CABIN LAMP (2531-1003 )
3RY P STARTER RELAY 1
1 (527-00006) - 99
(534-00085 )x2 0
0.85WR (2544-9033 )
2 143B 1.25RB
1.25B 144B 144A 3 0.85B 87a
1.25R I (2544-9033 ) 30 0.85Y
LCD GAUGE PANEL STARTER CONTROLLER
8 54Q 13E 87
00
(300426-00010A) 00 REAR VIEW CAMERA 0.5B 7
SEAT AIR SUSPENSION (OPT) 1.25RB 1.25RB 0.85L 176B A (2543-9015 ) 0.85LR
5A
(K1039941) SEAT HEATER N S 14B 0.85BW 14A 85 86
195A 195B
0.85WR
CN6-4 0.5Y 1.25R
0.85BR
V+ 9V AIR SUSPENSION 174A P1
0.5RW
(545-000 ) 0.85LY
0.85L
SEAT HEATER SWITCH 0.85L ENG STOP RELAY
196A 196B (401-00 ) 87a 174B 12B
V- CN6-5 0.5YB (549-00101/K1002406D1) 3RY 176A 0.85LR 19C B
1.25B 143C 1.25RB 30
Sig 197A CN6-6 0.5YL 197B P 0.85RG 0.85RG A
87 175B 0.85LW 175A P2 18B
Sig Gnd 198A CN6-7 0.5YW 198B 0.5RG
0.85BL
85 0.85B E E B P
0.85Y
CIGAR LIGHTER 86 0.5B 0.85B
CN6-3 54B 0.5WR 0.5WR 0.5WR (300730-00006) 13B
1.25WG
ILL. 13D STARTER RELAY 2
CN6-1 28B 0.5R 0.85R 0.85R (2544-9033 )
0.5LR ENG STOP MOTOR 0.85LR 87a
3RL 0.85BL
CN6-2 28C 0.5R 3RL (2523-9016 )
PILOT BUZZER 0.5RW 0.85BY 30
(2516-1116 )
1.25B 87 12A
11B
L1 1.25RB
+
0.5R 28G TRAVEL/SWING ALARM ASS’Y (OPT) FUEL HEATER (OPT) 0.85RY
0.5LR 86 85 0.5GB
L2 CN6-12 29B 0.5WB 29A - 62B 13C STARTER
89A
1.25W 0.85LR (300516-00020) 24V 7KW
L3 + 31B 0.85RY 0.85RY 87a
CN6-11 130D 0.5RW ALARM BUZZER 0.5GB 5C
1.25WR
- 0.85B 30 20C 2RG 0.5RG
0.85WR
0.85RG
0.85RY
0.85BR
1.25R
0.85R
1.25W
0.85LR
(516-00011 ) 0
/0.85LR
L4 59A 87
2RG
2RY
0.85L
3RL
3 2 87a 30B 2R 1 0
0.5P I 0.5W 59B 2
CN6-9 99 0.5B 30 85 86
L5 104C II 32B 0.85RG 0.5B 0.5RY 39A 3 I 125A 50A 20A 28A 52A 63A 124A 179A 62A 131A 34A 88A 19A
CN6-10 99 0.5B 31A 87 20B
0 39B 0.5B 7 8
L6 9 10 11 12 13 14 1 2 3 4 5 6 7 8 6A 1.25WR
I 5 0.5W 0.5W 85 86 0.5RG
0.85B 122B 0.85V 122A 6 54K 30A 20A 15A 15A 15A 15A 10A 10A 10A 10A 10A 10A 10A 10A
II 32C 32A FUEL HEATER
1.25WR
30C FUEL HEATER 1.25WR 2WR
0.85LR
0.85BY
OVER LOAD WARNING (OPT) 4bar
7 8 0.5WR
FUEL HEATER RELAY
(2544-9033 )
SWITCH
4G
17 18 2E
4D
15
2B
16
11A
54M ALARM RELAY (549-00101/K1002406D2) 15R 98A B
SWING PRESS SW (2544-9033 )
ALARM SWITCH 5W 5W ACC C
(549-00010 ) 0.5B 2B FUSE BOX 2 FUSE BOX 1
OVER LOAD (549-00103/K1002406D14) 5W 5W 13A
ONLY SWING (OPT) (K1001263 ) (K1001263 )
WARNING SWITCH B
(549-00102/K1002406D4) 0.5BW 4F 2D 4E 10A 6B BR 0.85Br
1 0
2 140B
0.5RG 0.5LB 15 16 2WR 17 18 2C 2WR R2
0.5BrY 57B 0.85RY 7A
0.5B 3 I 0.5RW 0.5RW HORN 1 A
H.F HORN RELAY 10A 10A 10A 10A 10A 10A 10A 10A 30A 20A 15A 15A 15A 15A R1 STARTER SWITCH
(300726-00002) 0.85B
0.5B 7 8 54P 0.5WR 0.5WR 0.5WR (2544-9033 ) (K1001654 )
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15A
WARNING LAMP 87a 60B
1.25RB
0.85BW
0.85RY
0.5RW
0.5WR
30 56B 0.85RB
0.5GB
0.5BG
0 56A 66A 30A 93A 177A 40A 130A 83A 42A 133A 143A 21A
L1 : CHARGE 28D 0.85R CN5-4 140A 141A 3 2 21B 57C 0.85RY 57A 87
+ I 0.5RL 0.85RY 60R
HORN 2 FUSIBLE LINK
0.85WR
L2 : ENG OIL PRESS
1.25BrR
1.25RB
0.85RB
1.25RL
0.85RG
0.85LB
0.85RL
0.85Y
0.85RB
0.5RW
PRESSURE SENSOR 139B 0.85BrW CN3-5 139A II L.F 0.85B 85 86 (2527-1023A)
CN2-6 56C 0.5RB
2LR
L3 : W/T OVER HEAT 55D 0.5RG (300726-00003) 0.5G 58A
(OWD) SIG
145A 0.85W CN3-6 145B 0
L4 : E/G WARNING - 141B CN2-4 0.5BrB (MANUAL) 5 21L
(2547-9045 ) I 0.5RL 0.85LB 2WR 2WR 2WR 2R
L5 : PREHEAT CN3-15 90A (DX220DTC) 22B CN2-5 0.5BrW (AUTO) 22A 6 II
+5V 0.85RG 0.85RG 0.85Br 2A 1B
L6 : WORK LAMP 28E 0.85R 8 54H
+ 15C CN2-13 0.5BW PREHEAT 0.5B 7 0.5WR 7B 0.5G
PRESSURE SENSOR(A) 0.5BW 0.5BW 0.5BW
LCD DISPLAY PANEL 74B 0.85GR CN3-1 74A 178B CN1-16 0.5LB AFTERHEAT
(FRONT PUMP) 00
SIG 0.85Y 0.85RY
HIGH SPEED SWITCH 0.5LB
WATER TEMPERATURE (2547-9045 ) 75A 0.85W CN3-2 75B DIODE 2 BATTERY RELAY
- 10B CN2-1 0.5BG KEY SW ’START’ (549-00097 ) 0.5BG 0.5BG 0.5BG CIRCUIT BREAKER
FUEL LEVEL (2544-9024 ) 2R
0.85BW
(K1048145) - DX220DTC (2527-9004 )
89B CN1-15 0.5GB START RELAY 0.5GB 0.5GB 0.5GB 8A 1A
28F 0.85R B
+ Py A
GRAPHIC DISPLAY 0.5G 1.25BrR 8W 8W 8W
76B 0.85GY CN3-3 76A 104A CN2-15 0.85P 104B 0.85B AUTO IDLE (1)
PRESSURE SENSOR(B) SIG
/ TRAVEL SW 0.5RW 0.5RW 0.5RW 4B 3B 3A
(REAR PUMP) 00 77A 0.85WL CN3-4 77B 19bar
- (2549-9112 ) 1.25BrW
(2547-9045 ) 21C CN1-1 0.85RL 0.5WR 0.5WR 15B 1.25BrW 8C BR
(K1048145) - DX220DTC 21D CN1-2 0.85RL 1.25RL 1.25RL 1.25RL 1.25RL
0.5GBr 192B E
CN4-8 9D 3 6C DIODE 7
9D CN2-14 0.5RW ALT ’I’ 0.5RW 0.5RW 0.5RW 1 0.5WR 1.25B
CN4-12 192A 8B
NC 0.85RL 0.5B 2 HOUR MASTER SWITCH 60R
120 COM 40B 0.85Y 0.5WR 10C
SOL-VALVE ASS’Y 0.85RB 00 (K1057605)
99 CN1-8 0.85B 0.85YG 41A NO HOUR METER
CN7-4 80A 80B
0.5BG
0.5Y CN4-4 (426-00262 ) DIODE 1 60B 1 2 60B 60R
15R
0.85B (2528-9043 ) 0.85BG
CN7-5 81B 99 CN1-9
81A 0.5YB CN4-5 0.85YG 41B PILOT CUT-OFF SWITCH
(C1) OFF 10W AFTER HEAT RELAY
CN7-6 82A 82B CN4-6 41C (549-00089 )
SHIELD 3 PILOT 0.5B E DR B+ (2544-9033 ) 9B
DA4-1 87a
120 CN7-8 191B 1 CUT OFF
0.85B 99 ON 83B 30
0.5RB 177C - + - +
CN7-7 191A
1
135B 0.5GL 135A CN4-1 TxD 0.85YL 0.85YL 61C (C2) QUICK CLAMP(OPT) 87 10D 0.5BG
12V 12V
136B 136A RxD 61B ROOM LAMP 86 85 178A PREHEAT FUSE
0.5GW CN4-2 RS-232 DA4-2
4
0.5RB 177D 0.5LB 00
2 BREAKER (534-00079 ) (300803-00086) BATTERY
CN7 CN6 137B 137A GND (고정) 1
0.5RG CN4-3 2
0.85B 99 (2506-6008)x2 - DX300LC, DX340LC (150AH)
101A 200A
DIAGNOSTIC
0.85BG
CONN
15W
0.5YB 6 21J HIGH 84B 84A
5 DA1-2 84C 0.5RW 0.5RW AVX
SPEED 0.85RY 2RW
TML 82C SHIELD 24C CN1-12 0.85Gr 24B 2 0.85Gr 24A QUICK CLAMP SW
1.25BrR
B BR R1 R2 C ACC 6 AIRCON UNIT
0.85RB
PST
0.85RL
DIODE 6 (549-00092 ) 0.5WR
0.5G
0.85RL 0.85RL 21E (920-00127A) 18A 4A 9A
OFF (C4)
~ 0.5RW P(R) B(B+) R(I)
CN4 AMP 040 12P
185A 0.5B CN4-7 185B 5 21H RELIEF SOL-VALVE 42C 10E 101B 15B
PREHEAT 14 DA1-1 LED 1~12 1.25LR CN11-2
28G 0.85R 130C CN9-6
23C CN1-11 0.85GrW 23B 1 0.85GrW 23A PRESS UP 0.85B C B
AMP MIC 21P
DIODE 11
5
DA1-3 0.5BW SG
99 SELECT DIODE 9 RECEIVER DRIER
1 0.85B 99 0.85LR
0.85YL 0.85GY (2204-6039A )
CN1
(545-00011 ) 9 107B CN8-12 0.5LW CN10-1 107A BLOWER MAGNET ALTERNATOR 50A - DX300LC,DX340LC (2502-9009 )
(300611-00138) 0.85BrB 94A 93B 0.85RL 0.85LW
0.5WR 54J 47C CLUTCH (300901-00034)
1.25BrR
CN11-4 ALTERNATOR 60A - DX220LC
0.85RB
0.85RY
72B CN3-7 72A
0.5WR
0.85YR 10
0.5G
FUEL SENSOR 0.85RY 151A 108A CN9-13 0.5GrG CN10-2 108B FRE (P1) 47A 47B ALTERNATOR 80A(OPTION) (300901-00033)
73B 0.85BR CN3-8 73A 3 INTAKE
(301316-00016) 101A CN1-10 0.85Or 101B 1 109A CN9-12 0.5GrY CN10-20 109B REC (P2) ACTUATOR
0.85BrR 133G
DIODE 4
5 0.85LgR 14 M
P/V-(A)
94B 2 95A 95B 0.85BrR 133H
26B 0.85LgR CN3-9 26A 13
0.85RL 150A 110A CN9-15 0.5OrR CN10-12 110B DEF (P1) 0.85B 0.85B
OIL TEMP SENSOR 102B CN1-21 0.85OrB 102A 3
27B 0.85LgW CN3-10 27A 6 0.85LgW 11
(K1003296) 111A CN9-14 0.5OrW CN10-13 111B VENT (P2)
4 M
0.85B 96B 96A 6 MODE TERMINAL NO
PUMP 43A CN9-16 0.5YB CN10-11 43B Vref MODE
0.5BrW 60A ACTUATOR
TERMINAL NO PROPORTIONAL V/V 16
AUXILIARY MODE SW 0.85BrL 134B 44A CN9-17 0.5YW CN10-10 44B MODE F/BACK
(549-00090 ) 15
0.85YL 61A 99 CN9-10 1.25B AMP MIC 13P AMP 070 18P AMP MIC 21P
78A CN1-19 78B 12
KET 118 9P DIAGNOSTIC CONN. 14P 0.85Lg 1 2 3 4 5 6 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
P/V-(C) (OPTION)
4 3 2 1 JOYSTICK LEVER SWITCH 112A CN9-1 0.5LgW CN10-19 112B WARM (P1)
FLOW CONTROL
79B CN1-20 0.85LgB 79A (420-00469 ) 7 8 9 10 11 12 13 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 201B 0.5LG CN3-18 201A ECO PROPORTIONAL V/V 113A CN9-18 0.5LgB CN10-3 113B COOL (P2)
M
9 8 7 6 5 3 2 1
0.5RW ROTATING S/V (OPT) 0.5B 99 6 3 58B 0.5G (CN12) WIPER CONT. (CN2) (CN1)
15 163B CN1-3 163A STD Px 114A CN9-3 0.5YR CN10-7 114B Vref MIX MIX
(CN13) 7 6 5 4 (426-00263 ) (HORN) (C)
103A 103B
AMP MIC 17P
10 164B 0.5WG 164A A/I CN2-16 0.85V 0.85B AUTO IDLE (2) SW 115A CN9-4 0.5YW CN10-9 115B MIX F/BACK ACTUATOR
CN1-4 AMP 040 28P AMP 070 16P AMP 040 12P AMP 040 20P
TIER-2
11 10 9 8
19bar (2549-9112 ) 146C 146B 1 0.85OrB 0.85OrB 146A 4 1 133B 0.85BrR
14 13 12 14 165B 0.5YL CN1-5 165A W/M CCW 167C CN9-2 1.25BL CN10-4 167A GND
MOLEX 4P 3 (ROTATE-CCW) (L)
17 166B 0.5LG CN1-6 166A O/H 67A CN2-17 0.85BW 67B 0.85B INDICATOR DA5-1 8 7 6 5 4 3 2 1
(A) 6 5 4 3 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
0.85RY
0.5WR
0.85RB
(170-00004) 1 0.85OrR 147A 5 2 133C 0.85BrR 116A CN8-2 0.5OrB CN10-15 116B
12 0.85B ENG CONTROL MOTOR DUCT 12 11 10 9 8 7 16 15 14 13 12 11 10 9 12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11
CN16
(CN14) 4 153A 147C 147B 2 0.85OrR (CN7) (CN6) (CN5) (CN4) (CN3)
0.85GW 153B P4 (471-00075) CW (ON JOYSTICK L.H)
(+) 4 45A CN8-1 0.5LgR CN10-14 45B
(B) DA5-2 WATER AMP 040-III 20P
AMP MIC 17P
AMP MIC 17P M 69A CN5-3 0.85RB 69B 0.85B PEDAL SWITCH SENSOR KET D/L 4P AMP 070 18P AMP 070 12P
2 3 0.85B
(-) 5 154B 0.85Y 154A P5 RETURN FILTER SW 0.85BrL 134C 133J 0.85BrR 2 2 1 8 7 6 5 4 3 2 1 5 4 3 2 1
8 7 6 5 4 3 2 1 1.0bar (549-00094 ) 9 8 7 6 5 4 3 2 1
P3 RETRACT 48A CN8-5 0.5LY CN10-17 48B 1 INCAR
CN5
3 6
(SHEAR-CLOSE) (L) 49A CN8-4
GND 92B CN3-17 0.5GB 92A 3 0.85YG 0.85YG 49B 1 SENSOR
(426-00263 ) 2
5 6 7 8 3 4 HIGH DA6-2 (547-00024A )
149C 149B 2 0.85Or 0.85Or 149A 5 2 151K 0.85BrR CN8 CN9
(OPEN)
ENGINE CONTROL DIAL (SHEAR-OPEN) (R)
(300611-00004)
8
149D AMP 12P + 18P
1 90A 0.5GR 0.5GR DA6-4
1 2 3 4 1 2 +(5V) 4 3 0.85B JOYSTICK LEVER SWITCH A/C CONTROL PANEL 2-PUMP CONTROL (OPTION)-DX300LC,DX340LC
2 91C 0.5G 0.5G (543-00107 ) 0.5WR
SIG (420-00468 )
0 1
3 92C 0.5GB 0.5GB (ON JOYSTICK R.H) 179B 2
DA1 ~ DA3 DA4 ~ DA6 GND 0.85RY
3 180A 180F 180C 2-PUMP S/V
9 177B 0.85RB 0.85RB 0.85RB 0.85RB I 0.85BrW 0.85BrW
0.5WR 54R 8 7 0.5B DIODE 8
70F 0.85GB 70C
2-PUMP SWITCH
(549-00101/K1002406D22)
Edition 1
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.
F
E
G
C
D
K
H
B I
FG004069
Figure 1
DANGER
DOOSAN warns any user, that the removal of the
counterweight from the machine, front attachment or any
other part, may affect the stability of the machine. This
could cause unexpected movement, resulting in death or
serious injuries. DOOSAN is not liable for any misuse.
Never remove the counterweight or front attachment unless
the upper structure is in-line with the lower structure.
Never rotate the upper structure once the counterweight or
front attachment has been removed.
FG000371
IMPORTANT Figure 2
WARNING
This procedure is only intended for routine removal or
replacement of the attachment, while working under
normal, safe operating conditions. In the event of a major
structural collapse of some part of the attachment, an
accident or complete loss of attachment hydraulic function,
DO NOT proceed with attachment disassembly unless you
are completely sure of what you are doing. Please call your
local DOOSAN distributor or DOOSAN After Sales Service
for assistance. DO NOT allow personnel to stand
underneath a weakened or only partially supported
attachment section. Keep clear of hydraulic lines that may
have fluid escaping at high-pressure - it can cause severe
or even fatal injuries.
WARNING
Secure the swing lock and tag and lock out controls in the
operator's cabin to keep anyone from moving or
inadvertently starting the engine. Restrict access to the
work site while sections of the attachment are in the air, or
while they are being supported by the assist crane. The safe
lifting capacity of the assist crane or hoist that is used must
exceed the weight of the heaviest section of the attachment,
the boom (approximately 2,000 kg [4,400 lb], not including
the weight of accessories or fixtures).
CAUTION
To make sure that the polished surfaces of cylinder rod
ends will not suffer accidental damage during disassembly
or removal procedures, wrap exposed rod surfaces
(especially those of boom cylinders) with a protective
covering material. Immediately following disassembly and
removal, cylinder rods should always be fully retracted.
This eases handling problems and also avoids possible
damage.
WARNING
Traveling the excavator, swinging the turntable or
movement over bumps or sloping, uneven surfaces could
all produce loss of control and possible accidents or
injuries, if the turntable deck has been unbalanced by
removal of weight from one end only.
WARNING
Before assembling the front attachment, make sure that the
individual boom, arm and bucket sections are all
compatible and can be used safely for work intended. Refer
to the General Safety Pages, Lift Ratings, Working Range
Diagrams and Weights of Materials sections in the
Operation and Maintenance Manual. Consult your dealer or
DOOSAN After Sales Service for more information if you
have any questions or require more information.
1Bucket
Edition 1
Bucket SP001852
Page 1
MEMO
Bucket SP001852
Page 2
Table of Contents
Bucket
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
Bucket Tooth Inspection and Replacement .......... 6
Bucket O-ring Replacement ................................. 7
Bucket Shimming Procedures .............................. 9
New Bucket Installation ................................................... 9
Bucket Attachment, Removal and Reversal ....... 11
Detaching the Bucket .................................................... 11
Attaching the Bucket ..................................................... 11
Reversing the Bucket .................................................... 12
Bucket SP001852
Page 3
MEMO
Bucket SP001852
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.
Bucket SP001852
Page 5
BUCKET TOOTH INSPECTION
AND REPLACEMENT
There are several different types of attachment methods for
replaceable bucket teeth. Some of the most common types are
shown in the following drawings.
Bucket teeth are usually replaced in sets but it may sometimes
be necessary to replace individual teeth.
Look for the following indications of wear or damage:
• Lock pins protrude unevenly on one side.
• Lock pins have been worn down so far that they no
longer make full contact through the length of the pin
hole.
• Lock washers or pins show obvious damage or
weakness.
• Wear points on the working surfaces of tooth points -
pits, cracks, chips or craters - are larger than 8 mm to
10 mm (1/3" to 1/2") across.
FG004607
Figure 1
HDO5057I-1
Figure 2
3. Once the worn tooth has been removed, use a putty knife 3
to scrape the adapter as clean as possible.
4. Slide the new tooth into position and insert the lock 2 1 FG000346
washer. Figure 3
5. Insert the locking pin into the tooth and with a hammer,
drive the pin in until the lock washer seats in the locking
groove.
Bucket SP001852
Page 6
BUCKET O-RING
REPLACEMENT
WARNING
Due to possibility of flying metal objects, always wear
safety helmet, protective gloves and eye protection when
changing pins.
ARO1350L
Figure 4
2. Roll the old O-ring (1, Figure 5) onto the boss (2) around
the bucket pin (3). Remove the bucket pin and move the 1 4
arm or bucket link (4) out of the way. 2
ARO1390L
Figure 5
ARO1391L
Figure 6
Bucket SP001852
Page 7
5. Roll the new O-ring (1, Figure 7) into the O-ring groove.
ARO1392L
Figure 7
Bucket SP001852
Page 8
BUCKET SHIMMING
PROCEDURES
WARNING
When performing this adjustment, put the hydraulic
cativation control lever in the LOCKED position and stop
the engine.
Improperly adjusted clearance could cause galing on the
contact surfaces of the bucket and arm, resulting in
excessive noise and damaged O-ring.
3
1 2 8 7
5 10
9 4 6
FG000415
Figure 8
Reference Reference
Description Description
Number Number
1 No Gap 6 Stopper
2 Arm Boss 7 Bolt
3 Bucket Clearance 8 Hard Washer
4 Shim 9 Flange
5 Pin 10 Bucket Boss
Bucket SP001852
Page 9
Shimming Procedures for Installed Bucket
The clearance of the bucket linkage on this machine can be
adjusted by shimming. If the gap between the bucket and the
arm becomes excessive, adjust bucket clearance to 1.0 mm.
The thickness of the shims are 1.0 mm (0.04 inch)
1. Position the machine on a level surface and lower the
bucket to the ground.
2. Slowly operate the swing control lever until arm boss (2)
and the bucket boss (10) are in full face contact at no gap
(1).
3. Place the hydraulic activation control lever in the LOCKED
position and stop the engine.
4. Measure bucket clearance (3), determine the number of
shim that need to be removed from shims (4) by using the
following calculation;
Subtract 1mm from bucket clearance (3).
5. Remove the appropriate number of shim at location (9) in
order to meet the above thickness. To remove the shim,
detach stopper (6) and bolts (7) from bucket.
6. After correcting the number of shim, install stopper (6) and
tighten bolts (7).
NOTE: Bolt torque: 27 kg•m (195 ft lb)
7. After installation, make sure that bucket clearance (3) is
still correct.
Bucket SP001852
Page 10
BUCKET ATTACHMENT,
REMOVAL AND REVERSAL
CAUTION
Use care pulling out the pin to avoid damaging the dust
seals on either end of the arm.
When the pin has been withdrawn, move the operating joystick
slightly to take weight off the remaining link pin. Disassemble the
link pin end retainers and pull out the pin.
Lift the arm away from the bucket so that the bucket can be carried
away or another end attachment can be put on the excavator.
When the link pin has been installed, withdraw the temporary
support rod from the bucket pin holes, lower and raise the arm
and boom and install the bucket pin.
WARNING
When making linkage alignments, never insert fingers into
pin holes. The attachment or bucket could shift position
and cause a severe injury. Match holes by visually lining
them up. Use the sharp-tipped, soft point of a pencil or a FG000607
similar tool to check for high spots or irregularities. Figure 10
Bucket SP001852
Page 11
Reversing the Bucket
Follow instructions for "Detaching the Bucket" and remove both
the bucket and link pins. Rotate the bucket 180° to change
bucket configuration. This procedure is greatly simplified if some
type of rotating or swiveling support can be used, on the ground
underneath the bucket. Follow instructions for "Bucket
Attachment" to replace pins.
WARNING
Bucket curl and dump levers must be used in opposite
directions, after the bucket has been reversed.
Bucket SP001852
Page 12