Doosan DX140R Shop Manual
  1. Manuals
  2. Brands
  3. Doosan Manuals
  4. Excavators
  5. DX140R
  6. Shop manual

Doosan DX140R Shop Manual

Hide thumbs Also See for DX140R:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
733
734
735
736
737
738
739
740
741
742
743
744
745
746
747
748
749
750
751
752
753
754
755
756
757
758
759
760
761
762
763
764
765
766
767
768
769
770
771
772
773
774
775
776
777
778
779
780
781
782
783
784
785
786
787
788
789
790
791
792
793
794
795
796
797
798
799
800
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
818
819
820
821
822
823
824
825
826
827
828
829
830
831
832
833
834
835
836
837
838
839
840
841
842
843
844
845
846
847
848
849
850
851
852
853
854
855
856
857
858
859
860
861
862
863
864
865
866
867
868
869
870
871
872
873
874
875
876
877
878
879
880
881
882
883
884
885
886
887
888
889
890
891
892
893
894
895
896
897
898
899
900
901
902
903
904
905
906
907
908
909
910
911
912
913
914
915
916
917
918
919
920
921
922
923
924
925
926
927
928
929
930
931
932
933
934
935
936
937
938
939
940
941
942
943
944
945
946
947
948
949
950
951
952
953
954
955
956
957
958
959
960
961
962
963
964
965
966
967
968
969
970
971
972
973
974
975
976
977
978
979
980
981
982
983
984
985
986
987
988
989
990
Table of Contents

Advertisement

Quick Links

EXCAVATOR
Shop
Manual
DX140R / DX140LCR
Serial Number 5001 and Up
K1049551BE
July 2011

Advertisement

Chapters

Table of Contents
loading
Need help?

Need help?

Do you have a question about the DX140R and is the answer not in the manual?

Questions and answers

daniel ARSICAUD
April 12, 2025

couple de serrage de la culasse moteur cummins B4.5-99C

0

Related Manuals for Doosan DX140R

Summary of Contents for Doosan DX140R

  • Page 1 K1049551BE July 2011 EXCAVATOR Shop Manual DX140R / DX140LCR Serial Number 5001 and Up...
  • Page 3 Shop Manual DX140R / DX140LCR EXCAVATOR Serial Number 5001 and Up DOOSAN and the DOOSAN logo are registered trademarks of DOOSAN Corporation in the United States and various other countries around the K1049551BE world. July 2011 Copyright DOOSAN 2011 Operation and Maintenance Manual...
  • Page 5 Product Label Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine Pub. No. K1049551BE...
  • Page 7 Table of Contents Safety Track Excavator Safety................. SP002281 Specifications Specification for DX140LCR ..............SP002379 General Maintenance General Maintenance Procedures ............SP000016 Standard Torques ................. SP000813 Upper Structure Cabin ....................SP002282 Counterweight..................SP001939 Fuel Tank....................SP001940 Fuel Transfer Pump ................SP000021 Swing Bearing..................
  • Page 8 Cylinders....................SP000030 Swing Motor..................SP001943 Travel Moter..................SP001346 Main Pump.................... SP001945 Main Control Valve ................SP001029 Remote Control Valve (Work Lever / Joystick) ........SP001646 Travel Control Valve (with Damper)............SP002262 Solenoid Valve Assembly ..............SP001944 Breaker EPPR Valve (Opt) ..............SP000192 Hydraulic Schematic (DX140LCR) ............
  • Page 9 Safety...
  • Page 11 SP002281 TRACK EXCAVATOR SAFETYSP002281 Track Excavator Safety Edition 1 Track Excavator Safety SP002281 Page 1...
  • Page 12 MEMO Track Excavator Safety SP002281 Page 2...

  • Page 13: Table Of Contents

    Table of Contents Track Excavator Safety Safety Precautions ..........5 Applicable Models ..........5 To the Operator of a Excavator ......6 General Safety Essentials ........9 Location of Safety Labels ........10 Summary of Safety Precautions for Lifting in Digging Mode .............
  • Page 14 MEMO Track Excavator Safety SP002281 Page 4...

  • Page 15: Track Excavator Safety

    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.

  • Page 16: To The Operator Of A Excavator

    TO THE OPERATOR OF A EXCAVATOR DANGER Unsafe use of the excavator could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
  • Page 17 In no event should you or others engage in prohibited uses or actions as described in this manual. DOOSAN delivers machines that comply with all applicable regulations and standards of the country to which it has been sent. If this machine has been purchased in another...
  • Page 18 Safety precautions are described in SAFETY from page -10 on. DOOSAN cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions.

  • Page 19: General Safety Essentials

    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.

  • Page 20: Location Of Safety Labels

    LOCATION OF SAFETY LABELS Location of safety labels (decals) can vary from unit to unit. Refer to appropriate Operation and Maintenance Manual, and parts manual for your unit. Always replace damaged or faded decals. Track Excavator Safety SP002281 Page 10...

  • Page 21: Summary Of Safety Precautions For Lifting In Digging Mode

    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 your individual operating environment, please consult your local DOOSAN representative. Track Excavator Safety SP002281 Page 11...

  • Page 22: Unauthorized Modifications

    UNAUTHORIZED MODIFICATIONS Any modification made without authorization or written approval from DOOSAN can create a safety hazard, for which the machine owner will be held responsible. For safety's sake, replace all OEM parts with the correct authorized or genuine DOOSAN part. For example, not taking...
  • Page 23 Inside Operator's Cabin When entering the operator's cabin, always remove all mud and oil from the soles of your shoes. If you operate the travel pedal with mud or oil stuck to your shoes, your foot may slip and this may cause a serious accident.
  • Page 24 Breathing Masks, Ear Protection May Be Required Do not forget that some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause disabling or permanent injuries. NOTE: equivalent continuous A-weighted...
  • Page 25 Recommendations for Limiting Vibrations Select the right machine, equipment and attachments for a particular application. Replace any damaged seat by a genuine DOOSAN part. Keep the seat maintained and adjusted. • Adjust the seat and suspension for the weight and size of the operator.
  • Page 26 Mounting and Dismounting Before getting on or off the machine, if there is any oil, grease, or mud on the handrails, steps, or track shoes, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts. Never jump on or off the machine.
  • Page 27 Precautions When Handling Fluids at High Temperature Immediately after operations are stopped, the coolant, engine oil, and hydraulic oil are at highest temperatures and the radiator and hydraulic tank are still under pressure. Attempting to remove cap, drain the oil or coolant, or replacing the filters may lead to serious burns.
  • Page 28 Injury from Work Equipment Do not enter or put your hand, arm or any other part of your body between movable parts, such as between the work equipment and cylinders, or between the machine and work equipment. If the control levers are operated, the clearance between the machine and the work equipment will change and this may lead to serious damage or personal injury.
  • Page 29 If any glass on the machine is broken, replace it with new glass immediately. 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...
  • Page 30 When carrying out disassembly or maintenance of accumulator, when disposing accumulator, the charged gas must be properly released. Contact your DOOSAN distributor. • Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil under pressure can penetrate the skin and cause serious injuries.
  • Page 31 Emergency Exit This machine is equipped with a glass breaking tool. It is on the upper left pillar 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.

  • Page 32: Before Starting Engine

    BEFORE STARTING ENGINE Work Site Precautions Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. Check the terrain and condition of the ground at the work site, and determine the best and safest method of operation. Make sure the ground surface is as hard and horizontal as possible before carrying out operations.
  • Page 33 Avoid operating your machine to close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground collapses, the machine could fall or tip over resulting in serious injury or death. Remember that soil after heavy rain, blasting or after earthquakes, is weakened.
  • Page 34 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.
  • Page 35 Before Operating Machine If checks are not carried out properly after starting the engine, it may result in a delay in discovering abnormalities in the machine, and this may lead to personal injury or damage to the machine. Carry out the checks in an open area where there are no obstructions.

  • Page 36: Machine Operation

    MACHINE OPERATION When Swinging or Changing Direction of Travel Before operating the machine or the work equipment, always observe the following precautions to prevent serious injury or death. • Start and operate the machine only while seated. • When changing travel direction from forward to reverse or from reverse to forward, reduce speed early and stop the machine before changing travel direction.
  • Page 37 When traveling over bridges or structures on private land, check first that bridge or structure can withstand the weight of the machine. When traveling on public roads, check with the local authorities and follow their instructions. Traveling on Slopes Never jump onto a machine that is running away to stop it. There is a danger of serious injury.
  • Page 38 Prohibited Operations Do not dig the work face under an overhang. This may cause the overhang to collapse and fall on top of the machine. FG000368 Figure 19 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.
  • Page 39 Precautions for Operation Be careful not to mistakenly travel too close to the edge of a cliff. Use the machine only for its main purpose. Using it for other purposes will cause failures. To ensure a good view, always do the following: •...
  • Page 40 • Never modify the operator’s cabin by welding, grinding, drilling holes or adding attachments unless instructed by DOOSAN. Changes to the cabin can cause loss of operator protection from rollover and falling objects, and operator may suffer serious injury or death.
  • Page 41 WARNING Never modify the operator cabin by welding, grinding, drilling holes or adding attachments unless instructed by DOOSAN. Changes to the cabin can cause loss of operator protection from rollover and falling objects, and result in serious injury or death.
  • Page 42 In a work site where falling rocks can cause damage and possibly crush personnel, or in a mining operation, be sure to install the falling object protective structure (2, Figure 26). Be sure to install any other additional protective structures required for work site conditions.
  • Page 43 Operations on Slopes When working on slopes. there is a danger that machine may lose its balance and turn over, when swinging, or when work equipment is operated. Always carry out these operations carefully. Do not swing the work equipment from the uphill side to the downhill side when the bucket is loaded.

  • Page 44: Maintenance

    OSHA certified lockout device and when performing inspection a length of chain or cable to keep the safety lever in the fully lowered, nonactive position. Warning tags, for controls are available from DOOSAN 190-00695A distributors. FG012195...
  • Page 45 Proper Tools Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools could cause personal injury. There is a danger that pieces from, chisels with crushed heads, or hammers, may get into your eyes and cause blindness. HDO1037L Figure 32 Use of Lighting...
  • Page 46 Burn Prevention When checking the radiator coolant level, shut down engine, let the engine and radiator cool down, then check the coolant recovery tank. If the coolant level in the coolant recovery tank is near the upper limit, there is enough coolant in the radiator. Loosen the radiator cap gradually to release the internal pressure before removing the radiator cap.
  • Page 47 Welding Repairs CAUTION When you connect or disconnect connectors between ECU and Engine or connector between ECU and the machine, always disconnect the source power to protect damage of the ECU. If you don't observe this procedure, the ECU would be damaged or the engine would operate abnormally.
  • Page 48 Warning for Counterweight and Front Attachment Removal 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.
  • Page 49 Precautions for Removal, Installation, and Storage of Attachments Before starting removal and installation of attachments, decide on the team leader. Do not allow anyone except the authorized workers close to the machine or attachment. Place attachments that have been removed from the machine in a safe place so they do not fall.
  • Page 50 Prevention of Crushing and Cutting You should always have at least two people working together if the engine must be run during service. One person needs to remain in the operator's seat, ready to work the controls or stop the machine and shut off the engine. Unless you are instructed otherwise, never attempt adjustments while the machine is moving or while the engine is running.
  • Page 51 If necessary depending on the type of failure, please contact your DOOSAN distributor for repairs. Precautions with High-pressure Lines, Tubes and Hoses When inspecting or replacing high-pressure piping or hoses, check to verify that pressure has been released from the circuit.
  • Page 52 Waste Materials Physical contact with used motor oil may pose a health risk. Wipe oil from your hands promptly and wash off any remaining residue. Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities. To prevent pollution of the environment, always do the following: •...

  • Page 53: Battery

    BATTERY Battery Hazard Prevention Battery electrolyte contains diluted sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is highly explosive, and mistakes in handling them can cause serious injury or fire. To prevent problems, always do the following: • Do not smoke or bring any flame near the battery. •...
  • Page 54 Boost Starting or Charging Engine Batteries If any mistake is made in the method of connecting the booster cables, it may cause an explosion or fire. Always do the following: • Turn off all electrical equipment before connecting leads to the battery. This includes electrical switches on the battery charger or boost starting equipment.

  • Page 55: Towing

    • If the engine on the problem machine will not start or there is a failure in the brake system. always contact your DOOSAN distributor. Towing Wire • Never go between the towing machine and the towed FG014871 machine during the towing operation.

  • Page 56: Shipping And Transportation

    SHIPPING AND TRANSPORTATION Obey State and Local Over-the-Road Regulations Check state and local restrictions regarding weight, width and length of a load before making any other preparation for transport. The hauling vehicle, trailer and load must all be in compliance with local regulations governing the intended shipping route.
  • Page 57 Specifications...
  • Page 59 SP002379 SPECIFICATION FOR DX140LCRSP002379 Specification for DX140LCR Edition 1 Specification for DX140LCR SP002379 Page 1...
  • Page 60 MEMO SP002379 Specification for DX140LCR Page 2...
  • Page 61 Table of Contents Specification for DX140LCR Safety Precautions ..........5 Applicable Models ..........5 General Description ..........6 Component Locations........... 6 General Dimensions ..........8 One - Piece Boom ............8 Two - Piece Boom ............9 Working Range ........... 10 One - Piece Boom ............
  • Page 62 MEMO SP002379 Specification for DX140LCR Page 4...

  • Page 63: Specification For Dx140Lcr

    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.

  • Page 64: General Description

    GENERAL DESCRIPTION The excavator has three main component sections: • The Upper Turntable • The Lower Undercarriage and Track Frames • The Excavator Front-end Attachment The following illustration identifies main components and their locations. (See Figure 1 on page -6.) COMPONENT LOCATIONS FG014632 Figure 1...
  • Page 65 Reference Reference Description Description Number Number Counterweight Bucket Cylinder Muffler Guide Link Fuel Tank Fill Cap Bucket Hood Push Link Hydraulic Oil Tank Tooth Point Fuel Tank Side Cutter Engine Idler Control Valves Track Adjuster Radiator and Oil Cooler Center Joint Swing Motor Track Guide Air Cleaner...

  • Page 66: General Dimensions

    1,190 mm (3' 11") 1,250 mm (4' 1") 1,990 mm (6' 6") 2,590 mm (8' 6") 600 mm (2' 0") 410 mm (1' 4") 2,795 mm (9' 1") * : DX140R ** : DX140LCR Specification for DX140LCR SP002379 Page 8...

  • Page 67: Two - Piece Boom

    2,440 mm (8' 0") 1,190 mm (3' 9") 1,250 mm (4' 1") 1,990 mm (6' 6") 2,590 mm (8' 6") 600 mm (2' 0") 410 mm (1' 4") 2,795 mm (9' 1") : DX140R : DX140LCR SP002379 Specification for DX140LCR Page 9...

  • Page 68: Working Range

    WORKING RANGE One - Piece Boom FG009599 Figure 2 4.6 m (15' 1") One - Piece BOOM DIM. 2.1 m (6' 11") Arm 2.5 m (8' 2") Arm 3.0 m (9' 10") Arm Max. Digging Reach 7,845 mm (25' 9") 8,295 mm (27' 2") 8,675 mm (28' 5") Max.

  • Page 69: Two - Piece Boom

    Two - Piece Boom FG009725 Figure 3 4.98 m (16' 4") Two - Piece BOOM DIM. 2.1 m (6' 11") Arm 2.5 m (8' 2") Arm Max. Digging Reach 8,270 mm (27' 2") 8,720 mm (28' 7") Max. Digging Depth 5,345 mm (17' 6") 5,735 mm (18' 10") Max.

  • Page 70: General Specifications

    GENERAL SPECIFICATIONS Shipping Weight 14.4 metric tons (31,568 lb), includes 10% fuel, 4,600 mm (15' 1") boom, 2,500 mm (8' 2") arm, standard backhoe bucket and standard shoes Operating Weight Add weight of full fuel tank and operator Shipping Weights With Optional Subtract 210 kg (463 lb) for 500 mm (19.7") shoes Track Shoes Add 210 kg (970 lb) for 700 mm (34") shoes...
  • Page 71 Overall Shipping Height 2,795 mm (9' 2") (to top of cabin) Track Shipping Length 3,750 mm (12' 4") Transport Trailer Capacity 20 tons (22 short tons), minimum load capacity Transport Loading Ramp 15° angle CAUTION: Refer to Transport Maximum Procedure for Safe Allowable Slope Shipping Instructions.

  • Page 72: Engine Performance Curves (Per Din 6270 Standard)

    ENGINE PERFORMANCE CURVES (PER DIN 6270 STANDARD) 1,000 1,200 1,400 1,600 1,800 2,000 Engine speed (RPM) 1,000 1,200 1,400 1,600 1,800 2,000 Engine speed (RPM) 0.45 0.40 0.35 0.30 0.25 1,000 1,200 1,400 1,600 1,800 2,000 Engine speed (RPM) FG013093 Figure 4 Specification for DX140LCR SP002379...
  • Page 73 Condition Specification Engine Model QSB4.5 Barometric Pressure 760 mmHg (20° C (68°F)) 595 mm, SUCKER Cooling Fan (23.4 in) Alternator 24V x 50A Air Cleaner Installed Muffler Installed Performance Standard DIN 6270 100 ps @ 1,800 rpm Power (98.5 hp @ 1,800 rpm) 45.8 kg m @ 1,400 rpm •...

  • Page 74: Approximate Weight Of Workload Materials

    APPROXIMATE WEIGHT OF WORKLOAD MATERIALS IMPORTANT Weights are approximations of estimated average volume and mass. Exposure to rain, snow or ground water; settling or compaction due to overhead weight, chemical or industrial processing or changes due to thermal or chemical transformations could all increase the value of weights listed in the table.
  • Page 75 Medium Weight or Low Weight or Density High Weight or Density Density Material 1,100 kg/m 2,000 kg/m 1,600 kg/m (1,850 lb/yd ), or Less (3,370 lb/yd ), or Less (2,700 lb/yd ), or Less 1,762 kg/m Earth, WET, muddy --------------------- --------------------- (2,970 lb/yd Gypsum, calcined,...

  • Page 76: Performance Tests

    PERFORMANCE TESTS Main Relief Pressure normal operation: 330 kg/cm (4,689 psi) with "Pressure Up": 350 kg/cm (4,970 psi) Actuator Speeds Operation Unit Standard Mode Power Mode 3.3 ± 0.4 3.0 ± 0.4 Boom Down 2.6 ± 0.3 2.6 ± 0.3 Dump 2.2 ±...

  • Page 77: Excavator Performance Standards

    EXCAVATOR PERFORMANCE STANDARDS Evaluation of equipment performance and operating condition can be made by running the excavator through a series of different tests, and recording results with a stop watch and tape measure. Compare results of performance tests against the specifications and standards that follow, which are for equipment in new or renewed condition.
  • Page 78 0.3 M - 0.5 M (1' - 2') 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.

  • Page 79: Swing Speed And Deceleration Force Test

    Travel Deviation To check steering deviation (travel motor balance), use a long tape or rope, or the edge of an undeviating straight road curb or other marker to verify side to side travel motor uniformity. Deviation distance should always be measured at the 20 m (65' 7-1/2") "finish line."...
  • Page 80 Swing Deceleration Force Test With the boom, arm and bucket in the same position as for the swing speed test, rotate the turntable so that the boom is evenly centered between the side frames, pointing straight ahead. Locate the 90° reference point, perpendicular to the boom. Mark the turntable and undercarriage with paint at the 90°...

  • Page 81: Cylinder Performance Tests

    Cylinder Performance Tests NOTE: All tests are performed with standard boom, arm and bucket configuration. The bucket should be empty. Boom Cylinders Test The starting points for the test are with the boom and arm extended away from the excavator, and the bucket curled inward.
  • Page 82 Travel Motor Jack-up Test Test travel motor operation on each side by painting or chalking a mark on one crawler shoe, with a corresponding mark on the travel frame. Use the attachment to jack up one side of the machine and operate the raised travel motor. Record the number of seconds it takes the crawler shoe to make 3 full rotations, during both high speed and low speed operation.
  • Page 83 General Maintenance...
  • Page 85 SP000016 GENERAL MAINTENANCE PROCEDURES SP000016 General Maintenance Procedures Edition 1 General Maintenance Procedures SP000016 Page 1...
  • Page 86 MEMO General Maintenance Procedures SP000016 Page 2...
  • Page 87 Table of Contents General Maintenance Procedures Safety Precautions..........5 Applicable Models..........5 Welding Precautions and Guidelines ....6 Hydraulic System - General Precautions ....7 Maintenance Service and Repair Procedure ..9 General Precautions ............9 Hydraulic System Cleanliness and Oil Leaks ..10 Maintenance Precautions for Hydraulic System Service10 Oil Leakage Precautions ..........
  • Page 88 MEMO General Maintenance Procedures SP000016 Page 4...

  • Page 89: General Maintenance Procedures

    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.

  • Page 90: Welding Precautions And Guidelines

    (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.

  • Page 91: Hydraulic System - General Precautions

    CAUTION Observe the following safety precautions: Use extra caution and adequate safety shielding when welding near fuel and oil tanks, batteries, hydraulic piping lines or other fire hazards. Never weld when the engine is running. Battery cables must be disconnected before the welding procedure is started.
  • Page 92 circuits are in neutral, or "OFF." That will prevent pumps or other components that may be temporarily oil starved from being run under a load. Replacement of any hydraulic system component could require thorough cleaning, flushing, and some amount of prefilling with fresh, clean oil if the protective seal on replacement parts has obviously been broken or if seal integrity may have been compromised.

  • Page 93: Maintenance Service And Repair Procedure

    MAINTENANCE SERVICE AND REPAIR PROCEDURE General Precautions Fluid level and condition should always be checked whenever any other type of maintenance service or repair is being performed. NOTE: If the unit is being used in an extreme temperature environment (in sub-freezing climates or in high temperature, high humidity tropical conditions), frequent purging of moisture condensation from the hydraulic reservoir drain tap should be a regular and...

  • Page 94: Hydraulic System Cleanliness And Oil Leaks

    HYDRAULIC SYSTEM CLEANLINESS AND OIL LEAKS Maintenance Precautions for Hydraulic System Service Whenever maintenance, repairs other type troubleshooting or service is being performed, it's important to remember that the hydraulic system - including both the interior and exterior surfaces of assemblies, and every drop of operating fluid - must be protected from contamination.

  • Page 95: Oil Leakage Precautions

    Oil Leakage Precautions Oil that is visibly seeping from joints or seals should always serve as a "red flag" alarm. Leaks must alert the machine operator and maintenance crew that air, water and dirt have an open, free passageway through which to enter the circuit.

  • Page 96: Cleaning And Inspection

    CLEANING AND INSPECTION General Guidelines All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or foreign material enters unit being assembled. Even minute particles can cause malfunction of close fitting parts such as thrust bearing, matched parts, etc.

  • Page 97: Bearing Inspection

    Be extremely careful when installing sealing members, to avoid cutting or scratching. Curling under of any seal lip will seriously impair its efficiency. Apply a thin coat of Loctite #120 to outer diameter, of metal casing, on oil seals to assure an oil tight fit into retainer.
  • Page 98 After inspection lightly coat the bearing and related parts with oil and wrap in a clean lintless cloth or paper and protect them from moisture and other foreign materials until installation. It is also important to inspect the bearing housing and/or shaft for grooved, galled or burred conditions that indicate that the bearing has been turning in its housing or on its shaft.
  • Page 99 Replace bearing. Figure 4 Galling Metal smears on roller ends due to overheat, lubricant failure or overload. Replace bearing - check seals and check for proper lubrication. Figure 5 Abrasive Step Wear Pattern on roller ends caused by fine abrasives. Clean all parts and housings, check all parts and housings, check seals and bearings and replace if leaking, rough or noisy.
  • Page 100 Etching Bearing surfaces appear gray or grayish black in color with related etching away of material usually at roller spacing. Replace bearings - check seals and check for proper lubrication. Figure 7 Misalignment Outer race misalignment due to foreign object. Clean related parts and replace bearing.
  • Page 101 Fatigue Spalling Flaking of surface metal resulting from fatigue. Replace bearing - clean all related parts. Figure 10 Brinelling Surface indentations in raceway caused by rollers either under impact loading or vibration while the bearing is not rotating. Replace bearing if rough or noisy. Figure 11 Cage Wear Wear around outside diameter of cage and roller pockets...
  • Page 102 Abrasive Roller Wear Pattern on races and rollers caused by fine abrasives. Clean all parts and housings, check seals and bearings and replace if leaking, rough or noisy. Figure 13 Cracked Inner Race Race cracked due to improper fit, cocking or poor bearing seat. Replace all parts and housings, check seals and bearings and replace if leaking.
  • Page 103 Frettage Corrosion set up by small relative movement of parts with no lubrication. Replace bearing. Clean all related parts. Check seals and check for proper lubrication. Figure 16 Heat Discoloration Heat discoloration can range from faint yellow to dark blue resulting from overload or incorrect lubrication.
  • Page 104 General Maintenance Procedures SP000016 Page 20...
  • Page 105 SP000813 STANDARD TORQUESSP000813 Standard Torques Edition 1 Standard Torques SP000813 Page 1...
  • Page 106 MEMO SP000813 Standard Torques Page 2...
  • Page 107 Table of Contents Standard Torques Safety Precautions ..........5 Applicable Models ..........5 Torque Values for Standard Metric Fasteners.............. 6 Torque Values for Standard U.S. Fasteners ..7 Type 8 Phosphate Coated Hardware ....9 Torque Values for Hose Clamps ......10 Torque Values for Split Flanges ......
  • Page 108 MEMO SP000813 Standard Torques Page 4...

  • Page 109: Standard Torques

    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.

  • Page 110: Torque Values For Standard Metric

    TORQUE VALUES FOR STANDARD METRIC FASTENERS NOTE: The units for the torque values are kg•m (ft lb). Grade Dia. x Pitch (mm) 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...

  • Page 111: Torque Values For Standard U.s. Fasteners

    TORQUE VALUES FOR STANDARD U.S. FASTENERS S.A.E. Bolt Head Type Description Grade Marking WILL HAVE NO MARKINGS IN THE CENTER OF THE HEAD. 1 OR 2 Low or Medium Carbon Steel Not Heat Treated. WILL HAVE THREE RADIAL LINES. Quenched and Tempered Medium Carbon Steel. WILL HAVE 6 RADIAL LINES.
  • Page 112 The following General Torque Values must be used in all cases where SPECIAL TORQUE VALUES are not given. NOTE: Torque values listed throughout this manual are lubricated (wet) threads; values should be increased 1/3 for nonlubricated (dry) threads. Heat Treated Material Grade 5 and Grade 8 Grade 5 Grade 8 Thread Size...

  • Page 113: Type 8 Phosphate Coated Hardware

    TYPE 8 PHOSPHATE COATED HARDWARE This chart provides tightening torque for general purpose applications using original equipment standard hardware as listed in the Parts Manual for the machine involved. DO NOT SUBSTITUTE. In most cases, original equipment standard hardware is defined as Type 8, coarse thread bolts and nuts and thru hardened flat washers (Rockwell "C"...

  • Page 114: Torque Values For Hose Clamps

    TORQUE VALUES FOR HOSE CLAMPS The following chart provides the tightening torques for hose clamps used in all rubber applications (radiator, air cleaner, operating lever boots, hydraulic system, etc.). Torque Radiator, Air Cleaner, Boots, Etc. Hydraulic System Clamp Type And Size Kilogram Meter Inch Pounds Kilogram Meter...

  • Page 115: Torque Values For Split Flanges

    TORQUE VALUES FOR SPLIT FLANGES The following chart provides the tightening torques for split flange connections used in hydraulic systems. Split flanges and fitting shoulders should fit squarely. Install all bolts, finger tight and then torque evenly. NOTE: Over torquing bolts will damage the flanges and/or bolts, which may cause leakage.

  • Page 116: Torque Wrench Extension Tools

    TORQUE WRENCH EXTENSION TOOLS Very large diameter, high grade fasteners (nuts, bolts, cap screws, etc.) require a great deal of turning force to achieve recommended tightening torque values. Common problems that could occur as a result are: • Recommended torque exceeds measuring capacity of the torque wrench.

  • Page 117: Other Uses For Torque Wrench Extension Tools

    torque wrench. Readings also inaccurate: • If the extension itself absorbs some of the tightening force and starts to bend or bow out. • If an extension has to be fabricated that is not perfectly straight (for example, an extension made to go around an obstruction, to allow access to a difficult to tighten fastener), the materials and methods used must be solid enough to transmit full tightening...
  • Page 118 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.
  • Page 119 I. "Loctite" Fastener Adhesives Breakaway Cure Product Application Color Removal Strength (in lb) of Sealer Alone Low strength for 6 mm (1/4") or Purple Hand tools smaller fasteners. Medium strength for 6 mm (1/4") and 242 or 243 Blue Hand tools larger fasteners.
  • Page 120 IV. "Loctite" retaining compounds Product Application Color Notes For bushings, sleeves, press fit Use Locquic "N" primer for increased bond bearings, splines and collars. For Green strength and all cold temperature gaps to 0.0002 mm (0.005"), applications. temperatures to 121°C (250°F). For high temperatures to 232°C Green Same as 609, above.
  • Page 121 Upper Structure...
  • Page 123 SP002282 CABIN SP002282 Cabin Edition 1 Cabin SP002282 Page 1...
  • Page 124 MEMO Cabin SP002282 Page 2...
  • Page 125 Table of Contents Cabin Safety Precautions ..........5 Applicable Models ..........5 Cab Identification ..........6 Roll Over Protective Structure (ROPS) When Required by Local Regulations ......6 Removal ............... 8 Installation ............12 Cabin SP002282 Page 3...
  • Page 126 MEMO Cabin SP002282 Page 4...

  • Page 127: Safety Precautions

    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 the load.

  • Page 128: Cab Identification

    • Never modify the operator’s cabin by welding, grinding, drilling holes or adding attachments unless instructed by DOOSAN. Changes to the cabin can cause loss of operator protection from rollover and falling objects, and operator may suffer serious injury or death.
  • Page 129 WARNING Never modify the operator cabin by welding, grinding, drilling holes or adding attachments unless instructed by DOOSAN. Changes to the cabin can cause loss of operator protection from rollover and falling objects, and result in serious injury or death.

  • Page 130: Removal

    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. Park on firm and level ground. Lower front attachment (bucket) to ground. Shut down engine. Set safety lever on "RELEASED"...
  • Page 131 12. Remove floor mat (1, Figure 3). 13. Remove seat (2, Figure 3). NOTE: Be careful not to damage seat covering. FG014977 Figure 3 14. Disconnect the cabin main harness connector (1, Figure 4) and remove harness connection mounting bracket from floor.
  • Page 132 17. Disconnect air conditioner harness connection inside the seat base (1, Figure 6) under seat. FG014981 Figure 6 18. Remove air ducts (1 and 2, Figure 7) on right side of cabin from main control duct. FG014982 Figure 7 19. Remove rear control duct (1, Figure 8). FG014983 Figure 8 20.
  • Page 133 22. Remove cabin inner handle. (1, Figure 10) FG015133 Figure 10 23. Remove bolts and washers (5 sets) from cabin floor (1, Figure 11). 24. Remove four mounting nuts and washers from four corners of cabin floor (1, Figure 9). FG015153 Figure 11 25.

  • Page 134: Installation

    INSTALLATION Using a suitable lifting device, attach slings to four lift points on top of cabin (Figure 12). NOTE: Cabin weights approximately 368 kg (811 lb). Lower cabin into position on cabin floor. Install four mounting nuts and washers in four corners of cabin floor (1, Figure 13).
  • Page 135 13. Connect cabin main harness at rear side of cabin and install the mounting bracket for harness (1, Figure 16) connection to floor. FG014978 Figure 16 14. Install seat (2, Figure 17). NOTE: Be careful not to damage seat covering. 15.
  • Page 136 Cabin SP002282 Page 14...
  • Page 137 SP001939 COUNTERWEIGHT SP001939 Counterweight Edition 1 Counterweight SP001939 Page 1...
  • Page 138 MEMO Counterweight SP001939 Page 2...
  • Page 139 Table of Contents Counterweight Safety Precautions ..........5 Applicable Models ..........5 General..............6 Warning for Counterweight and Front Attachment Removal ................6 Removal ............... 8 Installation ............10 Counterweight SP001939 Page 3...
  • Page 140 MEMO Counterweight SP001939 Page 4...

  • Page 141: Safety Precautions

    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.

  • Page 142: General

    Warning for Counterweight and Front Attachment Removal DANGER DOOSAN warns any user, that the removal of the counterweight from the machine, front attachment or any other part, may affect the stability of the machine. This could cause unexpected movement, resulting in death or serious injuries.
  • Page 143 Responsibility should be assigned to one person to be in charge of the lifting crew, and to verify that required safe lifting precautions have been taken before each part of this procedure has been started. All members of the working crew should know and understand the signals that will be used between the lifting leader, the assist crane operator and the remainder of the work crew.
  • Page 144 REMOVAL Park on firm and level ground. Lower front attachment (bucket) to the ground. Shut down engine. Set safety lever on "RELEASED" position. Turn starter switch to "I" (ON) position. WARNING when performing inspection WARNING 190-00695A FG014348 If engine must be run while performing maintenance, Figure 3 use extreme care.
  • Page 145 12. Remove two caps (1, Figure 4) from counterweight (2). 13. Install two lifting eyes in lifting holes (3, Figure 4). Model Lifting Eye Size DX140LCR M30x3.5 DX140LC DX180LC DX225LC DX225NLC M48x5.0 DX255LC DX300LC DX340LC 14. Using a suitable lifting device capable of handling a heavy load, partially support counterweight (2, Figure 4) before loosening four bolts (4).
  • Page 146 INSTALLATION Using suitable lifting device capable of handling a heavy load, raise counterweight (2, Figure 5) into position just above support frame (6) leaving counterweight suspended. Verify that counterweight is level and even. NOTE: Leave counterweight (2, Figure 5) suspended 3 mm (0.125") above support frame (6) until all four mounting...
  • Page 147 SP001940 FUEL TANK SP001940 Fuel Tank Edition 1 SP001940 Fuel Tank Page 1...
  • Page 148 MEMO Fuel Tank SP001940 Page 2...
  • Page 149 Table of Contents Fuel Tank Safety Precautions ..........5 Applicable Models ..........5 General Description ..........6 Parts List ................. 6 Specifications ..............7 Removal ............... 8 Installation ............12 Start-up Procedures ........... 15 SP001940 Fuel Tank Page 3...
  • Page 150 MEMO Fuel Tank SP001940 Page 4...
  • Page 151 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.
  • Page 152 GENERAL DESCRIPTION WARNING Engine fuel is highly flammable and potentially explosive. To prevent possible injury and/or damage to equipment, extinguish or move to a safe distance all potential fire hazards. Parts List Figure 1 FG014987 SP001940 Fuel Tank Page 6...
  • Page 153 Reference Reference Description Description Number Number Fuel Tank Bolt Cover Shim O-ring Shim Fuel Strainer Spacer Fuel Cap Fuel Sender Level Gauge Bolt Clip Spring Washer O-ring Plug Drain Valve O-ring Bolt Plug Spring Washer Bolt Specifications Fuel tank capacity is 234 liters (61.8 U.S. gal). Fuel Tank SP001940 Page 7...

  • Page 154: Removal

    REMOVAL Look at fuel level display (Figure 2) on instrument panel in operator's cabin to see what it displays. The display is divided into ten separated segments, each representing 10 percent of total fuel supply. Also, look at level gauge on side of tank to estimate volume of fuel left in tank.
  • Page 155 12. Clean area around fuel tank fill cap (11, Figure 5). Open fuel cap. FG014988 Figure 5 13. Place a large enough container under fuel tank to collect remaining fuel. Open drain valve (6, Figure 6) at bottom of tank and drain. NOTE: Fuel tank capacity is 234 liters (61.8 U.S.
  • Page 156 16. Remove fuel hose clamp (1, Figure 8). 17. Remove clamp connecting fuel hose and fuel prefilter (2, Figure 8). FG014991 Figure 8 18. Remove prefilter mounting bolt (1, Figure 9). 19. Remove fuel sensor harness connector (2, Figure 9). FG014992 Figure 9 20.
  • Page 157 22. Remove bracket tied with oil tank (1, Figure 11). FG014994 Figure 11 23. Install two 12 mm eyebolts in threaded holes (38 and 39, Figure 12). Using a suitable lifting device, sling eyebolts. 24. Remove four bolts (7) and spacers (13, Figure 12) holding tank (1) to frame.

  • Page 158: Installation

    INSTALLATION Install two 12 mm eyebolts in threaded holes (38 and 39, Figure 13). Using a suitable lifting device, sling eyebolts. Set fuel tank (1, Figure 13) into position. Install four bolts (7) and spacers (13) finger tight, to secure tank to frame. NOTE: The clear level gauge on the side of the tank is easily damaged.
  • Page 159 Install engine oil filter (1, Figure 15). Connect fuel return line (2,Figure 15). FG014993 Figure 15 Install fuel prefilter (1, Figure 16). Connect fuel sensor harness connector (2, Figure 16). FG014992 Figure 16 10. Fasten fuel hose clamp (1, Figure 17). 11.
  • Page 160 12. Connect fuel filler pump hose (1, Figure 18) (optional). 13. Install bracket tied with oil tank (2, Figure 18). FG014990 Figure 18 14. Make sure fuel tank drain valve (6, Figure 19) on bottom of tank is closed. 15. Fill fuel tank and check for signs of leaks. Correct any problems found.
  • Page 161 START-UP PROCEDURES If engine does not start, the fuel system may need priming. Prime the fuel system using the following procedure: Stop Engine. Open right rear door and then there is fuel filter. FG014421 Figure 20 Loosen plug (1, Figure 21) on top of fuel filter head. Pump hand operated primer pump (2, Figure 21) by the fuel injection pump.
  • Page 162 SP001940 Fuel Tank Page 16...
  • Page 163 SP000021 FUEL TRANSFER PUMPSP000021 Fuel Transfer Pump Edition 1 Fuel Transfer Pump SP000021 Page 1...
  • Page 164 MEMO Fuel Transfer Pump SP000021 Page 2...
  • Page 165 Table of Contents Fuel Transfer Pump Safety Precautions ..........5 Applicable Models ..........5 General Description ..........6 Theory of Operation ............6 Troubleshooting ............ 7 Replacement of Rotor and Vane ......7 Replacement of Rear Cover ......... 8 Replacement of Armature........8 Fuel Transfer Pump SP000021 Page 3...
  • Page 166 MEMO Fuel Transfer Pump SP000021 Page 4...

  • Page 167: Fuel Transfer Pump

    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.

  • Page 168: General Description

    GENERAL DESCRIPTION Theory of Operation Fuel Fuel Tank FG003881 Figure 1 Reference Reference Description Description Number Number Motor Inlet Hose Pump Outlet Hose Pump Cover Check Valve Rotor and Vane Strainer Cap The fuel pump consists of a motor, pump, switch, and hose assembly.

  • Page 169: Troubleshooting

    TROUBLESHOOTING On some pumps the ON-OFF switch is installed separately at a Switch Cover remote location. Connector "B" A thermal limiter, built into the motor, will automatically shut off power if motor is overheating to protect it from being damaged. NOTE: OPEN TEMP: 150 ±5°C (302 ±41°F).

  • Page 170: Replacement Of Rear Cover

    Insert vane, with the circled edge of vane facing in the counterclockwise direction. (Detail A) Insert a new O-ring during reassembly of pump cover. FG003883 Figure 6 REPLACEMENT OF REAR COVER Brush assembly and a thermal limiter are installed in the rear cover.
  • Page 171 SP001856 SWING BEARING SP001856 Swing Bearing Edition 1 Swing Bearing SP001856 Page 1...
  • Page 172 MEMO Swing Bearing SP001856 Page 2...
  • Page 173 Table of Contents Swing Bearing Safety Precautions ..........5 Applicable Models ..........5 Swing Bearing Maintenance ......... 6 Operating Recommendation ........... 6 Measuring Swing Bearing Axial Play....... 6 Measuring Bearing Lateral Play ........6 Swing Bearing Basic Operation........7 Disassembly ..............7 Assembly .................
  • Page 174 MEMO Swing Bearing SP001856 Page 4...

  • Page 175: Swing Bearing

    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.

  • Page 176: Swing Bearing Maintenance

    SWING BEARING MAINTENANCE Operating Recommendation The service life of the swing bearing may be extended if a conscious, daily effort is made to equalize usage over both ends of the excavator. If the excavator is used in the same operating configuration day in and day out (for example, with the travel motors always under the counterweight, or with the attachment over one side of the machine more than the other), the bearing's...

  • Page 177: Swing Bearing Basic Operation

    Swing Bearing Basic Operation The swing bearing, which connects the upper structure with the lower structure, consists of a inner ring, outer ring and ball bearings. During swing movement, power from the swing motor is transferred to the pinion by planetary gears connected to gears on the inner ring, which is fixed in the undercarriage.
  • Page 178 Lift outer ring and check that inner ring can move freely. See Figure 5, if not, replace seal (7, Figure 6). Figure 5 Turn inner ring and use magnet bar (C, Figure 6) to remove steel balls (5). Figure 6 Turn inner ring and use wire (D, Figure 7) to remove retainers (6).

  • Page 179: Assembly

    Assembly Clean (degrease) the seal groove for the outer and inner seals (7). Apply instant glue to seal (7). Install both seals respectively into position. Figure 8 Hoist the outer race by crane horizontally and match it with the inner race coaxially. Rotating the outer race, insert balls (5), support (6) into the plug (4) hole one by one with a round bar.
  • Page 180 Swing Bearing SP001856 Page 10...
  • Page 181 SP000921 SWING REDUCTION GEARSP000921 Swing Reduction Gear Edition 1 Swing Reduction Gear SP000921 Page 1...
  • Page 182 MEMO Swing Reduction Gear SP000921 Page 2...
  • Page 183 Table of Contents Swing Reduction Gear Safety Precautions ..........5 Applicable Models ..........5 General Description ..........7 Theory of Operation ............7 Reassembly ............8 Parts List ................. 8 Shrinkage Fitting of Shaft and Flexible Bearing . 10 Reassembly of Carrier Sub ........ 13 Assembly of the Main .........
  • Page 184 MEMO Swing Reduction Gear SP000921 Page 4...

  • Page 185: Swing Reduction Gear

    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 the load.
  • Page 186 Swing Reduction Gear SP000921 Page 6...

  • Page 187: General Description

    GENERAL DESCRIPTION Theory of Operation The swing motor final drive is a two-stage planetary gearbox with two planet gears, two sun gears and two-stage output reduction. The planetary gear engages the ring gear. The pinion gear is connected to the output shaft and spline. The final drive reduces swing motor rpm to increase swing motor output torque.

  • Page 188: Reassembly

    REASSEMBLY Parts List FG005349 Figure 1 Swing Reduction Gear SP000921 Page 8...
  • Page 189 Reference Reference Description Description Number Number Casing Driveshaft Roller Bearing Ring Gear Roller Bearing Planetary Gear Socket Bolt Sun Gear 2 Oil Seal Planetary Gear Plug Sun Gear 1 Plug Carrier 2 Spring Pin Carrier 1 Retainer Ring Pin Assembly Retainer Ring Pin Assembly Ring...

  • Page 190: Shrinkage Fitting Of Shaft And Flexible Bearing

    SHRINKAGE FITTING OF SHAFT AND FLEXIBLE BEARING Washing of shaft Remove fluids like anticorrosive fluid applied to the shaft and use an air conditioner to remove foreign substances. Insert the support plate and the NILOS ring into the prepared shaft as shown in the figure and heat bearings (#22314, 2109-1041) on the heater.
  • Page 191 Figure 4 Figure 5 When bearing is heated up to 90°C - 100°C, remove it from the heater, hold it with both hands, and insert it into the shaft evenly. To do so, slowly insert bearing 4-5 mm that it seats itself and then push it strongly to contact the NILOS ring.
  • Page 192 Figure 7 Swing Reduction Gear SP000921 Page 12...

  • Page 193: Reassembly Of Carrier Sub

    REASSEMBLY OF CARRIER SUB Washing of carrier Put in a steam washer the carrier whose burr is removed completely with corner face-milling and place it on the assembly die after checking if there is not left any foreign substance in it. Washing of planetary gear Check if planetary gear parts are washed or dented, and put them on the assembly die.
  • Page 194 Figure 11 Place the carrier with the pin being pressed in on the jig vertically, use a hammer to insert the spring pin (ø6 x 25 liter§), and drain valve it. Figure 12 Figure 13 Figure 14 Swing Reduction Gear SP000921 Page 14...
  • Page 195 Figure 15 Assemble 2 other parts in the same way. Figure 16 Put the thrust washer (B) in the middle of the carrier with all of pins being pressed in. Figure 17 Insert planetary gear #1 in 3 pins and put two thrust washers on them as shown in the figure.
  • Page 196 Figure 19 Install a retaining ring (ø30, C type, and for shaft) on each and check if gear rotates smooth. Figure 20 Figure 21 Swing Reduction Gear SP000921 Page 16...
  • Page 197 Reassembly of carrier #2 assembly Place the carrier #2 assembly on the assembly die, attach the thrust washer on a side of the planetary gear #2, and insert it in the carrier with the washer facing downward. CAUTION The calibers of gear and washer should be fit to holes of the carrier pins.
  • Page 198 Figure 26 Figure 27 After inserting the pin assembly, set the carrier vertically as shown in the figure, insert the spring pin (ø6 x 25 mm) by gently knocking with hammer, and push it to the end with a jig. Figure 28 Figure 29 Swing Reduction Gear...
  • Page 199 Figure 30 Use a punch to drain valve 2 or 3 places near hole where spring pin is inserted. Figure 31 Figure 32 Assemble other 3 parts and check if the gear runs smooth. Figure 33 Swing Reduction Gear SP000921 Page 19...

  • Page 200: Assembly Of The Main

    ASSEMBLY OF THE MAIN Washing of casing and other parts Wash casing and other parts with steam to remove remaining foreign substance after casting and machining. • Washing fluid: PK6540 (alkali) • Concentration : 3-5% • Temperature: 60 - 70°C Assembly of shaft and bearing Fix the washed casing on the turnover machine and rotate the turnover machine that the press fitting side...
  • Page 201 Figure 37 Figure 38 Figure 39 Remove the bearing press jig, align the support plate with the bolt tap of the case, and install 6 Loctite (#262) applied flat head bolts (M8 x 15 mm) and tighten them with torque wrench (torque :320 kg•cm). Figure 40 Swing Reduction Gear SP000921...
  • Page 202 Figure 41 Figure 42 Figure 43 After installing the support plate, rotate the turnover machine that the case is situated as shown in the figure. Figure 44 Swing Reduction Gear SP000921 Page 22...
  • Page 203 Apply grease to the lip of the oil seal (TC70 x 95 x 13, 2180-1254), insert it in the case, adjust it evenly, put jig on it, and use press to fit it. After press fitting, remove the jig and check its fitting state. Figure 45 Figure 46 Figure 47...
  • Page 204 Figure 49 Figure 50 Place bearing (2109-1042, NJ313) evenly, put jig on it, and use press to fit it. Figure 51 Figure 52 Swing Reduction Gear SP000921 Page 24...
  • Page 205 Figure 53 Figure 54 After the assembly of the bearing, fix retaining ring (ø65, shaft ring, C type, S6500650) on the shaft. Figure 55 Swing Reduction Gear SP000921 Page 25...
  • Page 206 Figure 56 Install drain valve on PT3/8 tap of the side of the case. Figure 57 Figure 58 Figure 59 Swing Reduction Gear SP000921 Page 26...
  • Page 207 Figure 60 Reassembly of ring gear and carrier assembly Apply liquid gasket (#1104) to the ring gear assembly parts of the case, lift the ring gear, and insert it with its groove facing downward as shown in figures. CAUTION Do not rotate the ring gear after it seats itself. Figure 61 Figure 62 Swing Reduction Gear...
  • Page 208 Figure 63 Figure 64 Put lock pins on the assigned 4 places, use jig and hammer insert them, install bolts symmetrically. Figure 65 Figure 66 Swing Reduction Gear SP000921 Page 28...
  • Page 209 Figure 67 Figure 68 Put the prepared carrier #2 assembly on the ring gear and turn it slowly right and left to have it engaged with gear. Assemble the spool line part of the carrier to the shaft in the same way. Figure 69 Swing Reduction Gear SP000921...
  • Page 210 Figure 70 Install the sun gear #2 in the way as shown in figures. Figure 71 Figure 72 Swing Reduction Gear SP000921 Page 30...
  • Page 211 Assemble the carrier #1 assembly in the same way as for the carrier #2. Figure 73 Figure 74 Assemble the sun gear #1. Figure 75 Figure 76 Swing Reduction Gear SP000921 Page 31...

  • Page 212: Test

    TEST Pneumatic pressure test After the reassembly of the carrier and the sun assemblies, loose bolts of the ring gear, place the pneumatic test jig, and tighten 4 bolts again. At this time, make sure that the pressure gauge is set to zero.
  • Page 213 Figure 80 Start motor in the advance and reverse directions (1,875 ±90 rpm, no idle) and check any noise or abnormal sound carefully. (Standard noise is 90dB at 30cm away.) Figure 81 Figure 82 Swing Reduction Gear SP000921 Page 33...
  • Page 214 At the end of the test open plug of drain port to remove contaminated gear oil completely and wipe remaining oil on the case surface with cloth. Figure 83 Figure 84 Swing Reduction Gear SP000921 Page 34...

  • Page 215: Reassembly Of Motor

    REASSEMBLY OF MOTOR Reassembly of motor Remove retaining bolts of ring gear, wipe the motor assembly cleanly with cloth, and apply fluid gasket (#1104). Figure 85 Use hoist to lift the motor, clean reassembled parts, and install retaining ring (ø30, shaft ring, and C type) in the shaft.
  • Page 216 Place the motor carefully on the reduction gear while arranging its direction as shown in figures (with caution not to have flange of the motor contact the applied fluid gasket). Assemble it by slowly turning it right and left that the spool line of the shaft engages with the threads of the sun gear #1.
  • Page 217 Insert 10 Loctite (#262) applied socket bolts (M12 x 110 mm) in holes and use impact wrench to tighten them (torque : 1,100 kg•cm). After tightening bolts, use torque wrench their tightening torque. Figure 90 Figure 91 Figure 92 Swing Reduction Gear SP000921 Page 37...
  • Page 218 Figure 93 Seal the level gauge port of the motor with teflon tape and use pipe wrench to tighten the level gauge pipe. CAUTION Do not insert the level gauge before filling gear oil. Figure 94 Swing Reduction Gear SP000921 Page 38...
  • Page 219 Figure 95 Figure 96 Filling of gear oil and grease Open oil nipple, fill gear oil (EP80W/90) of 2.4 liter, install PT1/2 plug again, insert the level gauge, and check oil level. Figure 97 Swing Reduction Gear SP000921 Page 39...
  • Page 220 Fill grease through grease fitting until grease is observed through the opposite hole and install PT1/8 plugs at both sides. Figure 98 Figure 99 Swing Reduction Gear SP000921 Page 40...
  • Page 221 Wipe grease and foreign substance with cloth and check the motor reassembly position again. Figure 100 Swing Reduction Gear SP000921 Page 41...
  • Page 222 Swing Reduction Gear SP000921 Page 42...
  • Page 223 Lower Structure and Chassis...
  • Page 225 SP001941 TRACK ASSEMBLY SP001941 Track Assembly Edition 1 Track Assembly SP001941 Page 1...
  • Page 226 MEMO Track Assembly SP001941 Page 2...
  • Page 227 Table of Contents Track Assembly Safety Precautions ..........5 Applicable Models ..........5 General Description ..........6 Track Tension ............6 Cleaning and Inspection (Wear Limits and Tolerances)......9 Track Shoe ..............10 Lower Roller ..............12 Upper Roller ..............13 Front Idler ..............
  • Page 228 MEMO Track Assembly SP001941 Page 4...

  • Page 229: Track Assembly

    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.

  • Page 230: General Description

    GENERAL DESCRIPTION The track assembly is composed of the following major components: Track Front Idler Roller Upper Roller Lower Roller Track Spring and Track Adjustment Cylinder TRACK TENSION WARNING Safely measuring track tension requires two people. One person must be in the operator's seat, running the controls to keep one side frame in the air, while the other person makes dimensional checks.
  • Page 231 Measuring the distance (A, Figure 2) between the bottom of the side frame and the top of the lowest crawler shoe. Recommended tension for operation over most types of terrain is distance "B" on below table. NOTE: This measurement can be thrown off if there is too much mud or dirt or other material in the track assembly.
  • Page 232 Track tension adjustments are made through the grease fitting (1, Figure 3) in the middle of each side frame. Adding grease increases the length of an adjustment cylinder (2). The longer the adjustment cylinder, the greater the pressure on the tension spring pushing the track idler wheel outward.

  • Page 233: Cleaning And Inspection

    CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) CAUTION Refer to the "Welding Precautions and Guidelines" information in "General Maintenance Procedures" section general recommendations specific safety precautions, before starting any lower travel frame component rebuilding procedure. The tables that follow provide factory specified dimensional limits (as new condition, recommended service and replacement limit) for lower travel frame components.

  • Page 234: Track Shoe

    Track Shoe FG003910 Figure 4 Track Assembly SP001941 Page 10...
  • Page 235 Limit for Use Recommended Limit for Check Item Standard Dimension (Repair - P or Maintenance Replace - R) 171.5 mm Link Pitch (6.752") Bushing Outside 53.9 mm 50 mm 47 mm [R] Diameter (2.122") (1.969") (1.850") 94.5 mm 89 mm 85 mm [P] Link Height (3.720")

  • Page 236: Lower Roller

    Lower Roller Figure 5 Limit for Use Recommended Limit for Check Item Standard Dimension (Repair - P or Maintenance Replace - R) Outside Diameter of 170 mm Flange (6.693") Outside Diameter of 140 mm 128 mm 125 mm [P] Tread (5.512") (5.039") (4.921")

  • Page 237: Upper Roller

    Upper Roller FG009714 Figure 6 Limit for Use Recommended Limit for Check Item Standard Dimension (Repair - P or Maintenance Replace - R) Outside Diameter of 140 mm flange (5.512") Outside Diameter of 120 mm 112 mm Tread (4.724") (4.409") 69 mm Width of Tread (2.717")

  • Page 238: Front Idler

    Front Idler Figure 7 Limit for Use Recommended Limit for Check Item Standard Dimension (Repair - P or Maintenance Replace - R) Outside Diameter of 489 mm flange (19.252") Outside Diameter of 454 mm 443 mm 440 mm [P] Tread (17.874") (17.441") (17.323")

  • Page 239: Track Shoes And Links

    TRACK SHOES AND LINKS Track Removal Position machine on a smooth level surface with adequate room for forward and reverse travel. Relieve track tension. Refer to "Track Tension" in this section for procedure. Move machine until master link (1, Figure 8) is positioned at approximately 10 o'clock from top position on front idle roller.

  • Page 240: Track Installation

    Track Installation Lay rebuilt or new track into position under track frame. End of track should be positioned under drive sprocket. With upper structure at 90° to track frame. Use bucket and boom to raise track frame off blocking. With blocking removed, lower track frame onto track. Make sure all rollers are properly positioned on track.

  • Page 241: Front Idler

    FRONT IDLER Parts List Figure 14 Reference Reference Description Description Number Number Front Bushing Plug Shaft Track Spring Assembly Bearing Bolt Floating Seal Washer O-ring Track Assembly SP001941 Page 17...

  • Page 242: Disassembly Of Front Idler

    Disassembly of Front Idler Detach T/Spring assembly from Idler assembly. Remove 4-M16 bolts and washers (10, 11, Figure 15). Remove the plug (8, Figure 14) from the bearing (4, Figure 14) (using 6mm "L" wrench). NOTE: About 330cc of oil will be discharged. Prepare an oil cloth or pan to prevent spillage on the ground.

  • Page 243: Reassembly Of Front Idler

    Reassembly of Front Idler Take care that foreign matters do not enter the front part. Wash all parts for assembly. Using the hydraulic press, assemble two bushings (2, Figure 19) at front (1, Figure 19). Use the hydraulic press. Take care to prevent accidents. NOTE: Apply a volatile lubricant on the bushing surface before insertion.
  • Page 244 10. Assemble shaft (3, Figure 14) with O-ring (6, Figure 14). Apply oil to O-ring to prevent damage when assembling bearing. 11. Apply oil to the lapped surface of the floating seal which was assembled with the bearing. 12. Assemble the bearing (4, Figure 23) on which the floating seal has been assembled.

  • Page 245: Lower Roller

    LOWER ROLLER Parts List FG000483 Figure 25 Reference Reference Description Description Number Number Roller Collar Floating Seal Shaft O-ring Bushing Plug Track Assembly SP001941 Page 21...

  • Page 246: Lower Roller Removal

    Lower Roller Removal Relieve track tension. Refer to "Track Tension" in this section for procedure. Swing upper structure at 90° to frame. Using bucket raise track off ground and place blocking under frame. Remove four bolts and lower roller assembly from track frame.

  • Page 247: Lower Roller Reassembly

    Detach O-rings (7, Figure 29) from the axle. Separate floating seals (6, Figure 29) from the collar and roller (1). Detach collar (2, Figure 29) and O-rings (7) from the axle, using press. FG001493 Figure 29 Lower Roller Reassembly Degrease, clean and dry all parts before reassembly. Insert bushing (4, Figure 30) into roller.

  • Page 248: Lower Roller Installation

    Install the collar (2, Figure 33), O-ring (7), and pin (5) on the remaining side. Fill with clean engine oil with approximately 330 cc (11.2 oz). Install plug (8, Figure 33) on the collar. FG001487 Figure 33 Lower Roller Installation Install four bolts to hold lower roller assembly to track frame.

  • Page 249: Upper Roller

    UPPER ROLLER Parts List Track Frame FG001141 Figure 35 Track Assembly SP001941 Page 25...

  • Page 250: Upper Roller Removal

    Reference Reference Description Description Number Number Roller Plug Shaft Cover Thrust Ring Washer Bushing Bolt Bushing Blot Floating Seal Spring Washer O-ring Spring Washer O-ring Upper Roller Removal Relieve track tension. This will allow track to be raised so that links clear top of roller. Position a bottle jack on top of track frame and apply pressure to track shoe.
  • Page 251 Remove the bolts (13, Figure 38) and cover (10). Detach bolts (12) and washer (11). FG001495 Figure 38 Separate the roller (1, Figure 39) from the axle (2). FG009907 Figure 39 Separate the floating seal (6, Figure 40) from the roller. Separate the O-ring (8) and thrust ring (3) from the axle.

  • Page 252: Upper Roller Reassembly

    Upper Roller Reassembly Degrease, clean and dry all parts before reassembly. Insert bushing (4 and 5, Figure 42) into the roller (1). FG003917 Figure 42 Insert floating seal (6, Figure 43) into the roller (1) and bushing. NOTE: Apply clean engine oil to the joint side of the floating seal.

  • Page 253: Track Spring And Track Adjusting Cylinder

    TRACK SPRING AND TRACK ADJUSTING CYLINDER Parts List 9 11 FG003918 Figure 45 Track Assembly SP001941 Page 29...
  • Page 254 Reference Reference Description Description Number Number Cylinder Lock Plate Piston Rod Bolt Yoke Spring Pin Spacer Spring Washer Shaft Packing Spring Backup Ring Lock Nut Dust Seal Track Assembly SP001941 Page 30...
  • Page 255 Engine and Drive Train...
  • Page 257 SP001671 QSB4.5 ENGINESP001671 QSB4.5 Engine Edition 1 QSB4.5 Engine SP001671 Page 1...
  • Page 258 MEMO SP001671 QSB4.5 Engine Page 2...
  • Page 259 Table of Contents QSB4.5 Engine Safety Precautions..........7 Applicable Models..........7 QSB4.5 Engine ............. 8 Important Reference Numbers ........9 General Information ..........10 To the Owner and Operator........... 10 About the Manual............10 How to Use the Manual ..........11 Illustrations..............
  • Page 260 Operating Instructions -Overview ........48 General Information............48 Normal Starting Procedure ..........50 Jump Starting ..............52 Cold Weather Starting ........... 53 Starting Procedure After Extended Shutdown or Oil Change ..............53 Operating the Engine ............ 53 Engine Operating Range ..........56 Engine Shutdown ............
  • Page 261 Fuel Filter (Spin-On Type) ..........77 Lubricating Oil and Filters..........79 Maintenance Procedures at 1,000 Hours or 1 Year ..............82 Maintenance Procedures - Overview ......82 Fan Hub, Belt Driven ............. 83 Maintenance Procedures at 2,000 Hours or 2 Years ............... 84 Air Compressor Discharge Lines (Not Used) ....
  • Page 262 Routine Service and Parts........... 142 Emergency and Technical Service ......142 Problem Solving ............142 Division and Regional Offices - Locations....144 Distributors and Branches - United States ....146 Distributors and Branches - Canada ......159 Distributors and Branches - Australia ......161 Distributors and Branches - New Zealand....

  • Page 263: Safety Precautions

    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.

  • Page 264: Qsb4.5 Engine

    QSB4.5 ENGINE Figure 1 QSB4.5 Engine SP001671 Page 8...

  • Page 265: Important Reference Numbers

    Engine Serial Number (ESN) Control Parts List (CPL) Fuel Pump Part Number Electronic Control Module (ECM) Electronic Control Module Serial Numbers (ECM) Filter Part Numbers Air Cleaner Element DOOSAN Lubricating Oil Filter Cummins Fleetguard DOOSAN Fuel Filter; Main Cummins Fleetguard DOOSAN Fuel-Water Separator;...

  • Page 266: General Information

    GENERAL INFORMATION To the Owner and Operator Preventive maintenance is the easiest and least expensive type of maintenance. Follow the maintenance schedule recommendations outlined in “Maintenance Guidelines” on page-59. Keep records of regularly scheduled maintenance. Use the correct fuel, lubricating oil, and coolant in your engine as specified in “Maintenance Specifications”...
  • Page 267 How to Use the Manual This manual is organized according to intervals at which maintenance on your engine is to be performed. A maintenance schedule, that states the required intervals and maintenance checks, is located in “Maintenance Guidelines” on page-59. Locate the interval at which you are performing maintenance;...

  • Page 268: General Safety Instructions

    General Safety Instructions Important Safety Notice WARNING! Improper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation, asphyxiation or other personal injury or death. Read and understand all of the safety precautions and warnings before performing any repair. This list contains the general safety precautions that must be followed to provide personal safety.
  • Page 269 • To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (Freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be properly emptied and filled using equipment that prevents release refrigerant...
  • Page 270 • Liquefied petroleum gas is heavier than air and can accumulate near the floor, in sumps, and low-lying areas. • Natural gas is lighter than air and can accumulate under hood and awnings. • To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect natural gas and liquefied petroleum gas lines in a well ventilated area.

  • Page 271: General Repair Instructions

    General Repair Instructions General Information This engine incorporates the latest technology at the time it was manufactured; yet, it is designed to be repaired using normal repair practices performed to quality standards. • Cummins Inc. does not recommend or authorize any modifications or repairs to engines or components except for those detailed in Cummins Service Information.
  • Page 272 • Provide a clean environment and follow the cleaning instructions specified in the procedures The engine and its components must be kept clean during any repair. Contamination of the engine or components will cause premature wear. • Perform the inspections specified in the procedures •...

  • Page 273: General Cleaning Instructions

    General Cleaning Instructions Definition of Clean Parts must be free of debris that can contaminate any engine system. This does not necessarily mean they have to appear as new. Sanding gasket surfaces until the factory machining marks are disturbed adds no value and is often harmful to forming a seal. It is important to maintain surface finish and flatness tolerances to form a quality sealing surface.
  • Page 274 Abrasive Pads and Abrasive Paper The keyword here is "abrasive." There is no part of an engine designed to withstand abrasion. That is they are all supposed to lock together or slide across each other. Abrasives and dirt particles will degrade both functions. WARNING! Abrasive material must be kept out of or removed from oil passages and parts wear points.
  • Page 275 All old gasket material must be removed from the parts gasket surfaces. However, it is not necessary to clean and polish the gasket surface until the machining marks are erased. Excessive sanding or buffing can damage the gasket surface. Many newer gaskets are of the edge molded type (a steel carrier with a sealing member bonded to the steel).
  • Page 276 Solvent and Acid Cleaning Several solvent and acid-type cleaners can be used to clean the disassembled engine parts (other than pistons. See Below). Experience has shown that the best results can be obtained using a cleaner that can be heated to 90° to 95° Celsius (180° to 200°...
  • Page 277 Steam Cleaning Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good method for cleaning the oil drillings and coolant passages WARNING! When using a steam cleaner, wear safety glasses or a face shield, and protective clothing.
  • Page 278 CAUTION! Do not contaminate wash tanks and tank type solvent cleaners with the foreign material and plastic beads. Remove the foreign material and plastic beads with compressed air, hot high-pressure water or steam before placing them in tanks or cleaners. The foreign material and plastic beads can contaminate the tank and any other engine parts cleaned in the tank.
  • Page 279 Cummins Inc. now recommends glass bead media NOT used to clean any engine parts. Glass media is too easily embedded into the material particularly in soft materials and when air pressures greater than media manufacturer's recommend are used. The glass is an abrasive so when it is in a moving part, that part is abrading all the parts in contact with it.

  • Page 280: Fuel System

    Fuel System When servicing any fuel system components, which can be exposed to potential contaminants, prior to disassembly, clean the fittings, mounting hardware, and the area around the component to be removed. If the surrounding areas are not cleaned, dirt or contaminants can be introduced into the fuel system.

  • Page 281: Acronyms And Abbreviations

    Acronyms and Abbreviations The following list contains some of the acronyms and abbreviations used in this manual. American Petroleum Institute Kilo Pascal ASTM American Society of Testing and Materials Liquid Natural Gas British Thermal Unit Low Temperature After Cooling °C Celsius Mega Pascal CARB...

  • Page 282: Engine Identification

    ENGINE IDENTIFICATION Engine Data Plate The engine data plate provides important facts about the engine. The engine serial number (ESN) and control parts list (CPL) provide information for service and ordering parts. The engine data plate must not be changed unless approved by Cummins Inc.
  • Page 283 Figure 7 Reference Reference Description Description Number Number Engine serial number Horsepower and rpm rating Engine model information Valve lash (overhead) setting If the engine dataplate (1) is not legible, the engine NOTE: serial number (2) can be identified on the engine block on top of the lubricating oil cooler housing.

  • Page 284: Cummins Engine Nomenclature

    Cummins Engine Nomenclature ® ISB 4 Cylinder 3.9 Liter ® ISB * 5.9 Liter The Cummins engine nomenclature provides the data as 5.9 Liter illustrated in the graphic. = Displacement = Horsepower Rating = Engine Model FG013912 Figure 9 Fuel Injection Pump Dataplate ®...

  • Page 285: Air Compressor (Not Used)

    Air Compressor (Not Used) Not all engines are equipped with an air compressor. NOTE: ® The Cummins branded air compressor dataplate, identified by the Cummins Inc. logo, is typically located on the side of the air compressor. The dataplate contains the following information which assist in servicing or replacement: ®...

  • Page 286: Engine Diagrams

    Engine Diagrams Engine Views The following illustrations show the locations of the major external engine components, filters, and other service and maintenance points. Some external components will be at different locations for different engine models. The illustrations are only a reference to show a NOTE: typical engine.
  • Page 287 Figure 14 QSB4.5 Engine Front View Reference Reference Description Description Number Number Air Inlet Fan or PTO Drive Flange Mounting Electronic Control Module Starter Mounting Location Engine Speed Sensor (Camshaft) Coolant Inet Engine Speed Sensor Water Pump (Crankshaft) Belt Tensioner Fuel Filter Alternator Vibration Damper (Optional)
  • Page 288 Figure 15 QSB4.5 Engine Rear View Reference Reference Description Description Number Number Rear Engine Lifting Bracket Flywheel Housing Air Outlet from Turbocharger Crankcase Breather Tube Air Inlet to Turbocharger Fuel Return Line Flywheel Engine Lifting Brackets QSB4.5 Engine SP001671 Page 32...
  • Page 289 Figure 16 QSB4.5 Engine Exhaust Side View Reference Reference Description Description Number Number Coolant Outlet Oil Pan Drain Plug Alternator Turbocharger Exhaust Outlet Oil Cooler Starter Coolant Inlet Flywheel Housing Oil Filter Turbocharger Compressor Inlet QSB4.5 Engine SP001671 Page 33...
  • Page 290 Figure 17 QSB 4.5 Engine Top View Reference Reference Description Description Number Number Turbocharger Wastegate Fuel Rail Pressure Sensor Actuator High-Pressure Fuel Lines Crankcase Breather Oil Fill Cap Air Compressor Coolant Tone Wheel Connection Coolant Temperature Sensor Intake Manifold Pressure/ Vibration Damper (Optional) temperature Sensor Coolant Outlet...

  • Page 291: Fan Control

    Fan Control Feature Description Various fan control features are available and while not all aspects of fan control are available on all engines, most (but not all) electronic controlled engines have some Electronic Control Module (ECM) fan control capability. Fan control capability means that the ECM is able to turn the fan on or off in response to any of the following inputs: Engine operating conditions (coolant temperature, intake manifold temperature, etc.)

  • Page 292: Water-In-Fuel Sensor

    Water-in-Fuel Sensor Feature Description The water-in-fuel sensor protects the fuel system by alerting the vehicle operator that water has accumulated in the fuel filter and this water mustbe drained. The operator will be warned of a high water condition by a flashing warning lamp on the dash. The fuel filter removes emulsified and free water from the fuel as it passes through the filter media.

  • Page 293: Idle Shutdown

    Idle Shutdown Feature Description The idle shutdown feature reduces the amount of fuel burned and increases engine life by shutting down the engine after a period of engine idling with no driver activity. Before the shutdown will occur a flashing warning lamp will warn the driver of an impending shutdown.
  • Page 294 Visual Aids The chart below indicates when manual and automatic overrides are available. Manual Override Automatic Override Below Cold Air Temperature No Yes Between Cold Air and Intermediate Air Temperature Between Intermediate Air and Hot Air Temperature Above Hot Air Temperature Yes No QSB4.5 Engine SP001671 Page 38...

  • Page 295: Accelerator Optionals

    Accelerator Optionals Feature Description This feature allows the user to determine the type of engine governor control. The two types available are the automotive (minimum or maximum) and Variable Speed or All Speed Governor types. The automotive governor provides a constant fueling for a given accelerator position.

  • Page 296: Intermediate Speed Control (Isc)

    Intermediate Speed Control (ISC) Feature Description Industrial applications use an engine speed control feature called Intermediate Speed Control. Up to three Intermediate Speed Control Set Speeds (1, 2, or 3) can be selected depending on Original Equipment Manufacturer (OEM) availability. To support this feature, a multi-position switch, or three toggle switches must be installed by the OEM.
  • Page 297 Driver Activation/Deactivation Using the Intermediate Speed Control Switched Set Speeds The operator can operate the engine using the Intermediate Speed Control Set Speeds with OEM installed Intermediate Speed Control Switches, or an equivalent OEM installed device. Activating Intermediate Speed Control can or can not cause Accelerator Pedal inputs to be ignored.

  • Page 298: Alternate Droop

    Alternate Droop Feature Description Alternate Droop allows the droop characteristics to be changed for the automotive (minimum or maximum) and for Variable Speed (VS) governor or All Speed Governor. In general less governor droop (lower percentage) provides a more responsive governor for more precise engine control.

  • Page 299: Switchable (Alternate) Torque

    Switchable (Alternate) Torque Feature Description Switchable (Alternate) Torque provides derated torque curves other than the 100 percent torque curve. These torque curves are normally used to help limit the torque output of the engine and helps to protect driveline components such as axles and transmissions and in some cases can help protect the engine from damage.

  • Page 300: Multiple Unit Synchronization

    Multiple Unit Synchronization Feature Description The multi unit synchronization feature allows two or more engines (up to a maximum of 11) to be controlled by a single throttle signal and run at a similar speed (See visual aids section). There is three engine configurations available with this feature: soft-coupled, hard-coupled, and soft-coupled marine.

  • Page 301: Hot Shutdown Monitor

    Hot Shutdown Monitor Feature Description The Hot Shutdown Monitor will log a fault in the Electronic Control Module (ECM) if the engine is shut down, either by the key switch or by the engine protection feature or other Original Equipment Manufacturer (OEM) devices, while still hot. The engine is considered hot if the load on the engine is above shutdown minimum...

  • Page 302: Automatic Boost Power

    Automatic Boost Power Feature Description Boost Power is a torque curve that is calibrated for a higher torque/horsepower than the normal engine rating and is available on QSB, QSC, CELECT Plus, QSM11, QSX15, QSK19, QSK45, and QSK60 industrial engines. The Electronic Control Module (ECM) will monitor engine speed, intake manifold temperature, and coolant temperature to determine if Boost Power can be activated.

  • Page 303: Fuel Consumption Rate Logger

    Fuel Consumption Rate Logger Feature Description Fuel Consumption Rate Logger is an industrial feature that monitors fuel usage over the life of the engine. The feature also maintains a bar graph (short term fuel consumption) that displays fuel consumption over the last 40 hours of engine operation.

  • Page 304: Operating Instructions

    OPERATING INSTRUCTIONS Operating Instructions -Overview WARNING! DO NOT OPERATE A DIESEL ENGINE WHERE THERE ARE OR CAN BE COMBUSTIBLE VAPORS. The vapors can be sucked through the air intake system and cause engine acceleration and overspeeding that can result in a fire, an explosion, and extensive property damage.
  • Page 305 Check the oil pressure indicators, temperature indicators, warning lights, and other gauges daily to make sure they are operational. Figure 18 WARNING! DO NOT OPERATE A DIESEL ENGINE WHERE THERE ARE OR CAN BE COMBUSTIBLE VAPORS. The vapors can be sucked through the air intake system and cause engine acceleration and overspeeding that can result in a fire, an explosion, and extensive property damage.

  • Page 306: Normal Starting Procedure

    Normal Starting Procedure General Information WARNING! Do not depress the accelerator pedal or move the accelerator lever from the idle position while cranking the engine. This can result in engine overspeed and severe damage to the engine. CAUTION! Figure 21 To prevent damage to the starting motor, do not engage the starting motor for more than 30 seconds.
  • Page 307 Idle the engine 3 to 5 minutes before operating with a load. Figure 23 After starting a cold engine, increase the engine speed (rpm) slowly to provide adequate lubrication to the bearings and to allow the oil pressure to stabilize. Figure 24 CAUTION! Do not operate engine at low idle for long periods with...

  • Page 308: Jump Starting

    Jump Starting WARNING! Batteries can emit explosive gases. To avoid personal injury, always ventilate the compartment before servicing the batteries. To avoid arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. CAUTION! When using jumper cables to start the engine, make sure to connect the cables in parallel: Positive (+) to positive (+) and negative (-) to negative (-).

  • Page 309: Cold Weather Starting

    Cold Weather Starting Using Starting Aids Cold weather starting aids are available for your engine. Contact the local Cummins Authorized Repair Location for more information. Figure 28 Starting Procedure After Extended Shutdown or Oil Change General Information Follow the Normal Starting Procedure in this section. The engine will not start until the minimum cranking oil pressure is detected by the ECM.
  • Page 310 Most failures give an early warning. Look and listen for changes in performance, sound, or engine appearance that can indicate service or engine repair is needed. Some changes to look for are: • Engine misfires • Vibration • Unusual engine noises •...
  • Page 311 Figure 32 QSB4.5 Engine SP001671 Page 55...

  • Page 312: Engine Operating Range

    Engine Operating Range CAUTION! Do not operate the engine at full throttle operation below peak torque rpm (refer to engine data plate for peak torque rpm) for more than 30 seconds. Operating the engine at full throttle below peak torque will shorten engine life to overhaul, can cause serious engine damage, and is considered engine abuse.

  • Page 313: Engine Shutdown

    Engine Shutdown General Information Allow the engine to idle 3 to 5 minutes before shutting it off after a full-load operation. This allows adequate cool down of pistons, cylinders, bearings, and turbocharger components. Turn the ignition starter switch to the OFF position. If the engine does not shut down, refer to “Troubleshooting Symptoms”...
  • Page 314 System EMI Radiation Levels Your Cummins product has been designed to emit minimum electromagnetic energy. Electronic components are required to pass various Cummins and industry EMI specifications. Testing has shown that when the engine is properly installed, it will not interfere with onboard communication equipment or with the vehicle's, equipment's, or vessel's ability to meet any applicable EMI standards and regulated specifications.

  • Page 315: Maintenance Guidelines

    MAINTENANCE GUIDELINES Maintenance Guidelines -Overview Cummins Inc. recommends that the engine be maintained according to the Maintenance Schedule in this section. If the engine is operating in ambient temperatures below -18°C (0°F) or above 38°C (100°F), perform maintenance at shorter intervals.

  • Page 316: Maintenance Schedule

    Maintenance Schedule For your convenience, listed below are the section numbers that contain specific instructions for performing the maintenance checks. Perform maintenance at whichever interval that occurs first. At each scheduled maintenance interval, perform all previous maintenance checks that are due for scheduled maintenance. SERVICE ITEM Air Intake Piping -Inspect Engine Lubricating Oil Level -Check/Correct...

  • Page 317: Oil Drain Intervals

    SERVICE ITEM Overhead Set -Adjust The lubricating oil and lubricating oil filter interval can be adjusted based on application, fuel consumption, gross vehicle weight, and idle time. See the Oil Drain Intervals in this section. Antifreeze check interval is every oil change or 500 hours or 6 months, whichever occurs first.

  • Page 318: Maintenance Procedures At Daily Interval

    MAINTENANCE PROCEDURES AT DAILY INTERVAL Daily Maintenance Procedures - Overview General Information Preventative maintenance begins with day-to-day awareness of the engine and its system. Before starting the engine, check the oil and coolant levels. Look for: • Leaks • Loose or damaged parts •...

  • Page 319: Air Tanks And Reservoirs

    Unusual Engine Noise During daily maintenance checks, listen for any unusual engine noise that can indicate that service is required. Figure 36 Air Tanks and Reservoirs Drain If automatic purging or spitter valves are used, confirm the valves are operating correctly. If a manual drain valve is used on the wet tank, open the draincock on the wet tank to drain any moisture accumulated in the air system.

  • Page 320: Fuel-Water Separator

    Fuel-Water Separator WARNING! Drain the water-fuel separator into a container and dispose of in accordance with local environmental regulations. CAUTION! When closing the drain valve, do not overtighten the valve. Overtightening can damage the threads. Drain Cummins Inc. requires a fuel-water separator or fuel filter be installed in the fuel supply system.

  • Page 321: Lubricating Oil Level

    Lubricating Oil Level Maintenance Check CAUTION! Never operate the engine with oil level below the L (low) mark or above the H (high) mark. Poor engine performance or engine damage can occur. The engine must be level when checking the oil level to make sure the measurement is correct.
  • Page 322 Cogged Belt Inspect the belts daily. Replace the belts if they are cracked, frayed, or have chunks of material missing. Small cracks are acceptable. Adjust the belts that have a glazed or shiny surface, which indicates belt slippage. Correctly installed and tensioned belts will show even pulley and belt wear.

  • Page 323: Air Cleaner Restriction

    Air Cleaner Restriction Maintenance Check Mechanical Indicator Do not remove the felt washer from the indicator. The NOTE: felt washer absorbs moisture. A mechanical restriction indicator is available to indicate excessive air restriction through a dry-type air cleaner. This instrument can be mounted in the air cleaner outlet or on the instrument panel.

  • Page 324: Air Compressor (Not Used)

    Air Compressor (Not Used) Maintenance Check Depending on application, it is possible engines will NOTE: not be equipped with an air compressor. Inspect compressor housing for cracks and damage. Inspect hydraulic pump couplings for cracks, wear, or damage (if equipped). Inspect air plumbing for splits or cracks.

  • Page 325: Radiator Hoses

    Radiator Hoses Maintenance Check Check all hoses for cracks, cuts, or collapsing. The silicone engine coolant hose will exhibit swelling NOTE: due to the elasticity of the hose. Figure 51 Air Intake Piping Maintenance Check Visually inspect the intake piping daily for wear points and damage to piping, loose clamps, or punctures that can damage the engine.

  • Page 326: Fan, Cooling

    Fan, Cooling Inspect for Reuse WARNING! Do not rotate the engine by pulling or prying on the fan. The fan blade(s) can be damaged and cause the fan to fail and cause personal injury or property damage. Use the accessory drive shaft or the crankshaft barring tool to Figure 53 rotate the crankshaft.

  • Page 327: Coolant Level

    Coolant Level Maintenance Check WARNING! Do not remove a pressure cap from a hot engine. Wait until the coolant temperature is below 50°C (120°F) before removing the pressure cap. Heated coolant spray or steam can cause personal injury. Figure 57 CAUTION! Never use a sealing additive to stop leaks in the cooling system.

  • Page 328: Maintenance Procedures At 500 Hours Or 6 Months

    MAINTENANCE PROCEDURES AT 500 HOURS OR 6 MONTHS Maintenance Procedures - Overview General Information All maintenance checks and inspections listed in previous maintenance intervals must also be performed at this time, in addition to those listed under this maintenance interval. Cooling System General Information WARNING!
  • Page 329 Fill the cooling system with coolant to the bottom of the fill neck in the radiator fill or recovery/expansion tank. Some radiators have two fill necks, both of which NOTE: must be filled when the cooling system is drained. Figure 62 Maintenance Check CAUTION! Over-concentration of antifreeze or use of high silicate...
  • Page 330 WARNING! Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. Drain the cooling system by opening the drain valve on the radiator and removing the plug in the bottom of the water inlet. A drain pan with a capacity of 19 liters [5 gal] will be adequate in most applications.
  • Page 331 An alternate to using sodium carbonate, as outlined NOTE: in this procedure, is to use Restore Restore is a heavy-duty cooling system cleaner that removes corrosion, silica gel, and other deposits. The performance of Restore dependent time, temperature, concentration levels. An extremely scaled or flow-restricted system, for example, can require higher concentrations of cleaners, higher temperatures, or longer cleaning times, or the use of Restore Plus...
  • Page 332 Operate the engine for 5 minutes with the coolant temperature above 80°C (176°F). Shut off the engine and drain the cooling system. If the water being drained is still dirty, the system NOTE: must be flushed again until the water is clean. Figure 72 Fill CAUTION!

  • Page 333: Fuel Filter (Spin-On Type)

    WARNING! Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C (122°F) before removing the pressure cap. Heated coolant spray or steam can cause personal injury. Install the pressure cap. Operate the engine until it reaches a temperature of 80°C (180°F) and check for coolant leaks.
  • Page 334 CAUTION! Do not pre-fill the on-engine fuel filter with fuel. The system must be primed after the fuel filter is installed. Pre-filling the fuel filter can result in debris entering the fuel system and damaging fuel system components. Use the correct fuel filter. See Cummins/Fleetguard¢Á/Nelson filter specifications for the correct part number.

  • Page 335: Lubricating Oil And Filters

    Lubricating Oil and Filters Drain WARNING! Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. If not reused, dispose of in accordance with local environmental regulations.
  • Page 336 Remove Clean the area around the lubricating oil filter head. Use the oil filter wrench, Part Number 3400158, to remove the filter. Clean the gasket surface of the filter head. The o-ring can stick on the filter head. Make sure it is NOTE: removed before installing the new filter.
  • Page 337 Fill Clean and check the lubricating oil drain plug threads and sealing surface. Use new sealing washer, if damaged. Install the lubricating oil pan drain plug. Automotive and Industrial Applications: Steel Oil Pan Drain Plug 60Nm 80Nm Torque Min 44 (ft-lb) Min 59 (ft-lb) Figure 86 Cast Aluminunl Oil Pan...

  • Page 338: Maintenance Procedures At 1,000 Hours Or 1 Year

    MAINTENANCE PROCEDURES AT 1,000 HOURS OR 1 YEAR Maintenance Procedures - Overview General Information All maintenance checks and inspections listed in previous maintenance intervals must also be performed at this time, in addition to those listed under this maintenance interval. Maintenance Check With the engine stopped, check the tensioner arm, pulley and stops for cracks.

  • Page 339: Fan Hub, Belt Driven

    Remove the drive belt. Refer to Procedure “Drive Belt, Cooling Fan” on page-115. With the belt removed, verify that the tensioner arm stop is in contact with the spring case stop. If they are not touching, the tensioner must be replaced. Figure 93 Fan Hub, Belt Driven Maintenance Check...

  • Page 340: Maintenance Procedures At 2,000 Hours Or 2 Years

    MAINTENANCE PROCEDURES AT 2,000 HOURS OR 2 YEARS Air Compressor Discharge Lines (Not Used) General Information All air compressors have a small amount of lubricating oil carryover that lubricates the piston rings and moving parts. When this lubricating oil is exposed to normal air compressor operating temperatures over time, the lubricating oil will form varnish or carbon deposits.
  • Page 341 Measure the total carbon deposit thickness inside the air discharge line as shown. If the total carbon deposit (X + X) exceeds 2 mm [1/16 in], clean and inspect the cylinder head, the valve assembly, and the discharge line. Replace if necessary. Contact Cummins Authorized...

  • Page 342: Cooling System

    Cooling System General Information WARNING! Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C (120°F) before removing the pressure cap. Heated coolant spray or steam can cause personal injury. Never use a sealing additive to stop leaks in the NOTE: coolant system.
  • Page 343 Drain WARNING! Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C (122°F) before removing the pressure cap. Heated coolant spray or steam can cause personal injury. Remove the radiator/expansion tank cap. Figure 104 WARNING! Coolant is toxic.
  • Page 344 Flush CAUTION! The system must be filled properly to prevent air locks. During filling, air must be vented from the engine coolant passages. Wait 2 to 3 minutes to allow air to be vented; then add mixture to bring the level to the top. To be sure air is vented during the fill process: •...
  • Page 345 CAUTION! The system must be filled properly to prevent air locks. During filling, air must be vented from the engine coolant passages. Wait 2 to 3 minutes to allow air to be vented; then add mixture to bring the level to the top. Operate the engine for 5 minutes with the coolant temperature above 80°C (176°F).
  • Page 346 Fill CAUTION! The system must be filled properly to prevent air locks. During filling, air must be vented from the engine coolant passages. Wait 2 to 3 minutes to allow air to be vented; then add mixture to bring the level to the top. To be sure air is vented during the fill process: •...

  • Page 347: Vibration Damper, Rubber

    Vibration Damper, Rubber Inspect Check the index lines (A) on the damper hub (B) and the inertia member (C). If the lines are more than 1.59 mm [1/16 in] out of alignment, replace the damper. Figure 116 Inspect the rubber member for deterioration. If pieces of rubber are missing or if the elastic member is more than 3.18 mm [1/8 in] below the metal surface, replace the damper.

  • Page 348: Overhead Set

    MAINTENANCE PROCEDURES AT 5000 HOURS OR 4 YEARS Overhead Set Preparatory Steps WARNING! Batteries can emit explosive gases. To reduce the possibility personal injury, always ventilate compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.
  • Page 349 If equipped, at the rear of the rocker lever cover, remove the banjo bolt and sealing washers connecting the breather oil drain line to the rocker lever cover. Not all engines with an internal mounted crankcase NOTE: breather are equipped with an external breather oil drain line.
  • Page 350 If the gasket has been removed from the rocker lever NOTE: cover, a new gasket must be used. If replacing the rocker lever gasket, the following installation procedure must be used when installing the press-in gasket. Press the molded gasket into the corners of the rocker lever cover Press the remaining gasket into the rocker lever cover.
  • Page 351 With the engine in this position, lash can be checked on the following rocker arms: (E = exhaust, I = Intake) Four-cylinder 1I, 1E, 2l, and 3E Six-cylinder 1I, 1E, 2I, 3E, 4I, and 5E. Lash Check Limits Intake 0.152mm MIN (0.006in) 0.381mm MAX (0.015in) Exhaust 0.381mm MIN (0.015in)
  • Page 352 Following the same steps and specifications as previously stated, measure lash for the following rockers: (E = Exhaust, I = Intake) Four-cylinder 2E, 3I, 4E, and 4I: Six-cylinder 2E, 3I, 4E, 5I, 6I, and 6E. Reset if out of specification. Figure 133 Install Stud Mounted Rocker Lever Cover.
  • Page 353 Prior to connecting the breather connection tube to the rocker lever cover, apply clean engine oil to the O-ring located on the breather tube connection. Figure 137 Connect the breather tube connection to the rocker lever cover. In general, two types of breather tube connections are used at the rocker lever cover: A clamping plate and capscrew hold the breather tube connection to the rocker lever cover.

  • Page 354: Alternator

    Alternator General Information Due to the number of different alternator brands and configurations, the following procedure has been generalized to cover the most common configurations. Consult the alternator manufacturer for any information that is not covered in this procedure. Figure 140 Initial Check Check the drive belt and alternator pulley to be sure the alternator is rotating properly.
  • Page 355 Initial Check Any multimeter reading of zero voltage indicates an NOTE: open circuit. Check for open circuits. Turn the keyswitch to the ON position. Connect a multimeter, Part Number 3164488 or 3164489, to the following locations: Delco Alternators Alternator "BAT" terminal to ground Alternator blade terminal "number 1"...
  • Page 356 Operate the engine at high idle and adjust the carbon-pile load- testing equipment to apply the maximum rated amperage load to the alternator. Refer to the OEM specifications. The alternator maximum rated amperage output is NOTE: normally stamped or labeled on the alternator. Measure the alternator amperage output.
  • Page 357 WARNING! Acid is extremely dangerous and can damage the machinery and can also cause serious burns. Always provide a tank of strong soda water as a neutralizing agent when servicing the batteries. Wear goggles and protective clothing to reduce the possibility of serious personal injury. •...
  • Page 358 Hinge Mount Remove the alternator link capscrew. Figure 151 Remove the alternator mounting capscrew. Remove the alternator. Figure 152 Install Spool Mount Install the alternator and the bottom alternator mounting capscrew and nut. Install the upper alternator link mounting capscrew at the top of the alternator.
  • Page 359 Hinge Mount Install the alternator. Install and tighten the alternator mounting capscrew. • Torque Value 40 n.m (30 ft-lb) Figure 155 Install the alternator link capscrew. • Torque Value 24 N•m (212 in-lb) Figure 156 Finishing Steps WARNING! Batteries can emit explosive gases. To reduce the possibility personal injury,...

  • Page 360: Charge-Air Cooler

    Charge-Air Cooler Clean If the engine experiences a turbocharger failure or any other occasion where oil or debris is put into the charge air cooler, the charge air cooler must be cleaned. Remove the charge air cooler piping and charge air cooler from the vehicle.
  • Page 361 Inspect for Reuse Inspect the charge air cooler for cracks, holes, or damage. Inspect the tubes, the fins, and the welds for tears, breaks, or other damage. If any damage causes the charge air cooler to fail the air leak check mentioned earlier in this procedure, the charge air cooler must be replaced.
  • Page 362 Determine if the pressure drop is caused by a leak in the charge air cooler or from a leaky connection. Use a spray bottle filled with soapy water applied to all hose connections, and watch for bubbles to appear at the location of the leak. If the pressure drop is caused by a leaky connection, repair the connection, and repeat the test.
  • Page 363 Perform a road test with the engine at peak power and a vehicle speed of 48 kph (30 mph) or greater. Record the intake manifold temperature and the ambient air temperature. Calculate the differential temperature: Intake Manifold Temperature - Ambient Air Temperature = Differential Temperature Maximum Differential Figure 168...
  • Page 364 Operate the engine at rated rpm and load. Record the readings on the manometer. If the differential pressure is greater than 152 mm Hg (6 in Hg), check the charge air cooler and associated piping for plugging. Clean or replace if necessary. Figure 172 Optional Method Obtain two (2) pressure gauges, Part No.

  • Page 365: Coolant Thermostat

    Coolant Thermostat General Information The thermostat controls the engine coolant temperature. When the coolant temperature is below the operating range, engine coolant is bypassed back to the inlet of the water pump. When the engine coolant temperature reaches the operating range, the thermostat opens, sealing off the bypass, forcing engine coolant to flow to the radiator or heat exchanger.
  • Page 366 Preparatory Steps WARNING! Batteries can emit explosive gases. To reduce the possibility personal injury, always ventilate compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Disconnect the batteries.
  • Page 367 Clean and Inspect for Reuse CAUTION! Do not let any debris fall into the thermostat cavity when cleaning the gasket surfaces. Damage to the cooling system and engine can occur. Clean the mating surfaces with a gasket scraper and a clean cloth.
  • Page 368 Install CAUTION! Always use the correct thermostat and do not operate the engine without a thermostat installed. The engine can overheat if operated without a thermostat because the path of least resistance for the coolant is through the bypass to the pump inlet.
  • Page 369 Connect the batteries. Operate the engine and check for leaks. Figure 188 SP001671 QSB4.5 Engine Page 113...

  • Page 370: Cooling Fan Belt Tensioner

    Cooling Fan Belt Tensioner Maintenance Check With the engine stopped, check the tensioner arm, pulley and stops for cracks. If any cracks are found, the tensioner must be replaced. Figure 189 With the belt installed, verify that neither tensioner arm stops is in contact with the spring casing stop.

  • Page 371: Drive Belt, Cooling Fan

    Drive Belt, Cooling Fan Remove Lift the tensioner to remove the drive belt. The belt tensioner winds in the direction that the NOTE: spring tang is bent over the tensioner body. To loosen the tension on the belt, rotate the tensioner to wind the spring tighter.

  • Page 372: Fan Spacer And Pulley

    Fan Spacer and Pulley Preparatory Steps • Remove the drive belt. Loosen the capscrews before removing the belt, and NOTE: tighten the capscrews after the belt is installed. Figure 196 Remove Remove the four capscrews, fan, and spacer. Figure 197 Inspect for Reuse Inspect the fan pulley for cracks near bolt holes.
  • Page 373 Install 3/8-Inch Square Drive Lift the tensioner, and install the belt. If difficulty is experienced installing the drive belt (the belt seems too short), position the belt over the grooved pulleys first; then, while holding the tensioner up, slide the belt over the water pump pulley.

  • Page 374: Starting Motor

    Starting Motor Rotation Check If the starter solenoid is making a sound but the engine is not rotating, turn the keyswitch to the OFF position, and attempt to bar the crankshaft in both directions. Bar the engine using the barring tool, Part Number 3824591. If the crankshaft will bar over, attempt to start the engine.
  • Page 375 Remove WARNING! Batteries can emit explosive gases. To reduce the possibility personal injury, always ventilate compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Disconnect the ground cable from the battery terminal.
  • Page 376 Clean and Inspect for Reuse For engines that use wet flywheel housings, clean any left over sealant from the starting motor mounting flange on both the flywheel housing and starting motor. Make sure these surfaces are clean of oil and debris. Figure 208 Inspect the starter motor pinion gear and/or flywheel ring gear for chipping or uneven wear.
  • Page 377 Install For engines with wet flywheel housings, apply a 1.5 to 2.0 mm (0.06 to 0.09 in) wide bead of sealant, Part Number 3164067 to the flywheel housing starting motor mounting flange. If a starting motor spacer is required, maker to apply NOTE: sealant to the side of the spacer that contacts the starting motor.
  • Page 378 Non-Cummins Branded Starters CAUTION! Do not overtighten the electrical connections. Starter damage can result. Use the location tags to help identify where each wire NOTE: connection goes. Install the starter motor electrical connections. For Non-Cummins branded starters, refer to the Original Equipment Manufacturer (OEM)

  • Page 379: System Diagrams

    SYSTEM DIAGRAMS General Information The following drawings show the flow through the engine systems. Although parts can change between different applications and installations, the flow remains the same. The systems shown are: • Fuel System • Lubricating Oil System • Coolant System •...

  • Page 380: Fuel System

    Fuel System Figure 214 Reference Reference Description Description Number Number Fuel From Supply Tank Fuel Rail Water/Fuel Separator To Injectors (not mounted on engine) High-Pressure Connector Ecm Cooling Plate Injector To Fuel Gear Pump Fuel Return from Injectors and To Fuel Filter Fuel Rail to Fuel Filter Head Fuel Filter Head Fuel Return from High-pressure...
  • Page 381 With Electric Lift Pump Figure 215 Reference Reference Description Description Number Number Fuel Inlet -ECM Cooling Plate Fuel Rail Pressure Sensor ECM Cooling Plate Fuel Pressure Relief Valve Lift Pump High-Pressure Fuel Line (Fuel Rail to Fuel Injector) Fuel Line (from Lift Pump to Fuel Filter) High-Pressure Connector to Fuel Injector...

  • Page 382: Lubricating Oil System

    Lubricating Oil System Figure 216 Reference Reference Description Description Number Number Gerotor Lubricating Oil Pump Filter Bypass Valve From Lubricating Oil Pump Filter Bypass Valve Closed Pressure Regulating Valve Filter Bypass Valve Open Closed To Lubricating Oil Filter Pressure Regulating Valve Open Full-flow Lubricating Oil Filter To Lubricating Oil Cooler From Lubricating Oil Filter...
  • Page 383 Figure 217 Lubrication for the Turbocharger Reference Reference Description Description Number Number Turbocharger Lubricating Oil Turbocharger Lubricating Oil Supply Drain QSB4.5 Engine SP001671 Page 127...
  • Page 384 Figure 218 Lubrication for the Power Components Reference Reference Description Description Number Number From lubricating oil cooler Crankshaft main journal Main lubricating oil rifle Oil supply to rod bearings To valve train Directed piston-cooling nozzle From main lubricating oil rifle To internal lubrication of air compressor To piston-cooling nozzle...
  • Page 385 Figure 219 Lubrication for the Overhead Components Reference Reference Description Description Number Number Main lubricating oil rifle Rocker lever shaft Rocker lever support Rocker lever bore Transfer slot Rocker lever QSB4.5 Engine SP001671 Page 129...
  • Page 386 Figure 220 Lubrication for the Accessory Drive Reference Reference Description Description Number Number Oil Feed from Block Oil Supply to Accessory Drive Oil returns to pan through the gear housing NOTE: QSB4.5 Engine SP001671 Page 130...

  • Page 387: Cooling System

    Cooling System Figure 221 Reference Reference Description Description Number Number Coolant Inlet Coolant Flow to Thermostat Housing Pump Impeller Coolant Bypass Passage Coolant Flow Past Lubricating Oil Cooler Coolant Flow Back to Radiator Coolant Flow Past Cylinders Bypass Open Coolant Flow From Cylinder Coolant Bypass in Cylinder Head Block to Cylinder Head Coolant Flow to Water Pump...

  • Page 388: Air Intake System

    Air Intake System Figure 222 Reference Reference Description Description Number Number Intake Air Inlet to Turbocharger Intake Manifold (Integral Part of the Cylinder Head) Turbocharger Air to Charge Air Cooler Intake Valve Charge Air Cooler QSB4.5 Engine SP001671 Page 132...

  • Page 389: Exhaust System

    Exhaust System Figure 223 Reference Reference Description Description Number Number Exhaust valve Turbocharger Exhaust manifold Turbocharger exhaust outlet SP001671 QSB4.5 Engine Page 133...
  • Page 390 Figure 224 Reference Reference Description Description Number Number Exhaust Gas to Manifold Exhaust Gas from EGR Valve to EGR Cooler Connection Exhaust Manifold EGR Cooler Exhaust Gas to Turbocharger Cooled Exhaust Gas to EGR Exhaust Gas to EGR Valve Connection Tube and EGR Mixer EGR Valve Figure 225 Reference...

  • Page 391: Compressed Air System

    Compressed Air System Figure 226 Reference Reference Description Description Number Number Air In Lubricating Oil in (Internal to the Gear Housing) Air out Lubricating Oil out (Internal to the Coolant In Gear Housing) Coolant Out SP001671 QSB4.5 Engine Page 135...

  • Page 392: Service Literature

    SERVICE LITERATURE Additional Service Literature General Information The following publications can be purchased. Bulletin Number Title of Publication 3379000 Air for Your Engines 3379001 Fuel for Cummins Engines Bulletin 3379009 Operation -Cold Weather Bulletin 3810340 Cummins Engine Oil Recommendations Bulletin 3666132 Coolant Requirements and Maintenance Bulletin 4021524...
  • Page 393 This new catalog was designed to provide you with the exact information you need to order parts for your engine. This will be valuable for customers that do not have easy access to the Cummins Electronic Parts Catalog or the Cummins Parts Microfilm System.

  • Page 394: Component Manufacturers Addresses

    Component Manufacturers Addresses The following list contains addresses and telephone NOTE: numbers of suppliers of accessories used on Cummins engines. Suppliers can be contacted directly for any specifications not covered in this manual. Air Compressors Air Cylinders Air Heaters Bendix Heavy Vehicles Systems Bendix Ltd.
  • Page 395 Belts Catalytic Converters Coolant Level Switches Robertshaw Controls Company T.B.A. Belting Ltd. P.O. Box 77 Donaldson Company, Inc. 1400 Wigan Lancashire West 94th Street P.O. Box 1299 P.O. Box 400 Knoxville, TN 37901 England Minneapolis, MN 55440 Telephone: (216) 885-1773 Telephone: (0)1942-259221 Telephone: (612) 887-3835 Dayco Mfg.
  • Page 396 Fan Clutches Fans Fault Lights Cutler-Hammer Products Eaton Kysor Cooling Systems N.A. 6040 Truflo Ltd. Westwood Road West 62nd Street Indianapolis, IN Birmingham B6 7JF England Corporation 4201 N. 27th Street 46278 Telephone: (0)121-3283041 Milwaukee, WI 53216 Telephone: (317) 328-3330 Telephone: (414) 449-6600 Hayes-Albion Corporation Jackson Holset Engineering Co.
  • Page 397 Fuel Pumps Fuel Warmers Gauges Robert Bosch Corp. Automotive Fleetguard, Inc. 1200 Fleetguard Grasslin U.K. Ltd. Vale Rise Group 2800 South 25th Ave. Road Cookeville, TN 38502 Tonbridge Kent TN9 1TB England Broadview, IL 60153 Telephone: (615) 526-9551 Telephone: (0)1732-359888 Datcon Instruments P.O.

  • Page 398: Service Assistance

    SERVICE ASSISTANCE Routine Service and Parts Personnel at your authorized dealer and Cummins Authorized Repair Locations can assist you with the correct operation and service of your engine. Cummins has a worldwide service network of more than 5,000 Distributors and Dealers who have been trained to provide sound advice, expert service, and complete parts support.
  • Page 399 Nature of problem Summary of the current problem arranged in the order of occurrence Name and location of the Cummins Distributor or Dealer If a problem cannot be resolved satisfactorily through your Cummins Authorized Repair Location or Division Office, write to: Cummins Customer Assistance Center - 41403, Cummins Inc., Box 3005, Columbus, IN 47202-3005 SP001671...

  • Page 400: Division And Regional Offices - Locations

    Division and Regional Offices - Locations Australia Regional Office Cummins Engine Company 2 Caribbean Drive Pty. Ltd. Scoresby, Victoria 3179 Australia Telephone: (61-3) 9765-3222 FAX: (61-3) 9763-0079 This office also serves New Zealand. NOTE: Cummins Americas Cummins America Inc. 3350 SW 148 Avenue Regional Office Suite 205 Miramar, FL 33027 Telephone: (1-954) 431-5511...
  • Page 401 SLP Mexico Cummins, S. de R.L. de C.V. Arquimedes No. 209 Col. Polanco Mexico, Distrito Federal ZIP / Postal Code: 11560 Mexico Telephone: (52-5) 254-3822 / 3783 / 3622 Telefax: (52-5) 254-3645 Russia-Moscow Cummins Engine Company, Park Place Inc. Office E708, 113/1 Leninskiy Prospect Moscow ZIP / Postal Code: 117198 Russia...

  • Page 402: Distributors And Branches - United States

    Distributors and Branches - United States Alabama Birmingham Cummins Mid-South, LLC 2200 Pinson Highway P.O. Box 1147 Birmingham, AL 35217 Telephone: (205) 841-0421 FAX: (205) 849-5926 Alabama Mobile Cummins Mid-South, LLC 1924 N. Beltline Hwy. Mobile, AL 36617 Telephone: (334) 456-2236 FAX: (334) 452-6419 Alaska Anchorage...
  • Page 403 California West Sacramento Cummins West, Inc. 875 Riverside Parkway West Sacramento, CA 95605-1502 Telephone: (916) 371-0630 FAX: (916) 371-2849 California Los Angeles Cummins Cal Pacific Inc. 1939 Deere Avenue (Irvine) Irvine, CA 92606 Telephone: (949) 253-6000 FAX: (949) 253-6070 California Montebello Cummins Cal Pacific Inc.
  • Page 404 Florida Hialeah (Miami) Cummins South Power, LLC 9900 N.W. 77th Avenue Hialeah Gardens, FL 33016 Telephone: (305) 821-4200 FAX: (305) 557-2992 Florida Ocala Cummins South Power, LLC 321 Southwest 52nd Ave. Ocala, FL 34474-1892 Telephone: (352) 861-1122 FAX: (352) 861-1130 Florida Orlando Cummins South Power, LLC...
  • Page 405 Georgia Savannah Cummins South, Inc. 8 Interchange Court Savannah, GA 31401-1627 Telephone: (912) 232-5565 FAX: (912) 232-5145 Hawaii Kapolei Distributor Cummins West Inc. 91-230 Kalaeloa Blvd. Kapolei, HI 96707 Telephone: (808) 682-8110 FAX: (808) 682-8477 Idaho Boise Cummins Rocky Mountain, LLC 8949 So.
  • Page 406 Indiana Evansville Cummins Cumberland, Inc. 7901 Highway 41 North Evansville, IN 47725 Telephone: (812) 867-4400 FAX: (812) 867-4411 Indiana Ft. Wayne Cummins Mid-States Power, Inc. 3415 Coliseum Blvd. West (At Jct. I-69 and 30/33) Ft. Wayne, IN 46808 Telephone: (219) 482-3691 FAX: (219) 484-8930 Indiana Gary...
  • Page 407 Maine Scarborough Cummins Northeast, Inc. 10 Gibson Road Scarborough, ME 04074 Telephone: (207) 883-8155 FAX: (207) 883-5526 Maryland Baltimore Cummins Power Systems, Inc. 1907 Park 100 Drive MD 21061 Telephone: (410) 590-8700 FAX: (410) 590-8731 Massachusetts Boston Cummins Northeast, Inc. 100 Allied Drive Dedham, MA 02026 Telephone: (781) 329-1750 FAX: (781) 329-4428...
  • Page 408 Missouri Kansas City Cummins Central Power, LLC 8201 NE Parvin Road Kansas City, MO 64161 Telephone: (816) 414-8200 FAX: (816) 414-8299 Missouri Joplin Cummins Central Power, LLC 3507 East 20th Street Joplin, MO 64801 Telephone: (417) 623-1661 FAX: (417) 623-1817 Missouri Springfield Cummins Central Power, LLC...
  • Page 409 New Jersey Newark Cummins Metropower, Inc. 41-85 Doremus Ave. Newark, NJ 07105 Telephone: (973) 491-0100 FAX: (973) 578-8873 New Mexico Albuquerque Cummins Rocky Mountain, LLC 1921 Broadway N.E. Albuquerque, NM 87102 Telephone: (505) 247-2441 FAX: (505) 842-0436 New Mexico Farmington Cummins Rocky Mountain, LLC 1101 North Troy King Road Farmington, NM 87401 Telephone: (505) 327-7331...
  • Page 410 Ohio Columbus Cummins Bridgeway, LLC 4000 Lyman Drive Hilliard (Columbus), OH 43026 Telephone: (614) 771-1000 FAX: (614) 771-0769 Ohio Cincinnati Cummins Interstate Power, Inc. 10470 Evendale Drive Cincinnati, OH 45241 Telephone: (513) 563-6670 FAX: (513) 563-0594 Ohio Cleveland Cummins Bridgeway, LLC 7585 Northfield Road Cleveland, OH 44146 Telephone: (440) 439-6800 FAX: (440) 439-7390...
  • Page 411 Pennsylvania Philadelphia Cummins Power Systems, Inc. 2727 Ford Road Bristol, PA 19007 Telephone: (215) 785-6005 FAX: (215) 785-4085 Pennsylvania Pittsburgh Cummins Power Systems, Inc. 3 Alpha Drive Pittsburgh, PA 15138-2901 Telephone: (412) 820-8300 FAX: (412) 820-8308 Pennsylvania Harrisburg Cummins Power Systems, Inc. 4499 Lewis Road Harrisburg, PA 17111-2541 Telephone: (717) 564-1344 FAX: (717) 558-8217...
  • Page 412 Texas Arlington Cummins Southern Plains, Ltd. 600 N Watson Road Arlington, TX 76004-76011 Telephone: (817) 640-6801 FAX: (817) 640-6852 Texas Amarillo Cummins Southern Plains, Ltd. 5224 Interstate 40 - Expressway East Amarillo, TX 79120-1570 Telephone: (806) 373-3793 (24 hours) FAX: (806) 372-8547 Texas Dallas Cummins Southern Plains, Ltd.
  • Page 413 Washington Seattle Cummins Northwest, Inc. 811 S.W. Grady Way Renton, WA 98055 Telephone: (425) 235-3400 FAX: (425) 235-8202 Toll Free: (800) 274-0336 Washington Chehalis Cummins Northwest, Inc. 926 N.W. Maryland Chehalis, WA 98532-0339 Telephone: (360) 748-8841 FAX: (360) 748-8843 Toll Free: (800) 451-5506 Washington Spokane Cummins Northwest, Inc.
  • Page 414 Wisconsin Wausau Cummins NPower, LLC 7815 Camp Philips Rd Wausau, WI 54476 Telephone: (715) 359-6888 FAX: (715) 359-3744 Wyoming Gillette Cummins Rocky Mountain, LLC 2700 Hwy. 14 and 16 North P.O. Box 1207 (82717) Gillette, WY 82716 Telephone: (307) 682-9611 FAX: (307) 682-8242 Toll Free: (800) 773-9611 Wyoming...

  • Page 415: Distributors And Branches - Canada

    Distributors and Branches - Canada Alberta Edmonton Cummins Western Canada 11751 - 181 Street Edmonton, AB T5S 2K5 Telephone: (780) 455-2151 FAX: (780) 454-9512 Alberta Edmonton Cummins Western Canada 4887 - 35th Street S.E. Calgary, Alberta T2B 3H6, Canada Telephone: (403) 569-1122 FAX: (403) 569-0027 Alberta Hinton...
  • Page 416 Newfoundland Wabush Cummins Eastern Canada, LP Wabush Industrial Park Wabush, Newfoundland A0R 1B0 Telephone: (709) 282-3626 FAX: (709) 282-3108 Nova Scotia Halifax Cummins Eastern Canada, LP 50 Simmonds Drive Dartmouth, Nova Scotia B3B 1R3 Telephone: (902) 468-7938 FAX: (902) 468-5177 Ontario Kenora Cummins Mid-Canada Ltd.

  • Page 417: Distributors And Branches - Australia

    Distributors and Branches - Australia Branches: Gepps Cross Cummins Engine Company, Pty. Ltd. P.O. Box 108 Blair Athol, 5084 South Australia, Australia Location: 45-49 Cavan Road Gepps Cross, 5094 Telephone: (61-8) 8262-5211 Branches: Dosra Cummins Engine Company, Pty. Ltd. P.O. Box 124 Darra, 4076 Queensland, Australia Location:.
  • Page 418 Branches: Grafton Cummins Engine Company, Pty. Ltd. P.O. Box 18 South Grafton, 2461 New South Wales, Australia Location: 18-20 Induna Street South Grafton, 2461 Telephone: (61-2) 6642-3655 Branches: Hexham Cummins Engine Company, Pty. Ltd. 21 Galleghan Street Hexham New South Wales, Australia Telephone: (61-2) 4964-8466 FAX: (61-2) 4964-8616 Branches:...
  • Page 419 Branches: Queanbeyan Cummins Engine Company, Pty. Ltd. P.O. Box 527 Queanbeyan, 2620 New South Wales, Australia Location: 15-27 Bayldon Road Queanbeyan, 2620 Telephone: (61-2) 6297-3433 FAX: (61-2) 6297-6709 Branches: Regency Park Cummins Engine Company, Pty. Ltd. P.O. Box 2147 Regency Park, SA 5942 Australia Location: 11 Manton Street Hindmarsh, SA 5942 Australia Telephone: (61-8) 8346-3832...

  • Page 420: Distributors And Branches - New Zealand

    Distributors and Branches - New Zealand Auckland Cummins Engine Company, Pty. Ltd. Private Bag 92804 Penrose, Auckland, New Zealand Location: 440 Church Street Penrose Telephone: (64-9) 579-0085 Branches: Auckland Cummins Engine Company, Pty. Ltd. Private Bag 92804 Penrose, Auckland, New Zealand Location: 440 Church Street Penrose Telephone: (64-9) 579-0085...

  • Page 421: Regional Offices - International - Locations

    Regional Offices - International - Locations Africa Regional Office - Daventry Cummins Engine Co. Ltd (Serving Czech Republic), Brussels (Middle East), (Africa) Telephone: (44-1327) 886 000 Royal Oak Way South Daventry, Northamptonshire Fax: (44-1327) 886 100 ZIP / Postal Code: NN11 8NU Countrie Covered: Burkina Faso...
  • Page 422 Middle East Regional Office - Daventry Cummins Engine Co. Ltd (Serving Czech Republic), Brussels (Middle East), (Africa) Telephone: (44-1327) 886 000 Royal Oak Way South Daventry, Northamptonshire Fax: (44-1327) 886 100 ZIP / Postal Code: NN11 8NU Countrie Covered: Afghanistan Bahrain Cyprus Egypt...
  • Page 423 Cummins India Ltd. Kothrud Telephone: (91-20) 2538-5435 / 0240 / 1105 Pune, Maharashtra Fax: (91-20) 2538-0125 ZIP / Postal Code: 411029 India Country Covered: Bhutan Nepal India Tokyo Regional Office - Japan Cummins Japan Ltd. ZIP / Postal Code: 105-0014 2nd Floor, Ichiboshi Shiba Bldg Japan 2-14, Shiba 2-chome...
  • Page 424 Moscow Regional Office - Russia Cummins Engine Co., Inc. Park Place Office E708 113/1 Leninsky Prospect Russia 117198 Telephone: (7-495) 956-51-22 / 23 Fax: (7-495) 956-53-62 Country Covered: Armenia Azerbaijan Moldova Belarus Russia Tajikistan Georgia Turkmenistan Kyrgyzstan Ukranie Kazakhstar Uzbekistan South And East Asia Area Regional Office - Singapore Cummins Diesel Sales Corporation Telephone: (65) 265-0155...

  • Page 425: Distributors - International - Locations

    Distributors - International - Locations Cummins Middle East FZE Cummins Middle East FZE P.O. Box No 17636, Units ZF 05 & 06 Jebel Ali Free Zone, Dubai United Arab Emirates Telephone: 00 9714 8838998 Fax: 00 9714 8838997 United Arab Emirates Cummins Emirates Sales P.O.
  • Page 426 ANTIGUA Miami (Office In U.S.A.) Cummins Power South, LLC 9900 N.W. 77 Ave. Hialeah Gardens, FL 33016 Telephone: (305) 821-4200 Fax: (305) 557-2992 ARGENTINA Buenos Aires Distribuidora Cummins, S.A. Ruta Panamericana KM 32.5 El Talar de Pacheco, Buenos Aires ZIP / Postal Code: CP 1618 Argentina Telephone: (54-11) 4736-6400 Fax: (54-11) 4736-6479 / 6466 ARUBA, ISLAND OF...
  • Page 427 AUSTRALIA Grafton Cummins 18 - 20 Induna Street South Grafton, New South Wales 2460 Australia Telephone: (61-2) 6641 1000 Fax: (61-2) 6641 1099 AUSTRALIA Hexham Cummins Engine Company, Pty. Ltd. 21 Galleghan Street Newcastle, New South Wales, Australia 2322 Telephone: (61-2) 4964-8466 Fax: (61-2) 4964-8616 AUSTRALIA Kalgoorlie...
  • Page 428 AUSTRALIA Swan Hill Cummins 5 McAllister Road Swan Hill, Victoria 3585 Australia Telephone: (61-3) 5033 1511 Fax: (61-3) 5032 9662 AUSTRALIA Tamworth Cummins Lot 65 Gunnedah Road Tamworth, New South Wales 2340 Australia Telephone: (61-2) 6765 5455 Fax: (61-2) 6765 5443 AUSTRALIA Townsville Cummins...
  • Page 429 BANGLADESH MIR Trading Co. House #55/1, Road # 8/A Dhamondi R/A Dhaka 1205 Bangladesh Telephone: (880-2) 8959425-7, 8960680-1, 8960643 Fax: (880-2) 8961373 BARBADOS Miami (Office in U.S.A.) Cummins Power South, LLC 900 N W 77th Ave. Hialeah Gardens, Florida 33016 Telephone: (305) 821-821-4200 Fax: (305) 557-2992 BELGIUM...
  • Page 430 BRAZIL Curitiba Distribuidora Parana de Motores Cummins Ltda. Abel Scuissiato 3020, Bairro Atuba Curitiba, PARANA 83408 Brazil Telephone: (55-41) 3675-4500 Fax: (55-41) 3675-6077 BRAZIL Fortaleza Distribuidora Cummins Diesel do Nordeste Ltda BR 116, km.10 - nr.10.001, Messejana Fortaleza, CEARA ZIP / Postal Code: 60871 Brazil Telephone: (55-85) 4011-6400 Fax: (55-85) 4011-6400 BRAZIL...
  • Page 431 BURKINA - FASO - See North/West/East and Central Africa Regional Office - Daventry Cummins Engine Company Ltd Royal Oak Way South Daventry, Northants ZIP / Postal Code: NN11 5NUUnited Kingdom Telephone: (44-1327) 886000 Fax: (44-1327) 886106 BULGARIA -See Germany Regional Office - Gross-Gerau Cummins Diesel Deutschland GmbH Odenwaldstrabe 23 Grob-Gerau, Hessen 64521 Germany...
  • Page 432 CHILE Santiago Distribuidora Cummins Chile, S.A. Avda. Americo Vespucio # 0631 Santiago, Quilicura ZIP / Postal Code: 873-0596 Chile Telephone: (56-2) 655-7253 / 7245 Fax: (56-2) 655-7216 / 7436 CHINA, PEOPLE'S Beijing Cummins Engine (Beijing) Co., Ltd. REPUBLIC No. 8, Wan Yuan Street Beijing Economic and Technology Development Zone Beijing, 100176 People's Republic of China Telephone: (86-10) 67882258...
  • Page 433 CHINA, PEOPLE'S Shenzhen Shenzhen Chongfa Cummins Engine Company Ltd. REPUBLIC Tian An Che Gong Miao Industrial Estate, Unit F2.6 - 2D Shenzhen Shennan Da Dao Shenzhen, Guangdong 518040 China Telephone: (86-755) 83415479 Fax: (86-755) 83415480 COLOMBIA Barranquilla Cummins de Colombia, S.A. Calle 65 (Avenida Murillo) #6-31 Diagonal a Gran Abastos Soledad, Atlantico Colombia...
  • Page 434 CORSICA - See France (Please contact) Cummins Diesel S.A. 39 rue Ampere BP 190 Chassieu cedex 69680 Telephone: (33-4) 479 100 Fax: (33-4) 78 90 19 56 COSTA RICA San Jose Oficina Regional Cummins de Centro America Urbanizacion Rincon Verde Dos Casa 13E San Pablo de Heredia Costa Rica Telephone: (506) 238-1160 Fax: (506) 238-1108...
  • Page 435 ECUADOR Guayaquil Indusur S.A. Ave. Carlos Julio Arosemena Km. 4 Guayaquil, Guayas Ecuador Telephone: (593-4) 220-1177 / 220-0655 Fax: (593-4) 220-1052 ECUADOR Quito Rectificadora Botar S.A. Av. 10 de Agosto # 5980 Quito, Pichincha Ecuador Telephone: (593-2) 2265-177 / 2265-209 / 2265-225 / 2265-193 Fax: (593-2) 2459-031 EGYPT...
  • Page 436 FIJI - See Cummins New Zealand Cummins 9 Langley Road Manukau City Centre, Auckland 1702 New Zealand Telephone: (64-3) 277 1000 Fax: (64-3) 277 1001 FINLAND Helsinki Machinery Oy Ansatie 5 Vantaa ZIP / Postal Code: FIN-01741 Finland Telephone: (358-9) 89551 FRANCE Lyon CUMMINS DIESEL S.A.
  • Page 437 GRENADA Miami (Office in U.S.A.) Cummins Power South, LLC 9900 N W 77th Ave. Hialeah Gardens, Florida 33016 Telephone: (305) 821-4200 Fax: (305) 557-2992 GUADELOUPE Miami (Office in U.S.A.) Cummins Power South, LLC 9900 N W 77th Ave. Hialeah Gardens, Florida 33016 Telephone: (305) 821-4200 Fax: (305) 557-2992 GUAM...
  • Page 438 HONDURAS Tegucigalpa Comercial Laeisz Honduras, S.A. Desvio Colonia La Pradera, Blvd. Toncontin Tegucigalpa Honduras Telephone: (504) 233-5615 / 234-7072 Fax: (504) 233-9531 / 234-3718 HONG KONG Kowloon Cummins Hong Kong Ltd. 2/F Unison Industrial Centre 27-31 Au Pui Wan Street, Fo Tan, Shatin, N.T. Hong Kong, Hong Kong S.A.R.ong Kong Telephone: (852) 2606-5678...
  • Page 439 IRAQ - See Middle East Regional Office or United Arab Emirates Cummins Emirates Sales & Service LLC P.O. Box No 54044 Al Quoz Industrial Estate, Dubai United Arab Emirates Telephone: 00 9714 3478184 Fax: 00 9714 3478185 Toll Free: 800 4184 IRELAND Wellingborough Cummins UK...
  • Page 440 KOREA - SOUTH KOREA Seoul Cummins Diesel Sales & Service Co., Ltd. 354-4, Chonheung-ri, Songgo-eup Chonan-city, Choongchungnam-do 330-836 South Korea Telephone: (82-41) 620-9202/3 Fax: (82-41) 621-9121 to 2 KOREA - SOUTH KOREA Seoul Cummins Korea Ltd 2nd Floor, Choyang Bldg. 113 Samsung Dong, Kangnam-ku Seoul, Korea Telephone: (82-2) 3420-0901 Fax: (82-2) 3452-4113 / 539-6569...
  • Page 441 LUXEMBOURG Cummins Diesel Deutschland GmbH Odenwaldstrabe 23 Grob-Gerau, Hessen 64521 Germany Telephone: (49-6152) 174-0 Fax: (49-6152) 174-141 MACAU - See Hong Kong Cummins Hong Kong Ltd. 2/F Unison Industrial Centre 27-31 Au Pui Wan Street, Fo Tan, Shatin, N.T.cccc Hong Kong, Hong Kong Hong Kong S.A.R.
  • Page 442 MEXICO Monterrey Converto Dexel Monterrey Privada Nazry Hasbun #2, Carr. Migue Aleman 14.8 Parque Industrial Hasna Apodaca, Nuevo Leon 66473 Mexico Telephone: (52-81) 81310200 Fax: (52-81) 81310200 MEXICO Merida Distribuidora Megamak del Sureste Av. Aviacion Civil No. 647 Col. Sambula Merida, Yucatan 97259 Mexico Telephone: (52-9) 930-1300 Fax: (52-9) 930-1315 MEXICO...
  • Page 443 NEW GUINEA - See Papua New Guinea Cummins Macdhui Street Lae Papua New Guinea Telephone: (675) 472 3699 Fax: (675) 472 3803 New Zealand Auckland Cummins 9 Langley Road Manukau City Centre, South Auckland 1702 New Zealand Telephone: (64-9) 277 1000 Fax: (64-9) 277 1001 New Zealand Christchurch...
  • Page 444 NORTHERN IRELAND - See United Kingdom Cummins Engine Company Ltd Royal Oak Way South Daventry, Northants ZIP / Postal Code: NN11 5NU United Kingdom Telephone: (44-1327) 886000 Fax: (44-1327) 886106 NORWAY Oslo Cummins Norway A S Hestehagen 3 Postboks 151 Drobak 1441 Norway Telephone: (47) 64 90 70 80 Fax: (47) 64 90 70 90 OMAN...
  • Page 445 QATAR Doha Jaidah Motors & Trading Co. P.O. Box 150 Doha, Qatar (Arabian Gulf) Telephone: (974) 4466888 Fax: (974) 441 4100 / 441 5400 REUNION - See Lyon Regional Office - Lyon CUMMINS DIESEL S.A. 39 rue Ampere BP 190 Chassieu cedex 69680 France Telephone: (33-4) 72 22 92 72 Fax: (33-4) 78 90 19 56...
  • Page 446 SAUDI ARABIA Al-Khobar General Contracting Company - OLAYAN P.O. Box 356 King Abdul Aziz Road Al-Khobar Saudi Arabia Telephone: (966-3) 882-0888 Fax: (966-3) 8828560 / 8827914 SCOTLAND - See United Kingdom Cummins UK Rutherford Drive Park Farm South Wellingborough, Northants ZIP / Postal Code: NN8 6AN United Kingdom Telephone: (44-1933) 334200 Fax: (44-1933) 334198...
  • Page 447 SOMALIA - see Southern Africa Regional Office (Please contact) Cummins Diesel South Africa (Pty) Ltd 13 Eastern Service Road Kelvin (Neighbourhood), Alexandra Gauteng, South Africa 2054 South Africa Telephone: (27-11) 321 8700 Fax: (27-11) 444 2012 SOUTH AFRICA Johannesburg Cummins Diesel South Africa (Pty) Ltd 13 Eastern Service Road Kelvin (Neighbourhood), Alexandra Gauteng, South Africa 2054 South Africa...
  • Page 448 SWAZILAND - See South Africa Cummins Diesel South Africa (Pty) Ltd 13 Eastern Service Road Kelvin (Neighbourhood), Alexandra Gauteng, South Africa ZIP / Postal Code: 2054 South Africa Telephone: (27-11) 321 8700 Fax: (27-11) 444 2012 SWEDEN Stockholm Cummins Sweden Maskingata 17C Brista Industriomade Marsta, Stockholm 195 60 Sweden Telephone: (46-8) 595 133 90...
  • Page 449 TONGA, ISLAND OF -See SOUTH PACIFIC ISLANDS (Please contact) Cummins 2 Caribbean Drive Scoresby 3179 Victoria AUSTRALIA Telephone: (61-3) 9765-3222 Fax: (61-3) 9763-0079 TRINIDAD and TOBAGO Cummins Power South, LLC 9900 N W 77th Ave. Hialeah Gardens, FL 33016 Telephone: (305) 821-4200 Fax: (305) 557-2992 TURKEY Istanbul...
  • Page 450 WESTERN SAMOA -See SOUTH PACIFIC ISLANDS (Please contact) Cummins 2 Caribbean Drive Scoresby 3179 Victoria AUSTRALIA Telephone: (61-3) 9765-3222 Fax: (61-3) 9763-0079 YEMEN Sana'a Zubieri Trading Company Al Qiyadah Street Sana'a Republic of Yemen Telephone: (967-1) 223943 / 224051 Fax: (967-1) 221611 / 245838 SERBIA &...

  • Page 451: Troubleshooting Symptoms

    TROUBLESHOOTING SYMPTOMS Troubleshooting Procedures and Techniques General Informatin This guide describes some typical engine operating problems, their causes, and some acceptable corrections to those problems. Unless noted otherwise, the problems listed are those which an operator can diagnose and repair. WARNING! Performing troubleshooting procedures NOT outlined in this section can result in equipment damage or personal...
  • Page 452 Air Compressor Air Pressure Rises Slowly Cause Correction Replace the air compressor air cleaner (if installed). Check the air intake piping. Check STEP 1 engine air intake restriction if the air compressor Air intake system restriction to air compressor is inlet is plumbed to the vehicle or equipment intake excessive system.
  • Page 453 Air Compressor Noise is Excessive Cause Correction Check for carbon buildup. Replace the air STEP 1 compressor discharge line and cylinder head Carbon buildup is excessive in the air discharge assembly if necessary. Refer to “Section 7” on line, downstream air valves, or cylinder head page-60.
  • Page 454 Air Compressor Pumping Excess Lubricating Oil into the Air System Cause Correction STEP 1 Verify the correct lubricating oil drain interval. Refer to “Maintenance Guidelines” on page-59. Lubricating oil drain interval is excessive Go To Next Step Replace the air compressor air cleaner (if STEP 2 installed).
  • Page 455 Air Compressor Will Not Stop Pumping Cause Correction Block the vehicle wheels and check the air system for leaks with spring brakes applied and STEP 1 released. Check for leaks from the air compressor Air system leaks gaskets and the air system hoses, fittings, tanks, and valves.
  • Page 456 Alternator Not Charging or Insufficient Charging Cause Correction STEP 1 Tighten the pulley. Refer to OEM service manual. Alternator pulley is loose on the shaft Go To Next Step Check the condition of the batteries. Replace the STEP 2 batteries, if necessary. Refer to OEM service Batteries have malfunctioned manual.
  • Page 457 Alternator Overcharging Cause Correction Check the condition of the batteries. Replace the STEP 1 batteries, if necessary. Refer to the OEM service Battery have failed manual. Go To Next Step Check the voltage regulator. Replace the voltage STEP 2 regulator, if necessary. Refer to an Authorized Voltage regulator is malfunctioning Cummins Repair Facility.
  • Page 458 Coolant Loss - External Cause Correction Inspect the engine and cooling system for STEP 1 external coolant leaks. Repair if necessary. Add Coolant level is below specification coolant. Refer to the OEM service manual. Go To Next Step Inspect the engine for coolant leaking from hoses, draincocks, water manifold, jumper tubes, expansion and pipe plugs, fittings, radiator core, STEP 2...
  • Page 459 Coolant Temperature Above Normal - Gradual Overheat Cause Correction STEP 1 Inspect the charge air cooler, air conditioner condenser, and radiator fins. Clean, if necessary. Charge air cooler fins, radiator fins, or air Refer to “Section 4” on page-60 and OEM conditioner condenser fins are damaged or service manual.
  • Page 460 Cause Correction Go To Next Step STEP 10 Test the temperature gauge. Repair or replace the gauge, if necessary. Coolant temperature gauge is malfunctioning Go To Next Step STEP 11 Check the fan drive belt. Refer to “Section 4” on page-60 4.
  • Page 461 Coolant Temperature Above Normal - Sudden Overheat Cause Correction Inspect the engine and cooling system for STEP 1 external coolant leaks. Repair if necessary. Add Coolant level is below specification coolant. Refer to “Section 3” on page-60. Go To Next Step For instructions on how to read active fault codes, STEP 2 refer to “Operating Instructions”...
  • Page 462 Coolant Temperature Below Normal Cause Correction STEP 1 Test the gauge and the sensor. Repair or replace, Coolant temperature gauge or sensor is if necessary. Refer to OEM service manual. malfunctioning Go To Next Step For instructions on how to read active fault codes, STEP 2 refer to “Operating Instructions”...
  • Page 463 Engine Acceleration or Response Poor Cause Correction STEP 1 Refer to “Operating Instructions” on page-48 . Operator technique is not correct Go To Next Step STEP 2 Fill the supply tank. Refer to the OEM service manual. Fuel level is low in the tank Go To Next Step Check the vehicle brakes for dragging, STEP 3...
  • Page 464 Cause Correction Go To Next Step Check for loose or damaged piping connections STEP 11 and missing pipe plugs. Check the turbocharger and exhaust manifold mounting. Refer to “Section Air intake or exhaust leaks 4” on page-60. Go To Next Step Check the air intake system for restriction.
  • Page 465 Engine Difficult to Start or Will Not Start (Exhaust Smoke) Cause Correction STEP 1 Verify the correct starting procedure. Refer to “Operating Instructions” on page-48. Starting procedure is not correct Go To Next Step STEP 2 Fill the supply tank. Refer to the OEM service manual.
  • Page 466 Cause Correction Go To Next Step Check the fuel lines, fuel connections, and fuel STEP 11 filters for leaks. Check the fuel lines to the supply Fuel leak tanks. Refer to the OEM service manual. Go To Next Step Check for air in the fuel system. Tighten or STEP 12 replace the fuel connections, fuel lines, fuel tank Air in the fuel system...
  • Page 467 Engine Difficult to Start or Will Not Start (No Exhaust Smoke) Cause Correction STEP 1 Verify the correct starting procedure. Refer to “Operating Instructions” on page-48. Starting procedure is not correct Go To Next Step STEP 2 Fill the supply tank. Refer to the OEM service manual.
  • Page 468 Cause Correction Go To Next Step STEP 11 Disconnect the battery cables for 30 seconds. Connect the battery cables, and start the engine. Electronic control module (ECM) is locked up Go To Next Step Replace the fuel filter. Refer to “Section 5” on STEP 12 page-60.
  • Page 469 Engine Noise Excessive Cause Correction STEP 1 Check the fan drive belt. Refer to “Section 3” on page-60. Fan drive belt is loose, tight, or not in alignment Go To Next Step STEP 2 Refer to the Lubricating Oil Specifications in “Maintenance Specifications”...
  • Page 470 Engine Noise Excessive - Combustion Knocks Cause Correction Check the winterfront, shutters, and under-the- hood air. Use under-the-hood intake air in cold STEP 1 weather. Refer to Cold temperature Weather Engine is operating at low ambient temperature Operation, see Bulletin 3387266, and “Operating Instructions”...
  • Page 471 Engine Power Output Low Cause Correction For instructions on how to read active fault codes, STEP 1 refer to “Operating Instructions” on page-48. If fault codes are active, contact a Cummins Electronic fault codes are active. Authorized Repair Facility Go To Next Step Operate the engine from a tank of high-quality STEP 2 fuel.
  • Page 472 Cause Correction Go To Next Step Check the fuel lines, fuel connections, and fuel STEP 10 filters for leaks. Check the fuel lines to the supply Fuel leak tanks. Refer to the OEM service manual. Go To Next Step Check for air in the fuel system. Tighten or STEP 11 replace the fuel connections, fuel lines, fuel tank Air in the fuel system...
  • Page 473 Engine Runs Rough at Idle Cause Correction Allow engine warm operating STEP 1 temperature. If the engine will not reach operating temperature, refer to the Coolant Temperature Engine is cold Below Normal symptom tree. Go To Next Step For instructions on how to read active fault codes, STEP 2 refer to “Operating Instructions”...
  • Page 474 Engine Runs Rough or Misfires Cause Correction Allow engine warm operating STEP 1 temperature. If the engine will not reach operating temperature, refer to the Coolant Temperature Engine is cold Below Normal symptom tree. Go To Next Step For instructions on how to read active fault codes, STEP 2 refer to Diagnostic Fault Codes Procedure 101- 007.
  • Page 475 Cause Correction STEP 10 Dry the connectors with Cummins electronic cleaner, Part Number 3824510. Moisture in the wiring harness connectors Go To Next Step STEP 11 Contact a Cummins Authorized Repair Facility QSB4.5 Engine SP001671 Page 219...
  • Page 476 Engine Shuts Off Unexpectedly or Dies During Deceleration Cause Correction STEP 1 Refer to the Engine Difficult to Start or Will Not Start symptom tree. Engine will not restart Go To Next Step STEP 2 Fill the supply tank. Refer to the OEM service manual.
  • Page 477 Engine Speed Surges at Low or High Idle Cause Correction STEP 1 Fill the supply tank. Refer to the OEM service manual. Fuel level is low in the tank Go To Next Step STEP 2 Adjust the idle speed. Refer to an Authorized Cummins Repair Facility.
  • Page 478 Engine Speed Surges Under Load or in Operating Range Cause Correction STEP 1 Fill the supply tank. Refer to the OEM service manual. Fuel level is low in the tank Go To Next Step For instructions on how to read active fault codes, STEP 2 refer to “Operating Instructions”...
  • Page 479 Cause Correction Compare the drivetrain specifications to Cummins STEP 10 recommendations. Check the clutch for correct Clutch is malfunctioning or is not correct operation. Refer to the OEM service manual. Go To Next Step STEP 11 Contact a Cummins Authorized Repair Facility TEngine Speed Surges in PTO or Cruise Control Cause Correction...
  • Page 480 Engine Starts But Will Not Keep Running Cause Correction STEP 1 Fill the supply tank. Refer to the OEM service manual. Fuel level is low in the tank Go To Next Step STEP 2 Check the battery connections. Refer to the OEM Battery voltage supply to the electronic control service manual.
  • Page 481 Engine Vibration Excessive Cause Correction Check hub, alternator, refrigerant compressor, and hydraulic pump for interference. STEP 1 Isolate belt-driven accessories and check for Belt-driven accessories are malfunctioning vibration. Refer to “Section 3” on page-60 and “Section 4” on page-60. Go To Next Step STEP 2 Refer to the Air Compressor Cycles Frequently symptom tree.
  • Page 482 Engine Will Not Crank or Cranks Slowly (Air Starter) Cause Correction STEP 1 Increase air pressure with an external air source. Refer to the OEM service manual. Air pressure is low in the air tanks Go To Next Step STEP 2 Disengage engine-driven units.
  • Page 483 Engine Will Not Crank or Cranks Slowly (Electric Starter) Cause Correction STEP 1 Check battery heater. Refer manufacturer's instructions. Battery are cold Go To Next Step STEP 2 Check the battery cables and connections. Battery cables or connections are loose, broken, or corroded (excessive resistance) Go To Next Step STEP 3...
  • Page 484 Engine Will Not Reach Rated Speed (RPM) Cause Correction For instructions on how to read active fault codes, STEP 1 refer to Diagnostic Fault Codes Procedure 101- 007. If fault codes are active, contact a Cummins Electronic fault codes are active Authorized Repair Facility.
  • Page 485 Cause Correction STEP 10 Refer to the Engine Power Output Low symptom tree. Engine power output is low Go To Next Step STEP 11 Contact a Cummins Authorized Repair Facility QSB4.5 Engine SP001671 Page 229...
  • Page 486 Fault Code Warning Lights Stay On (No Apparent Reason) Cause Correction STEP 1 Remove the diagnostic shorting plug. Diagnostic shorting plug is installed Go To Next Step STEP 2 Turn off the diagnostic switch. Diagnostic switch is in the ON position Go To Next Step For instructions on how to read active fault codes, STEP 3...
  • Page 487 Fuel Consumption Excessive Cause Correction Explain correct engine operation to the operator. STEP 1 Refer to Operating Instructions, Procedure 101- Operator technique is not correct 999. Go To Next Step For instructions on how to read active fault codes, STEP 2 refer to Diagnostic Fault Codes, Procedure 101- 007.
  • Page 488 Fuel in Coolant Cause Correction Check the bulk coolant supply. Drain the coolant STEP 1 replace with noncontaminated coolant. Replace the coolant filters. Replace the coolant Bulk coolant supply is contaminated filter. Refer to Procedure 008-006. Go To Next Step STEP 2 Contact a Cummins Authorized Repair Facility Fuel in the Lubricating Oil...
  • Page 489 Intake Manifold Air Temperature Above Specification Cause Correction STEP 1 Inspect the charge air cooler, air conditioner condenser, and radiator fins. Clean, if necessary. Charge air cooler fins, radiator fins, or air Refer to Procedure 010-027 and the OEM service conditioner condenser fins are damaged or manual.
  • Page 490 Intake Manifold Pressure (Boost) is Below Normal Cause Correction Check for loose or damaged piping connections STEP 1 and missing pipe plugs. Check the turbocharger exhaust manifold mounting. Refer Air intake or exhaust leaks Procedure 010-033. Go To Next Step Check the air intake system for restriction.
  • Page 491 Lubricating Oil Consumption Excessive Cause Correction STEP 1 Check and clean the crankcase breather and vent tube. Refer to Procedure 003-018. Crankcase ventilation system is plugged Go To Next Step STEP 2 Change the oil and filters. Refer to Procedure 007- 002.
  • Page 492 Lubricating Oil Contaminated Cause Correction Change the oil and filters. Refer to the Lubricating STEP 1 Oil Sludge in the Crankcase Excessive symptom Lubricating oil sludge is excessive tree. Go To Next Step Change the oil and filters. Refer to “Section 5” on STEP 2 page-60.
  • Page 493 Lubricating Oil Loss Cause Correction Inspect the engine for external oil leaks. Tighten STEP 1 the capscrews, pipe plugs, and fittings. Replace gaskets, if necessary. Refer to the OEM service Lubricating oil leak (external) manual. Go To Next Step Check the oil level. Verify the dipstick calibration STEP 2 and the oil pan capacity.
  • Page 494 Lubricating Oil Pressure High Cause Correction STEP 1 Refer to the Coolant Temperature Below Normal symptom tree. Coolant temperature is above specification Go To Next Step STEP 2 Change the oil and filters. Refer to Procedure 007- 002. Use the oil recommended in Lubricating oil does not meet specifications for “Maintenance Specifications”...
  • Page 495 Lubricating Oil Pressure Low Cause Correction STEP 1 Refer to the engine data sheet. Engine angularity during operation exceeds specification Go To Next Step STEP 2 Change the oil and filters. Refer to Procedure 007- 002. Use the oil recommended in Lubricating oil does not meet specifications for “Maintenance Specifications”...
  • Page 496 Lubricating Oil Sludge in the Crankcase Excessive Cause Correction Check the bulk oil supply. Drain the oil and STEP 1 replace with noncontaminated oil. Replace the oil Bulk oil supply is contaminated filters. Go To Next Step STEP 2 Refer to the Coolant Temperature Below Normal symptom tree.
  • Page 497 Smoke, Black - Excessive Cause Correction For instructions on how to read active fault codes, STEP 1 refer to Diagnostic Fault Codes Procedure 101- 007. If fault codes are active, contact a Cummins Electronic fault codes are active Authorized Repair Facility. Go To Next Step Check the air intake system for restriction.
  • Page 498 Smoke, White - Excessive Cause Correction STEP 1 Verify the correct starting procedure. Refer to “Operating Instructions” on page-48. Starting procedure is not correct Go To Next Step Allow the engine to warm to operating STEP 2 temperature. If the engine will not reach operating temperature, refer to the Coolant Temperature Engine is cold Below Normal symptom tree.
  • Page 499 Cause Correction Go To Next Step STEP 10 Inspect the charge air cooler for air restrictions or leaks. Refer to Procedure 010-027. Charge air cooler is restricted or leaking Go To Next Step STEP 11 Contact a Cummins Authorized Repair Facility QSB4.5 Engine SP001671 Page 243...
  • Page 500 Turbocharger Leaks Engine Oil or Fuel Cause Correction STEP 1 Review the engine operating instructions in “Operating Instructions” on page-48. Engine is operating for extended periods under light- or no-load conditions (slobbering) Go To Next Step STEP 2 Remove the intake and exhaust piping, and check for oil or fuel.
  • Page 501 MAINTENANCE SPECIFICATIONS General Engine Listed below are the general specifications for this engine. Item Specifications Bore x Stroke 107 mm (4.21 in) x 124 mm (4.88in) Horsepower Refer to engine data plate Displacement Four-Cylinder Engine 4.5 liters (274 C.I.D.) Six-Cylinder Engine 6.7 liters (409 C.I.D.) Firing Order Four-Cylinder Engine...
  • Page 502 Fuel System Preparatory Steps For performance and fuel rate values, refer to the Engine Data Sheet Cummins Common Rail Fuel System Specifications Maximum Fuel Inlet Restriction -With gear pump only (no engine mounted electric fuel lift pump) 69 kPa (10 psi) (at gear pump inlet) Rail Pressure - 4.5 liters (274 C.I.D.) and 6.7 liters 250 to 1600 bar (3,626 to 23,206 psi)
  • Page 503 Lubricating Oil System All Applications Except Marine Specifications Oil Pressure Low Idle (minimum allowed) 69 kPa (10 psi) At Rated (minimum allowed) 207 kPa (30 psi) Oil-regulating valve-opening pressure range to 517 kPa (75 psi) 448 kPa (65 psi) Oil filter differential pressure to open bypass 345 kPa (50 psi) Lubricating Oil Filter Capacity 0.95 liters (1 qt)
  • Page 504 Cooling System All Applications Except Marine Specifications Coolant Capacity (four-cylinder engine only) 8.5 liters (2.2 qt) Coolant Capacity (six-cylinder engine only) 10 liters (2.6 qt) Standard Modulating Thermostat - Range - Industrial 88 to 97°C (190 to 207°F) Applications Maximum Allowed Operating Temperature - 107°C (225°F) Industrial Applications Minimum Recommended Operating Temperature...
  • Page 505 Electrical System Specifications Recommended Battery Capacity System Voltage Ambient Temperatures 18°C [0°F] -29°C [-20°F] Reserve Capacity Cold Cranking Reserve Capacity Cold Cranking Amperes Amperes (Minutes) (Minutes) 6 cylinder engines 12-VDC 1500 1900 24-VDC 4 cylinder engines 12-VDC 1200 1500 24-VDC The number of plates within a given battery size determines reserve capacity.
  • Page 506 Cummins/Fleetguard Filter Specifications ® General Information ® Fleetguard Nelson is a subsidiary of Cummins Inc. Fleetguard/ ® Nelson filters are developed through joint testing at Cummins ® ® Fleetguard /Nelson. Fleetguard /Nelson filters ® standard Cummins engines. Cummins Inc. recommends their use. ®...
  • Page 507 Fuel Recommendations and Specifications Fuel Recommendations WARNING! Do not mix gasoline, alcohol, or gasohol with diesel fuel. This mixture can cause an explosion. CAUTION! Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept clean and free of dirt or water.
  • Page 508 The following chart lists acceptable substitute fuels for this engine. Acceptable Substitute Fuels No. 1D No. 2D No. 1K Jet-A Jet-A1 JP-5 JP-8 Jet-B JP-4 CITE Diesel (1) (2) (3) Diesel (3) Kerosen Not OK Not OK Not OK Not OK An "A"...
  • Page 509 Lubricating Oil Recommendations and Specifications General Information CAUTION! The fuel sulphur content should not exceed 0.5 mass percent sulphur. If the fuel sulphur content is greater than 0.5 mass percent sulphur, seek advice from your local Cummins Distributor. For recommendations of fuel for Cummins engines, refer to Fuel for Cummins Engines, Bulletin 3379001.
  • Page 510 CG-4/SH and E-3 oils can be used in areas where none of the recommended oils are available, but the oil drain interval must be reduced by one half of the interval given in the maintenance schedule. See the oil drain interval information in “Maintenance Guidelines”...
  • Page 511 The center section identifies the SAE oil viscosity grade. Figure 228 As the engine oil becomes contaminated, essential oil additives are depleted. Lubricating oils protect the engine as long as these additives are functioning properly. Progressive contamination of the oil between oil and filter change intervals is normal. The amount of contamination will vary depending on the operation of the engine, kilometers or miles on the oil, fuel consumed, and new oil added.
  • Page 512 Coolant Recommendations and Specifications Fully Formulated Coolant/Antifreeze Cummins Inc. recommends the use of fully formulated antifreeze/coolant meeting Cummins Engineering Standards (C.E.S.) 14603. For further details and discussion of coolant for ® Cummins engines, refer to Coolant Requirements and Maintenance, Bulletin 3666132. Typically, antifreeze/coolants meeting ASTM4985 (GM6038M specification) or ASTM D6210 criteria are acceptable antifreeze/coolants for engines covered by the manual.
  • Page 513 Fully formulated antifreeze must be mixed with good-quality water at a 50/50 ratio (40-to 60-percent working range). A 50/50 mixture of antifreeze and water gives a 36°C (-33°F) freezing Freezing point and a 108°C (226°F) boiling point, which is adequate for Point locations in North America.
  • Page 514 Cooling System Sealing Additives Do not use sealing additives in the cooling system. The use of sealing additives will: • Buildup in coolant low-flow areas • Plug the radiator and oil cooler • Possibly damage the water pump Figure 235 Cooling System Soluble Oils Do not use soluble oils in the cooling system.
  • Page 515 Drive Belt Tension Tension Chart SAE Belt Size Belt Tension Gauge Part No. Belt Tension New Belt Tension Range Used* Click-type Burroughs 0.380 in 3822524 270 to 490 60 to 110 0.440 in 3822524 270 to 490 60 to 110 1/2 in 3822524 ST-1138...
  • Page 516 Engine Component Torque Values Torque Table Torque Value Component ft lb Alternator Link Alternator Mounting Bolt Belt Tensioner Mounting Crankshaft Damper and Pulley Crossover Clamp 44 in-lb Tee Bolt Type Clamp 71 in-lb Exhaust Outlet Pipe, V Band Clamp 71 in-lb Fan Bracket Mounting Fan Pulley Fuel Filter...
  • Page 517 Cap Screw Markings and Torque Values General Information CAUTION! When replacing cap screws, always use a cap screw of the same measurement and strength as the cap screw being replaced. Using the wrong cap screws can result in engine damage. Metric cap screws and nuts are identified by the grade number stamped on the head of the cap screw or on the surface of the nuts.
  • Page 518 Cap Screw Markings and Torque Values - Metric Commercial Steel Class 10.9 12.9 Cap Screws Head Markings Body Size Torque Torque Torque Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum ft lb ft lb ft lb ft lb ft lb ft lb QSB4.5 Engine...
  • Page 519 Cap Screw Markings and Torque Values - U.S. Customary SAE Grade Cap Screws Head Markings These are all SAE Grade 5 (3 line) Cap Screw Torque - Grade 5 Cap Screw Cap Screw Torque - Grade 8 Cap Screw Cap Screw Cast Iron Aluminum Cast Iron...
  • Page 520 WARRANTY All Engines United States and Canada Industrial (Off-Highway) Coverage Products Warranted This warranty applies to new Engines sold by Cummins and delivered to the first user on or after April 1, 1999, that are used in industrial (off-highway) applications in the United States* and Canada, except for Engines used in marine, generator drive and certain defense applications, for which different warranty coverage is provided.
  • Page 521 Cummins' Responsibilities During The Base Engine Warranty Cummins will pay for all parts and labor needed to repair the damage to the Engine resulting from a Warrantable Failure. Cummins will pay for the lubricating oil, antifreeze, filter elements, and other maintenance items that are not reusable due to the Warrantable Failure.
  • Page 522 Limitations Cummins is not responsible for failures or damage resulting from what Cummins determines to be abuse or neglect, including, but not limited to: operation without adequate coolants or lubricants; over fueling; overspeeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in or shutdown practices;...
  • Page 523 Emission Warranty Products Warranted This emission warranty applies to new Engines marketed by Cummins that are used in the United States* in vehicles designed for Industrial off-highway use. This warranty applies to Engines delivered to the ultimate purchaser on or after April 1, 1999 for engines up to 750 horsepower, on or after January 1, 2000 for engines 751 horsepower and over.
  • Page 524 All Engines International Industrial (Off-Highway) Coverage Products Warranted This warranty applies to new Engines sold by Cummins and delivered to the first user on or after April 1, 1999, that are used in industrial (off-highway) applications anywhere in the world where Cummins-approved service is available, except the United States* and Canada.
  • Page 525 Cummins will pay reasonable costs for mechanics to travel to and from the equipment site, including meals, mileage and lodging, when the repair is performed at the site of the failure. Cummins will pay reasonable labor costs for Engine removal and reinstallation when necessary to repair a Warrantable Failure.
  • Page 526 Limitations Cummins is not responsible for failures or damage resulting from what Cummins determines to be abuse or neglect, including, but not limited to: operation without adequate coolants or lubricants; over fueling; overspeeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in or shutdown practices;...
  • Page 527 California Emission Control System Warranty, Off-Highway Products Warranted This Emission Control System Warranty applies to off-road diesel engines certified with the California Air Resources Board beginning with the year 1996 for engines up to 750 horsepower, beginning with the year 2000 for 751 horsepower and over, marketed by Cummins, and registered in California for use in industrial off-highway applications.
  • Page 528 Coverage This emission control system warranty applies only to the following A series, B3.3, B3.9, B4.5s, B5.9, B6.7s, QSB3.9- 30, QSB4.5-30, QSB5.9-30, QSB5.9-44, C8.3, QSC8.3, and QSL9 emission control parts: Fuel Pump Intake Manifold Static Timing Charge Air Cooler Delivery Valve Aftercooler Injection Control Valve Module Exhaust Manifold...
  • Page 529 Cummins distributor, authorized dealer or other repair location approved by Cummins and deliver the engine to such facility for repair. Repair locations are listed in Cummins United States and Canada Service Directory. Owner responsible incidental costs such communication expenses, meals, lodging incurred by Owner oremployees of Owner as a result of a warrantable failure.
  • Page 530 Emergency Repairs In the case of an emergency where a Cummins distributor, authorized dealer, or other repair location approved by Cummins is not available, repairs may be performed by any available repair location using any replacement parts. Cummins will reimburse the Owner for expenses (including diagnosis), not to exceed the manufacturer's suggested retail price for all warranted parts replaced and labor charges based on the manufacturer's recommended time allowance for the warranty...
  • Page 531 SP001326 DRIVE COUPLING (MAIN PUMP)SP001326 Drive Coupling (Main Pump) Edition 1 Drive Coupling (Main Pump) SP001326 Page 1...
  • Page 532 MEMO Drive Coupling (Main Pump) SP001326 Page 2...
  • Page 533 Table of Contents Drive Coupling (Main Pump) Safety Precautions ..........5 Applicable Models ..........5 Drive Coupling ............7 Special Tools ............8 Installation of Drive Coupling ........ 9 Installation Procedure............ 10 Drive Coupling (Main Pump) SP001326 Page 3...
  • Page 534 MEMO Drive Coupling (Main Pump) SP001326 Page 4...
  • Page 535 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.
  • Page 536 Drive Coupling (Main Pump) SP001326 Page 6...
  • Page 537 DRIVE COUPLING It is very important to set specified clearance between the end of the pump drive shaft (the "Dimension H" described below) and the coupling hub surface when installing the main pump in the engine. The Figure 1 shows installation of a typical drive coupling. Figure 1 Drive Coupling (Main Pump) SP001326...
  • Page 538 SPECIAL TOOLS This tool is used to adjust the clearance, referred to as "Measure H" in the installation instructions below, between the pump drive shaft and the front side of the drive coupling hub (4, Figure 2). NOTE: Dimensions A and B are the same as Measure H in Figure 3.
  • Page 539 INSTALLATION OF DRIVE COUPLING Follow the installation dimensions and procedures whenever installing the drive coupling in the main pump. NOTE: Failure to follow the procedures results in noise and the shortage of the service life of the drive coupling or the main pump.
  • Page 540 Parts and Torques References Parts Q'ty Torque Spring Pin Insert Bolt Fly Wheel Spring Pin Insert Bolt Pump Shaft Fixing Nut Element Ensure to follow the specification of Measure H from the front hub surface to the pump shaft and tightening torques of bolts and screws.
  • Page 541 Install spring pin (1) and then insert (2) with bolt (3) into engine fly wheel (4). NOTE: Tighten the bolt using the torque Ta value specified in the table. Install two spring pins (5) and then insert (6) in bolt (8) of hub (7).
  • Page 542 Drive Coupling (Main Pump) SP001326 Page 12...
  • Page 543 Hydraulics...
  • Page 545 SP001942 HYDRAULIC SYSTEM TROUBLESHOOTING, TESTING AND ADJUSTMENTSP001942 Hydraulic System Troubleshooting, Testing and Adjustment Edition 1 Hydraulic System Troubleshooting, Testing and Adjustment SP001942 Page 1...
  • Page 546 MEMO SP001942 Hydraulic System Troubleshooting, Testing and Adjustment Page 2...
  • Page 547 Table of Contents Hydraulic System Troubleshooting, Testing and Adjustment Safety Precautions ..........5 Applicable Models ..........5 Hydraulic System - General Notes ....... 6 Hydraulic Schematic..........7 General Notes ..............7 Operation of Working Components ...... 9 Boom Operating Circuit ........... 9 Boom Up Circuit ..............
  • Page 548 Control Valve Pressure and Current Adjustments..18 Pressure Up Valve..........19 Checks and Adjustments..........19 Pump Input Power Control ......... 21 Pump Regulator Adjustment ......... 21 Flow Meter and Flow Meter Kit Installation and Testing ..............25 Swing System Troubleshooting ......27 Precautions/Initial Checks ..........

  • Page 549: Hydraulic System Troubleshooting, Testing And Adjustment

    SAFETY PRECAUTIONS CAUTION Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that are in good working order. Use lifting and hoisting equipment capable of safely handling load.

  • Page 550: Hydraulic System - General Notes

    HYDRAULIC SYSTEM - GENERAL NOTES CENTER JOINT TRAVEL MOTOR TRAVEL MOTOR FG009803 Figure 1 hydraulic system several improvements over conventional hydraulic systems - including cross-sensing total horsepower control - to maximize output efficiency. The system features an electronically controlled output optimization system, which allows the operator to choose between two, distinctly different power modes: high-output/rapid cycling maximum speed power mode, and a standard power...

  • Page 551: Hydraulic Schematic

    HYDRAULIC SCHEMATIC The hydraulic schematic(s) is available in the "Hydraulic and Electrical Schematic Shop Manual." This manual is a collection of diagrams and schematics for a number of models. General Notes When referring to the schematic, refer to the following items: •...
  • Page 552 • The hydraulic reservoir return line and the pilot circuit both have 10 micron full flow filters. The disposable elements in these two canister type filters trap and remove impurities from the oil in the system. An 80 mesh, 177 micron reservoir intake strainer also helps maintain system cleanliness and should be cleaned each time hydraulic fluid is drained and replaced.

  • Page 553: Operation Of Working Components

    OPERATION OF WORKING COMPONENTS Boom Operating Circuit The boom operating circuit includes the right and left main hydraulic pumps (both halves of the main pump assembly), both sides of the control valve and the boom cylinder. The circuit operates in boom down mode through the first shift position and through the second shift position in boom up mode.

  • Page 554: Arm Operating Circuit

    Arm Operating Circuit The arm operating circuit includes both the front and rear hydraulic main pumps, the right and left halves of the control valve, a slow return orifice, and the arm cylinder. The circuit can be operated in the two-stage speed control mode which works through both halves of the control valve and doubles the volume of oil flowing to the cylinder.

  • Page 555: Bucket Operating Circuit

    Bucket Operating Circuit The bucket operating circuit includes the left main pump, the left half of the control valve and the bucket cylinder. 350 kg/cm (4,978 psi) overload relief valves at BKT and BKTD 1 ports of the control valve protect the circuit and its components from being damaged.

  • Page 556: Right Swing Operating Circuit

    Right Swing Operating Circuit When the swing control lever is pushed to the right swing position, pilot pressure from the left side pilot valve is directed to CONTROL the front side pump regulator and left half of the control valve. VALVE(L) Output flow from the front pump is then directed through the PR PILOT VALVE...

  • Page 557: Forward Travel Circuit

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

  • Page 558: Procedural Troubleshooting Baseline Recommendations

    PROCEDURAL TROUBLESHOOTING BASELINE RECOMMENDATIONS Initial Checks and Tests to Establish Operating Condition of the Excavator Triage Summary An excavator that fails to deliver designed performance should be checked for the following: • Hydraulic flow, first, and. • Hydraulic pressure, afterwards, in a specified order of priority through different points of the system.
  • Page 559 System specification performance tests of NOTE: individual activator function determined by flow rate through the component or circuit, not the control pressure or system pressure available to the actuator. Poor flow through the individual circuit may indicate that the component is worn beyond tolerance limits, while all other hydraulic functions are adequate.

  • Page 560: Pilot Pressure

    PILOT PRESSURE Adjustment and Testing WARNING This procedure should be done with two people. To reduce the chance of accident or unintended start-up, one person should remain at the operator's control stand while checks and adjustments are made. Vent hydraulic pressure from the reservoir before breaking the seal on fittings to install two in-line "T-style"...

  • Page 561: Power Mode Valve

    The jumper harness (which is available through DOOSAN After Sales Service, or could be spliced together from commonly available, purchased parts) has extra leads so that a VOM meter can be connected to the circuit.

  • Page 562: Swing Priority Valve

    SWING PRIORITY VALVE Control Valve Pressure and Current Adjustments WARNING This procedure should be done with two people. To reduce the chance of accident or unintended start-up, one person should remain at the operator's control stand while checks and adjustments are made. The swing priority control valve is inside the compartment behind the cabin.

  • Page 563: Pressure Up Valve

    PRESSURE UP VALVE Checks and Adjustments WARNING This procedure should be done with two people. To reduce the chance of accident or unintended start-up, one person should remain at the operator's control stand while checks and adjustments are made. Vent hydraulic pressure from the reservoir to install an in-line "T- style"...
  • Page 564 Main Pressure and Pilot Pressure and Power Mode Operation Tolerance Tolerance 20 - 40 bar 30 bar +10 bar Power Mode Neutral, No Operation (290 - 580 psi) (435 psi +145 psi) 330 bar +5 bar 30 bar +10 bar Power Mode Cylinder Stall (4,785 psi +75 psi)

  • Page 565: Pump Input Power Control

    PUMP INPUT POWER CONTROL Pump Regulator Adjustment WARNING This procedure should be done with two people. To reduce the chance of accident or unintended start-up, one person should remain at the operator's control stand while checks and adjustments are made. To perform these adjustments accurately the use of a flow meter is strongly recommended, as is consulting the factory (before starting work) to validate the need for making regulator...
  • Page 566 To check pump imbalance without a flow meter, travel the excavator forward on flat, level terrain. If the machine veers off despite neutral control input and even, balanced track adjustment, the pump which supplies output to the track frame toward which the excavator is veering is weak. FG000654 Figure 12 Refer to the illustration of the pump regulator control valve...
  • Page 567 Check and record the arm dump speed performance test before and after input power adjustment, whether or not a flow meter is used. Regulator adjustments affect total cumulative NOTE: horsepower, since each regulator compensates for the output of the other. It is not necessary to adjust both regulators at the same time, but after checking or adjusting one of them, the remaining unit should also be checked.
  • Page 568 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. HDA3008L Figure 15 Hydraulic System Troubleshooting, Testing and Adjustment...

  • Page 569: Flow Meter And Flow Meter Kit Installation And Testing

    The After Sales Service department of the nearest local DOOSAN dealer can assist you with these tests or, if you prefer carrying out your own testing, they should be able to help in putting together a hose and fitting kit (or the required dimensions and specifications for hoses and fittings) to allow you to install a flow meter downstream from the main pump assembly.
  • Page 570 The third column of test results should provide a record of engine rpm measured during each of the following tests – with the engine speed control dial set at maximum, the power mode selector at Power Mode and the work mode selector at digging mode: •...

  • Page 571: Swing System Troubleshooting

    SWING SYSTEM TROUBLESHOOTING Precautions/Initial Checks Stop work. Release all weight or any type of load safely before proceeding. Avoid risking injury or adding to damage. 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.

  • Page 572: Swing Relief Valve Checking And Adjustment

    Swing Relief Valve Checking and Adjustment Make a check of operating pressures through the swing relief valve if: • The swing motor fails to turn. • Swings in one direction only. • Swings but continues to coast. • There is drifting on a slope. Check operation by connecting: Two 600 bar (8,700 psi) pressure gauges to the inlet and outlet measuring ports on top of the swing motor.
  • Page 573 When pressure through the port is at the recommended level, the brake release valve should disengage the swing brake, allowing the swing motor to rotate the excavator. If pressure adjustment to the valve has been restored but the brake still fails to release, the brake piston or friction plate may be frozen, requiring disassembly of the motor and parts repair/replacement.

  • Page 574: Troubleshooting - Swing Gearbox

    TROUBLESHOOTING – SWING GEARBOX Problem Possible Cause Remedy Swing motor fails to operate and: Three pressure tests at Swing relief valve defective Brake Adjust pressure to recommended range motor, brake or makeup release valve defective Motor in affected valve. valve show low reading(s). makeup valve defective.

  • Page 575: Troubleshooting - Hydraulic Problems

    Problem Possible Cause Remedy Pressure at swing motor Swing motor drive shaft damage. Replace swing motor. inlet shows no increase, Internal damage to gearbox drive Repair/Replace broken or faulty and the swing motor is train. assemblies. making irregular noises. Pressure at swing motor Hydraulic pump or valve problem.
  • Page 576 Problem Possible Cause Remedy Oil temperature abnormally Oil cooler clogged or air circulation Clean. high. to cooler blocked. Cooling fan belt tension too loose. Readjust belt tension. Relief valve set too low. Readjust valve. Relief valve in constant use. Reduce or slow work load or cycling rate. Hydraulic oil severely neglected or Replace oil.

  • Page 577: Troubleshooting - Control Valve

    TROUBLESHOOTING – CONTROL VALVE Check control valve problems only after other hydraulic circuit operational tests have been made. Refer "Troubleshooting Baseline Recommendations" procedure. Pump flow, pilot pressure, Negacon pressure, main relief pressure, and port relief pressure should all be checked before starting to work on the control valve.

  • Page 578: Troubleshooting - Travel Control Valve

    Problem Possible Cause Remedy Pressure does not increase Main poppet or pilot poppet stuck Clean/replace. at all. open. Irregular or uneven Poppet seat damaged or pilot Clean/replace. pressure. piston sticking to main poppet. Loose lock nut and adjusting screw. Readjust. Components worn out, past wear Replace.

  • Page 579: Troubleshooting - Joystick Control Valve

    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.
  • Page 580 Hydraulic System Troubleshooting, Testing and Adjustment SP001942 Page 36...
  • Page 581 SP000028 ACCUMULATOR SP000028 Accumulator Edition 1 Accumulator SP000028 Page 1...
  • Page 582 MEMO Accumulator SP000028 Page 2...
  • Page 583 Table of Contents Accumulator Safety Precautions ..........5 Applicable Models ..........5 General Description ..........6 Specifications ..............8 Accumulator SP000028 Page 3...
  • Page 584 MEMO Accumulator SP000028 Page 4...

  • Page 585: Safety Precautions

    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.

  • Page 586: General Description

    GENERAL DESCRIPTION The accumulator is a gas-charged storage device designed to hold a reserve quantity of hydraulic fluid under pressure. Accumulators are used in hydraulic circuits in much the same way that condensers (or capacitors) are used to collect, store and maintain electrical charge in a circuit.
  • Page 587 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.

  • Page 588: Specifications

    Specifications Model Serial Number System Charge Pressure Volume 320 cc 10 kg/cm DX140LC S/N 5001 and Up Pilot (140 psi) (19.53 in 320 cc 10 kg/cm DX140LCR S/N 5001 and Up Pilot (140 psi) (19.53 in 320 cc 10 kg/cm DX180LC S/N 5001 and Up Pilot...
  • Page 589 SP000029 CENTER JOINT (SWIVEL)SP000029 Center Joint (Swivel) Edition 1 Center Joint (Swivel) SP000029 Page 1...
  • Page 590 MEMO Center Joint (Swivel) SP000029 Page 2...
  • Page 591 Table of Contents Center Joint (Swivel) Safety Precautions ..........5 Applicable Models ..........5 General Description ..........6 Parts List ................. 7 Troubleshooting, Testing and Adjustment .... 8 Inspection ................ 8 Testing................8 Disassembly ............9 Reassembly ............10 Center Joint (Swivel) SP000029 Page 3...
  • Page 592 MEMO Center Joint (Swivel) SP000029 Page 4...

  • Page 593: Center Joint (Swivel)

    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.

  • Page 594: General Description

    GENERAL DESCRIPTION The center joint (swivel) is designed to allow hydraulic oil from the upper structure to flow to components in the lower structure. It is capable of allowing continuous 360° rotation of the upper structure in relationship to the lower structure. Center Joint (Swivel) SP000029 Page 6...

  • Page 595: Parts List

    Parts List FG000536 Figure 1 Reference Reference Description Description Number Number Body O-ring Spindle Plug Cover Plug Spacer Bolt Shim Spring Washer Wear Ring Bolt Slipper Ring Spring Washer O-ring Bolt O-ring Spring Washer Center Joint (Swivel) SP000029 Page 7...

  • Page 596: Troubleshooting, Testing And Adjustment

    TROUBLESHOOTING, TESTING AND ADJUSTMENT Inspection The center joint should be checked for evidence of external oil leakage every 2,000 operating hours. Leaking or defective O- rings are an indication that dirt and other contaminants could be getting inside the assembly, which will promote accelerated, abnormal wear and may cause early failure of the assembly.

  • Page 597: Disassembly

    DISASSEMBLY Refer to the assembly drawing of the swivel joint for component references (Figure 1). IMPORTANT Do not unbolt the center joint from the lower car body until an adequate number of piping block-off plates are available, for disconnected piping lines. Be sure that system pressure has been vented - including the hydraulic accumulator and tank reserve pressure - before disassembly is started.

  • Page 598: Reassembly

    REASSEMBLY Prelubricate O-rings with hydraulic oil, white grease or petroleum jelly. CAUTION Apply a very light film of white grease or petroleum jelly to the lower rim of the stem and inner surface of the center swivel body. Apply slow, even-handed pressure, using both hands, to slowly push the stem into the body.
  • Page 599 SP000030 CYLINDERS SP000030 Cylinders Edition 1 Cylinders SP000030 Page 1...
  • Page 600 MEMO Cylinders SP000030 Page 2...
  • Page 601 Table of Contents Cylinders Safety Precautions ..........5 Applicable Models ..........5 General Description ..........6 Theory of Operation ............6 Parts List ................. 7 Special Tools and Materials ......... 9 Piston Nut................ 9 Piston Jig ............... 10 Steel Bushing Jig............12 Dust Wiper Jig ...............
  • Page 602 MEMO Cylinders SP000030 Page 4...

  • Page 603: Safety Precautions

    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.

  • Page 604: General Description

    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).
  • Page 605 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. π(D = S x π(D = S x...

  • Page 606: Parts List

    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.
  • Page 607 Reference Reference Description Description Number Number Tube Assembly Wear Ring Bushing Ring Rod Assembly O-ring Bushing Backup Ring Rod Cover Piston Nut DD-Bushing Set Screw Retaining Ring Socket Head Bolt Buffer Seal Pipe Band Assembly U-Packing Hex Socket Bolt Backup Ring Check Valve Dust Wiper Spring...

  • Page 608: Special Tools And Materials

    SPECIAL TOOLS AND MATERIALS Piston Nut -0.1 -0.2 (C3~C5) ∅ Through Hole R(R15 ~ R20) ARS4730L Figure 6 Material SM45C (AISI 1045) Rockwell Harden from 22 - 27 Oil Quench Cylinders SP000030 Page 10...
  • Page 609 ∅A ∅B MODEL CYLINDER MODEL (CYLINDER) 125.0 mm 85.0 mm 12.0 mm 5.0 mm BOOM (4.92 in) (3.35 in) (0.47 in) (0.20 in) DX140LC / 130.0 mm 90.0 mm 12.0 mm 5.0 mm DX140LCR (5.12 in) (3.54 in) (0.47 in) (0.20 in) 115.0 mm 75.0 mm...

  • Page 610: Piston Jig

    Piston Jig 2-∅"B" ∅ Through Hole R(R15~20) ARS4740L Figure 7 Material SM45C (AISI 1045) Rockwell Harden from 22 - 27 Oil Quench Cylinders SP000030 Page 12...
  • Page 611 ∅ ∅ ∅ MODEL CYLINDER A ( ±0.1) MODEL (CYLINDER) 80.0 mm 11.0 mm 58.0 mm 110.0 mm BOOM (3.15 in) (0.43 in) (2.28 in) (4.33 in) DX140LC / 80.0 mm 11.0 mm 58.0 mm 110.0 mm DX140LCR (3.15 in) (0.43 in) (2.28 in) (4.33 in)

  • Page 612: Steel Bushing Jig

    Steel Bushing Jig (∅20) ARS4750L Figure 8 Material: SM45C which is done thermal refining <QT> Hrc 22 - 28 Undefined Chamfer C/R = 0.5 Max. Place: Finally work to used DNMG Tip <Nose R0.4> Cylinders SP000030 Page 14...
  • Page 613 MODEL ∅ ∅ MODEL CYLINDER Part B ( ±0.1) -0.05 +0.05 (CYLINDER) -0.15 71.0 mm 86.0 mm 40.0 mm 6.5 mm BOOM (2.80 in) (3.39 in) (1.57 in) (0.26 in) DX140LC / 71.0 mm 86.0 mm 40.0 mm 7.0 mm DX140LCR (2.80 in) (3.39 in)

  • Page 614: Dust Wiper Jig

    Dust Wiper Jig ARS4760L Figure 9 Material: SM45C which is done thermal refining <QT> Hrc 22 - 28 Undefined Chamfer C/R = 0.5 Max. Place: Finally work to used DNMG Tip <Nose R0.4> Cylinders SP000030 Page 16...
  • Page 615 ∅ ∅ MODEL CYLINDER -0.2 -0.2 MODEL (CYLINDER) -0.3 -0.3 -0.1 75.0 mm 89.0 mm 6.0 mm 7.0 mm BOOM (2.95 in) (3.50 in) (0.24 in) (0.28 in) DX140LC / 80.0 mm 94.0 mm 6.0 mm 7.0 mm DX140LCR (3.15 in) (3.70 in) (0.24 in) (0.28 in)

  • Page 616: Slipper Seal Jig

    Slipper Seal Jig (B+40) ARS4770L Figure 10 Cylinders SP000030 Page 18...
  • Page 617 ∅ MODEL CYLINDER +0.2 +0.2 MODEL (CYLINDER) +0.1 +0.1 110.0 mm 28.5 mm BOOM (4.33 in) (1.12 in) DX140LC / 115.0 mm 28.5 mm DX140LCR (4.53 in) (1.12 in) 95.0 mm 28.5 mm BUCKET (3.74 in) (1.12 in) 115.0 mm 28.5 mm BOOM (4.53 in)

  • Page 618: Slipper Seal Straightening Jig

    Slipper Seal Straightening Jig ∅ ARS4780L Figure 11 Cylinders SP000030 Page 20...
  • Page 619 ∅ MODEL CYLINDER +0.2 MODEL (CYLINDER) +0.1 110.0 mm BOOM (4.33 in) DX140LC / 115.0 mm DX140LCR (4.53 in) 95.0 mm BUCKET (3.74 in) 115.0 mm BOOM (4.53 in) 125.0 mm DX180LC (4.92 in) 110.0 mm BUCKET (4.33 in) 140.0 mm BOOM (5.51 in) 150.0 mm...

  • Page 620: Disassembly

    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.
  • Page 621 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.
  • Page 622 Figure 19 Fabricate or purchase a piston nut removal wrench. (Dimensions are called off at beginning of this procedure. This tool may also be ordered through your local DOOSAN Parts distributor). Remove nut from end of piston. Figure 20 10. Use second piston tool described at beginning of this procedure to separate piston.
  • Page 623 12. Use a dull, rounded tip tool to pry off O-ring (13) and backup ring (14). HAOF37OL Figure 23 13. Find a screwdriver with an appropriate width tip to facilitate removal of slipper seal (18), wear ring (19) and slide ring (20) from piston (17).
  • Page 624 16. Disassemble retaining ring (12) and dust wiper (11). Separate retaining ring (7) and rod bushing (6). Figure 27 17. Force out pin bushing (2), (4) from body of cylinder. Figure 28 Cylinders SP000030 Page 26...

  • Page 625: Reassembly

    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.
  • Page 626 Prelubricate O-rings and seals before reassembly (Figure 31). Figure 31 Before starting to rebuild piston assembly, heat slipper seal for 5 minutes in an oil bath warmed to 150° - 180°C (302° - 356°F). Use special slipper seal jig (third item in list of specialized tools at the beginning of this procedure) to attach seal.
  • Page 627 Use specially fabricate or factory sourced tool to tighten piston nut (23). Figure 35 Assemble wear ring (19), slide ring (20) and set screw (24) to piston assembly. Reference Description Number Set Screw Figure 36 Immobilize body of cylinder before reassembly. Figure 37 Preapply fastener locking compound (Loctite #242 or #243 or an alternate manufacturer's equivalent product) to all end cover...
  • Page 628 Cylinders SP000030 Page 30...
  • Page 629 SP001943 SWING MOTOR SP001943 Swing Motor Edition 1 Swing Motor SP001943 Page 1...
  • Page 630 MEMO SP001943 Swing Motor Page 2...
  • Page 631 Table of Contents Swing Motor Safety Precautions ..........5 Applicable Models ..........5 Instruction Manual ..........6 Indication of Type ............6 Specifications ..............7 Construction and Principles of Working ......8 Precaution in Use ............15 Troubleshooting............. 19 Maintenance Manual .......... 22 Disassembling and Assembling ........

  • Page 632: Swing Motor

    MEMO SP001943 Swing Motor Page 4...

  • Page 633: Safety Precautions

    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 the load.

  • Page 634: Instruction Manual

    INSTRUCTION MANUAL Indication of Type — / 270 Relief Valve Setting Pre. Design Code Specification A: Swing Specification Shaft Geometry 10 : Male Spline 20 : Female Spline Mechanical Brake Yes Or No B : Brake Built-in Valve Cover Code Displacement 64 : 64 cc/rev 72 : 72 cc/rev...
  • Page 635 Specifications Name TSM72CHB-10A-03/270-IRV Displacement (cc•rev) Pressure (kg • Theoretical output torque (kgf•m) 30.9 Rated flow (min) Maximum speed (rpm) 1,833 Brake torque (kgf 36.8 • Brake release pressure (kgf • Weight (kgf) 41.3 *1. The theoretical value at the rated pressure, not NOTE: including mechanical efficiency.

  • Page 636: Construction And Principles Of Working

    Construction and Principles of Working Construction The Construction 307 308 106 102 FG001843 Figure 1 Construction of Motor Swing Motor SP001943 Page 8...
  • Page 637 Parts No. and Names Reference Reference Description Description Number Number Valve Casing Roller Plug Washer Spring Spring Plunger Ring Snap Swing Reactionless Valve Ass'y Valve Plate O-ring Casing Relief Valve Oil Seal Ball Bearing Ball Bearing Socket Bolt Parallel Pin Vp Plug Separation Plate O-ring...
  • Page 638 Principles of Working Motor Part High-pressure oil from the control valve is routed through valve casing and valve plate to pistons. When the oil enters the cylinder bores through port, it forces the pistons against the fixed inclined swash plate (F1,F2). The force (F2) causes the piston shoes to slide on the swash plate forcing the rotating group to turn, thereby rotating the output shaft.
  • Page 639 Valve Casing Part Anticavitation Check Valve The motor can be rotated faster than supplied oil flow because there is no counterbalancing valve to prevent over speed ; to prevent cavitation of the motor, oil compensation insufficient flow is drawn through the anti-cavitation check C Port valve.
  • Page 640 Spring (321) Piston (302) h R Port P Port (Pressure : P1) Hyd. Area A2 Adjustment Plug (401) Hyd. Area Al Plunger (301) (Pressure : Pg) Pressure : Ps Pressure : Ps FG007422 Figure 4 Relief Valve : KRD22EK10C Working Description Swing Motor SP001943 Page 12...
  • Page 641 Swing Reactionless Valve By the spool's shift in the main control valve, oil is supplied to Hydraulic motor's A port (or B port), and moving the poppet of reactionless valve, blocks the bypass and operates swing-device. (Figure 5-(1)) Returning the spool to neutral position, block the two ports of Hydraulic motor, but the swing-device tends to swing by inertia-force.
  • Page 642 Brake Part The swing brake is spring applied and hydraulically released. Friction plate are splined to and rotate with cylinder block (111). separation plates (743) are splined to the motor casing (301). When the swing controller blocks pilot pressure at port (SH), the brake springs (712) force on brake piston (702) squeeze the separation and friction plates together to prevent the upper structure from swinging.

  • Page 643: Precaution In Use

    Precaution in Use Inspection Before installation of a new motor, inspect the following items. Inspect whether or not there is any damage during transit, or if any parts are lost missing. Inspect each tightened part is loosened or not. Check whether or not covers for flange surface and drain port are perfect, and the inside of the motor is dirty with intruded dust.
  • Page 644 External Load of Shaft Pay attention to the shaft of motor in order not to applied radial and thrust load. Hydraulic Fluids and Range of Temperature Mineral Oil Please use a highly viscosity index working fluid which has additions of anti-foam agent, oxidation inhibitors, corrosion inhibitors, viscosity index improvers, oiliness agent and the oil with a high viscosity.
  • Page 645 Except Mineral Oil Incase if using special fluid (phosphate ester compounds, water-glycol, fluid fatly acid ester compound, etc.), please consult us for instruction before use. Filter If fine particles of dirt and metal are mixed with oil, they enter into sliding surfaces and accelerate wear in each part, and in the worst case seizure will be likely to occur.
  • Page 646 Oil Filling and Air Bleeder Fill in the casing with oil using the drain port before the operating. In the motor, there are many kinds of high-speed sliding surface like bearing, piston, shoe, spherical bushing, and etc. So If there isn't enough oil, can make some problem like sticking or breaking in those parts.

  • Page 647: Troubleshooting

    Troubleshooting General Cautions Here, counter-measures to be taken when troubles have happened while the motor is in operation are described. As for general precaution. Consider a cause of the trouble before repairing Before setting to work, think whether the same thing has happened before or not.
  • Page 648 Condition and Countermeasures of Troubles Motor does not rotation Condition Cause Remedy The pressure of the 1. Setting pressure of relief valve is 1. Reset the pressure to correct value. circuit is not increasing incorrect. 2. Working defectiveness of relief valve. 1) Revise or exchange of stick face.
  • Page 649 Brake torque is not sufficient. Condition Cause Remedy Brake torque is not 1. Friction plates are worn. 1. Disassembly or inspection. sufficient 2. Brake piston is becoming stick. When it is worn better than standard, replace it. 3. Brake releasing pressure is not working.

  • Page 650: Maintenance Manual

    MAINTENANCE MANUAL Disassembling and Assembling Tightening Torque of Bolts In table 1. is shown tightening torque of bolts used in motor. In case of reassembling, tighten accurately each bolt in accordance with table 1. Table 1 ) : TSM72 Tightening Torque Bolt Size Name Part No.
  • Page 651 Necessary Tools In table 2, 3 Figure 11. is shown necessary tools for disassembling and reassembling. Table 2 ) : TSM72 Name Size 2-face width Application part Tool Hexagon bolt Brake valve Hexagon wrench socket wrench Hexagon socket bolt M20 (M16) 17 (14) Hexagon wrench Plug...
  • Page 652 2 x 7 (Effectiveness Screw Length : 20) 169 (TSM140) FG007428 Figure 11 Special Tool for Removing the Brake Piston Swing Motor SP001943 Page 24...
  • Page 653 Procedures for Disassembly Please use the following procedures for the inspection and repair of the motor. Numerals given in parentheses following the parts names indicate the parts number shown by the drawing in the instruction and maintenance manual. Wind the wire rope at motor outside, lift up the motor, and clean the motor with cleaning oil.
  • Page 654 Remove RO plug (102) and take out spring (103) and plunger (104) from valve casing (101). Figure 15 Remove swing reactionless valve ass'y (105) from valve casing (101). Figure 16 Remove hex socket bolts (109, 110) and disassemble valve casing (101) from casing (301) (When loosening bolts, the valve casing will be raised by brake springs (310).
  • Page 655 10. Disassemble brake piston (309) from casing (301) by using the special tool for removing the brake piston. Lit it up straight by using the bolt hole in the brake piston. Figure 19 11. After placing the motor horizontally, take out cylinder block (205) from casing (301).
  • Page 656 Do next step if required. Remove parallel pin (304) from casing (301). FG001867 Figure 23 Remove ball bearing (303) with a press from the Press driveshaft (201). Strike the rod lightly and do not reuse the Drive Shaft disassembling bearing. Ball Bearing Press Table Hangs in the Inner Ring.
  • Page 657 Procedures for Assembly Following are caution to be specially borne in mind. Rework damaged parts and before assembling, prepare all parts to be replaced. Clean all parts and dry with compressed air. Coat the sliding parts and bearing with clean hydraulic oil.
  • Page 658 Insert the driveshaft (101) complete with ball bearing into casing (301). Impact the outside surface of outer loop uniformly till stop at casing section. Coat the lip of the oil seal with grease and tape the shaft spline for the protection of spline. Tap evenly.
  • Page 659 Place spacer (208), spherical bushing (206) to the cylinder block (205). Figure 34 Assemble the retainer with the piston sub assembly (203, 204) unit to the cylinder block (205). Figure 35 10. Insert cylinder block to driveshaft (101) aligning the spline. Figure 36 11.
  • Page 660 12. Mount O-ring (307, 308) to casing (301). (Coat the O-rings with grease. O-ring can be protected by grease.) FG001881 Figure 38 13. Assemble brake piston (309) to casing (301). The piston is difficult to assemble because of the restriction of the O-ring;...
  • Page 661 16. Assemble valve plate (231) to valve casing (101) and fit O-ring (113). Be careful to note the direction of the valve plate. Mount the valve plate with its round part toward the opposite side of the flange. Coat lightly with grease. Figure 42 17.
  • Page 662 20. Assemble relief valve (107) with O-ring to valve casing (101). FG001858 Figure 46 21. Assemble brake valve (400) to casing (301) and tightening the hex socket bolts to specified torque. FG001856 Figure 47 22. The assembly is completed. Swing Motor SP001943 Page 34...
  • Page 663 Maintenance Standards Standards for Replacement of Worn Parts If the various parts of the motor have been worn out beyond the following standard values, please replace them. But this shall apply only to those cases when is no remarkable outside damage.
  • Page 664 Swing Motor SP001943 Page 36...
  • Page 665 SP001346 TRAVEL MOTER SP001346 Travel Moter Edition 1 Travel Moter SP001346 Page 1...
  • Page 666 MEMO SP001346 Travel Moter Page 2...
  • Page 667 Table of Contents Travel Moter Safety Precautions ..........5 Applicable Models ..........5 Product Overview ..........6 General Specifications ............ 6 External Dimensions..........7 General Description ..........8 Operating Description ......... 11 Reduction Gear ............. 11 Hydraulic Drives ............12 Precautions for Use ..........
  • Page 668 Seals ................52 Maintenance Standards for Wearable Parts ....52 Assembling ............54 Preparation ..............54 General Precautions for Assembling Work ....54 Order of Assembling............55 Travel Moter SP001346 Page 4...

  • Page 669: Safety Precautions

    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.

  • Page 670: Product Overview

    PRODUCT OVERVIEW This product is a hydraulic driven rotary actuator. The product contains a reduction gear, hydraulic motor, brake valve and parking brake in one compact unit. It has been developed for use as an actuator for application requiring low- rpm, high torque operation such as construction and marine machinery.

  • Page 671: External Dimensions

    EXTERNAL DIMENSIONS Figure 1 SP001346 Travel Moter Page 7...

  • Page 672: General Description

    GENERAL DESCRIPTION Figure 2 Travel Moter SP001346 Page 8...
  • Page 673 Reference Reference Description Q’ty Description Q’ty Number Number Timing Plate Spindle Washer Carrier Assembly (1) Piston Carrier (1) Spring Planetary Gear (1) Spring Carrier Pin (1) Friction Plate Thrust Washer (1) Mating Plate Parallel Pin (1) Oil Seal Needle Roller Bearing O-ring Carrier Assembly (2) O-ring...
  • Page 674 Reference Reference Description Q’ty Description Q’ty Number Number Plug Plug Washer Plug Spring Piston Orifice O-ring O-ring Orifice Plug Hex. Socket Plug Steel Ball Hex. Socket Plug Hex. Socket Plug Name Plate Plug Parallel Pin O-ring Hex. Socket Bolt O-ring Spool Spring Orifice...

  • Page 675: Operating Description

    OPERATING DESCRIPTION Reduction Gear Function This reduction gear unit is composed of two stage planetary gear mechanism. The reduction gear reduces the high speed of hydraulic motor and converts it low-speed, high-torque rotation. Operating Description The rotation of hydraulic motor shaft is transmitted to sun gear (4) of the first stage which is linked with shaft (102) in spline.

  • Page 676: Hydraulic Drives

    Hydraulic Drives Function Hydraulic Motor This hydraulic motor is a swash plate type axial piston motor, converting the hydraulic force from the pump to rotary motion. Brake Valve Controls inertia when stopping the hydraulic motor, in order to provide smooth stopping. Prevents runaway rotation when the hydraulic motor is rotated by external force.
  • Page 677 Operating Principles and Description Hydraulic Motor Hydraulic fluid fed from the hydraulic pump enters the GM motor through the rear flange (101), passes through the brake valve and timing plate (109) and enters the cylinder block (104). This hydraulic fluid is fed only into one side of a line connecting the upper and lower dead points (Y1-Y2) of the piston stroke (105).
  • Page 678 Brake Valve Operation (Brake released) The pressure oil is led to through port (A), opens valve (327), and led to port (C) on the section side of hydraulic motor to rotate hydraulic motor. At the same time, the pressure oil enters chamber (a) through orifice (329), and exerts on the end of spool (323) to generate the force.
  • Page 679 Stop / Stall (Braking Operation) If pressurized oil supply through the port (A) is suspended while traveling, the hydraulic force to push up the spool (323) is lost, and the spool (323) which is slid to left side, tries to return to the neutral position due to the spring (328) force.
  • Page 680 Figure 6 Travel Moter SP001346 Page 16...
  • Page 681 Self-traveling While machine is being operated, as the travel speed is increased due to steep slope, the oil flow rate of the hydraulic motor is higher than the supply flow rate of the hydraulic oil pump. The rotation of the hydraulic motor in this case is called a self-traveling.
  • Page 682 High-Low 2-Speed Switching Mechanism Low Speed When the pilot pressure is not supplied through the port (P), the valve (363) is pushed up to the upper position due to the spring (366) force and pressurized oil through the port (A) or (B), the pressurized oil is cut off at port (C), and oil in the chamber (W) is released into the drain (motor case) through the valve (363).
  • Page 683 High Speed When the pilot pressure is supplied through the port (D), it defeats the spring (366) force and pressurized oil through the port (A) or (B) to push down the valve (363) to lower position, the pressurized oil at the port (C) is led to the chamber (P) through the valve (363), and the piston (161) pushes the swash plate (103) up to the plane X and maintain it at its position.
  • Page 684 PRECAUTIONS FOR USE Installation (Refer to Diagram of External Dimensions) Before installation remove plugs from oil level check ports, and confirm that reduction gear oil has penetrated as far as the oil level check ports. CAUTION When lifting a GM motor for transportation or installation, never enter the area below the GM motor.

  • Page 685: Tubing

    Tubing During delivery, ports are covered with plugs or other coverings. This is to prevent entry of dust, welding scale, etc. Coverings should be removed before connecting tubing. CAUTION Before connecting tubing, confirm the direction of GM motor rotation, and the position of the ports. (Refer to Diagram of External Dimensions.) Failure to do so may result in reverse rotation, or injury.

  • Page 686: Maintenance And Inspection

    MAINTENANCE AND INSPECTION Daily Inspection The following daily maintenance and inspection items should be verified before operating the GM motor. CAUTION Except for confirmation of the following third abnormal sounds, maintenance and inspection must always be performed when the product is stopped. Inspection during operation may cause injury or burns.

  • Page 687: Changing Fluid

    Changing Fluid The standard interval for changing hydraulic fluid is every 1000 hours or one year. Hydraulic fluid may be changed within the standard interval if there is significant reduction in volume, subject to the following standards. Test item Change standard Viscosity change (40°C) ±...
  • Page 688 Avoid mixing different types of lubricating oils. When changing the type of lubrication oil, be sure to flush the interior of the reduction gear. Gear Oil Change Volume : 2.1 liters Gear Oil Change Procedure CAUTION Immediately after operation, the case may be extremely hot. Touching with the hands may cause burns.

  • Page 689: Seals Table

    • Tightening torque: 98.1 ± 19.6 N-m (10.0 ± 2.0 kgf-m) Add gear oil to the oil fill port. Stop filling just before the gear oil overflows at the oil level check port. Re-place the plugs on the oil fill ports and level check port. •...

  • Page 690: Troubleshooting

    TROUBLESHOOTING Please contact our company, when the disposal to which "O" mark is attached is required. Problem 1 Problem 2 Possible Cause Action Relief set pressure is too Check the main relief valve Pressure will not Pump failure Repair increase Direction switching valve is Repair damaged...
  • Page 691 Problem 1 Problem 2 Possible Cause Action Left-right ejection volume Repair pump imbalance Occurs at low pressure Left-right hydraulic motor Replace GM motor drain volume imbalance Left-right ejection volume Repair pump Meanders when imbalance used as drive Left-right hydraulic motor motor Replace GM motor drain volume imbalance...

  • Page 692: Outline Of Maintenance

    OUTLINE OF MAINTENANCE Tools Name · Specification Q'ty Type Hex-Spanner 2.5 (M5), 3 (M6), 4 (NPTF 1/16,) 5 (PF 1/8), 6 (PF 1/4) 8 (M10,PF 3/8), 10 (M12,PF 1/2) Socket Wrench (Ratchet Handel) Tumbler type (JIS B 4641) Torque Wrench Dial type : 50[N] , Dial type : 100[N], (JIS B 4650) Dial type :300[N] , Dial type :560[N]...

  • Page 693: Equipments

    Equipments Application · Specification Name Type Q'ty (Use or P/N) Assembling & Work Bench Disassembling Washing Wash Tank · Washing final washing (product & parts) 24 : press Cap. 9800[N] (1000[kgf]) min. 24, 104, 149 Press Work Bench 104 : press cap. 1960[N] (200[kgf]) min. 149 : press cap 1960[N] (200[kgf]) min.
  • Page 694 Pressing Tool (II) • Used for removing the Deep Groove Ball Bearing (149) from Shaft (102). FG009806 Figure 14 Oil Seal Inserter • Used fro pressure-inserting Oil Seal (132) into the oil seal groove on the Spindle (2). FG009807 Figure 15 Lock Washer Inserter •...
  • Page 695 Steel Rod (I) • Used to remove Angular Ball Bearing (24) from the hub. FG009810 Figure 18 Long Eye Bolt • Used to hang Travel Motor, Spindle (2), and Hub (1). "A" M 16 M 10 Spindle M 16 Travel Motor M 16 "A"...
  • Page 696 11. Floating Seal Assembler (II) • Use to assemble Floating Seal[29] with Hub[1] and Spindle (2). Figure 22 12. Floating Seal Assembler (III) • Use to assemble Floating Seal[29] with Spindle (2). FG009815 Figure 23 Travel Moter SP001346 Page 32...

  • Page 697: Torque

    Torque Parts Bolts & Nuts Hex-2 Face Width (Structural Q'ty Torque (N•m) ( mm) Name Spec. Diagram) 30, 357 Plug PF 1/2 98.1 ± 19.6 (10.0 ± 2.0) Hex Groove M10 (P1.5) 66.7 ± 3.92 (6.8 ± 0.4) Sleeve PF 1/2 98.1 ±...

  • Page 698: Disassembling

    DISASSEMBLING Work Preparation Prepare following for disassembling; Work Bench • Prepare the work bench for Travel Motor. • bench must rigid enough disassembling and reassembling the internal parts of the Travel Motor. The bench must have sufficient area to place all the parts.

  • Page 699: Disassembling Order

    Even hard and rigid parts must not be knocked or exerted with excessive force. Otherwise, the part may become unable to assemble or degraded in performance. Work with patience and care. Take measures of rust or dust proofing if disassembled parts have to be left unassembled for a long while.
  • Page 700 Removing the Lubricant Lay down the Travel Motor(with the outlet port pointing downward). Loosen the Plug (30) at the oiling port to release the pressure in the reduction gear, and tighten the plug lightly. NOTE: reduction gear depressurized, lubricant may eject out when the plug on the discharge port is loosened.
  • Page 701 Removing the Thrust Plate Remove the Thrust Plate (13). Figure 26 Removing the 1st Stage Gears Remove the Sun Gear (1, 4). NOTE: Take care not to drop the Sun Gear (1) down, which is slippery with lubricant. Figure 27 Join bolts in the three M12 Tabs on the Carrier (1, 3).
  • Page 702 Removing the 2nd Stage Gears Join eye bolts in the 3 M12 Tabs, for hanging, on the 3 points of the Carrier (2, 7). Lift the Carrier Assembly (2) with crane and move it. NOTE: When lifting the Carrier Assembly (2) up, align the center lines of the Hub (1) and the Carrier Assembly (2), and lift up slowly in order to prevent the end of the Planetary...
  • Page 703 10. Removing the Hub Remove the hex-groove bolt joining the Hub and the turn-over table. Mount an eye bolt (M10) on the Hub and lift it up with crane. WARNING Lift the Hub up keeping it parallel with the Spindle shaft, slowly.
  • Page 704 13. Removing the Rear Flange Turn the Travel Motor over(with Motor side up). NOTE: Following procedures are for removing the Plug easily, when disassembling the inside of the Rear Flange. Loosen the Plug so that it can be removed with hand. Do not loosen the Plug unless the Rear Flange inside is to be disassembled.
  • Page 705 Remove the two Relief Valve Assemblies (including 203). NOTE: Do not reuse the removed O-rings (207, 209, 212) and Back-up Rings (208, 210). Figure 39 Unscrew the ten hex groove bolts (343) and remove them from the Rear Flange (301). Remove the Rear Flange (301) from the Spindle[2].
  • Page 706 14. Disassembling the Rear Flange Assembly Place the Rear Flange (301) with the fitting surface with the Spindle (2) upside. Remove the Timing Plate (109) from the Rear Flange (301). NOTE: Removing the Rear Flange (301) may require some force because of the oil on the fitting surface.
  • Page 707 15. Disassembling the Brake Valve Parts in the Rear Flange Remove the two Plugs (324) from the Rear Flange (301). Remove the Washers (325) and springs (328), 2 each, from the Rear Flange (301). Figure 46 Remove the Spool (323) from the Rear Flange (301). NOTE: Tilt the Plug Port of the Rear Flange (301), then the Spool (323) will slide out.
  • Page 708 16. Disassembling the 2-Speed Switching Spool From the Rear Flange (301), remove the Plug (357). Remove the O-ring (359) from the Plug (357). NOTE: Do not reuse the removed O-ring (359). Figure 49 Remove the Spool (363) and spring (366) from the Rear Flange (301).
  • Page 709 18. Disassembling the Check Valve Ball From the Rear Flange (301), remove the two Plugs (352). Remove the O-ring[358] from the Plug (352). NOTE: Do not reuse the removed O-ring (358). Figure 53 Remove the Steel Ball (353) from the Rear Flange (301).
  • Page 710 20. Disassembling the Hydraulic Motor Parts NOTE: Oil will come out when the Travel Motor is laid down. Place an oil pan under the Travel Motor. Lay the Travel Motor down in 90 degrees. Remove the oil in the Travel Motor. Select the four Opposite Plates (116) and the three Friction Plates (115).
  • Page 711 From the Retainer Plate (107), take the Piston Assemblies (105, 106) out (9 sets). Figure 60 Remove the Thrust Ball (108) from the Cylinder Block (104). Figure 61 Remove the three Collars (151) from the Cylinder Block (104). Figure 62 21.
  • Page 712 Place the press tool (1) on the Washer (110), press the tool (1) strongly with a press, and remove the THS Snap Ring (145) out from the snap ring groove on the Cylinder Block (104), with a snap ring plier. CAUTION Release the press slowly.
  • Page 713 Remove the 2-speed switching Piston Assembly and the Spring (185) from the Spindle (2). Figure 68 23. Removing the Deep Grooved Ball Bearing NOTE: Remove the Deep Grooved Ball Bearing only for replacement. Place a press tool (II) on the press work bench, and insert the Shaft (102) in it.
  • Page 714 Remove the Floating Seal (29) from the Spindle (2). Figure 71 Remove the Oil Seal 132 from the Spindle (2). NOTE: Do not reuse the removed Floating Seal (29) and Oil Seal (132). Figure 72 25. Washing the Parts Classify the Hub[1], Spindle (2), Cover[14], Rear Flange (301) and other pats.
  • Page 715 26. Final Washing Put the parts in the finish washing tank containing kerosene. Rotate the parts slowly, wash them clean to the inside. Figure 74 Wipe the kerosene on the parts with clean cloth. NOTE: Dry the inside of the Hub[1] and Spindle[2] with compressed air, where there is no dust and moisture.

  • Page 716: Maintenance Standards

    MAINTENANCE STANDARDS GM Motor has to be disassembled and inspected in compliance with this standard. Take utmost care not to scratch on the moving and reciprocating surfaces. Seals Seals (O-ring, oil seals, floating seas) must be replaced with new seals, regardless of the damage, once disassembled. Maintenance Standards for Wearable Parts Any parts which show visible defect must be replaced with new ones.
  • Page 717 Part Allowable Name Defect Description Standard Size Range · Biased wear on the reciprocating surface with the Shoe (106) Retainer Plate · Scratch or biased wear on the reciprocating surface with the Thrust Ball (108). · Biased wear on the spherical Thrust Ball reciprocating surface with the Retainer Plate (107).

  • Page 718: Assembling

    ASSEMBLING Assembling, in principle, shall be carried out in the reverse order of the disassembling. Preparation Prepare work table, tools, devices, same as those described in the Disassembling Section. General Precautions for Assembling Work Cautions for assembling work, in principle, are same as those defined in the Disassembling Section.

  • Page 719: Order Of Assembling

    Order of Assembling When replacing reassembling parts, pre-pressure adjustment of Ball Bearing is required. Therefore, make sure that the parts below have been replaced before assembling. NOTE: Replacement parts for pre-pressure adjustment of Ball Bearing .Hub (1), Spindle (2), Ball Bearing (24) NOTE: When replacing and reassembling the above listed parts, make sure to use the pre-adjusted parts.
  • Page 720 Assembling the Spindle Part Apply grease on the O-ring of the Floating Seal[29]. Insert the Floating Seal (29) into the floating seal groove on the Spindle (2). NOTE: To assemble the Floating Seal (29), place the F/S assembling tool (I), Floating Seal (29), and F/S assembling tool (II), in the listed order, and press until the F/S assembling tool (II) touches the F/S...
  • Page 721 Adjusting the Pre-pressure of the Angular Ball Bearing NOTE: When the Hub (1), Angular Ball Bearing (24) or Spindle (2) is replaced, carry out pre=pressure adjustment. pre-pressure appropriate, the Angular Ball Bearing may be fractured soon. Insert the Lock Washer (22) in the Spindle (2), and measure size C.
  • Page 722 Assembling the Hub Align the central axes of the hung Hub[1] and Spindle (2) straight, lower the Spindle (2) slowly and insert into the Angular Ball Bearing (24). Figure 83 Ø Tighten a lock hex-groove bolt in the 14 hole of the Hub to fix with the work bench.
  • Page 723 Assembling the Motor Parts in the Spindle Insert the Oil Seal (132) into the Spindle[2] using oil seal press-fitting tool and hammer. NOTE: When assembling the Oil Seal, apply lithium grease on the Oil Seal lip Take care that the assembling direction of the Oil Seal (132) is correct.
  • Page 724 Insert the Swash Plate (103) into the Spindle (2). NOTE: Apply grease on the fitting surface of the Swash Plate (103) with the Spindle (2). Insert the Swash Plate (103) into the Spindle matching pivot mounting grooves on the Swash Plate (103) with the two Pivots (167) inserted onto the Spindle (2).
  • Page 725 Assembling the Hydraulic Motor Parts Insert the three needle-type Collars (151) into the groove on the Cylinder Block (104), and place the Thrust Ball (108) on them. Figure 94 Insert the nine Piston Assemblies into the Retainer Plate (107). NOTE: Soak the whole assembly in machine oil.
  • Page 726 Assembling the Packing Brake NOTE: Soak the Friction Plate (115) in machine oil before assembling. Turn the work bench by 90 degrees. On the Cylinder Block (104), assemble the four Opposite Plates (116) and the three Friction Plates in turns. Apply grease thinly and insert the O-rings (135, 139) into the O-ring groove on the Piston (112).
  • Page 727 11. Assembling the Check Ball Part Assemble the two O-rings (358) with the two Plugs (352). NOTE: Apply grease on the O-ring (358). Insert the Steel Ball (353) into the Rear Flange (301). Figure 102 Tighten the Plug (352) with the Rear Flange (301) using a hex-wrench, temporarily.
  • Page 728 13. Reassembling the Brake Valve Insert the Spool (323) into the Rear Flange (301). NOTE: Apply machine oil on the Spool (323) and insert the Spool (323) into the Rear Flange (301). Align the center lines of the Spool (323) and the Rear Flange (301) to prevent the damage on the inner surface of the Rear Flange (301) and the outer surface of the...
  • Page 729 14. Assembling the Rear Flange Components Apply machine oil on the Deep Grooved Ball Bearing (150) and insert the Ball Bearing (150) into the Rear Flange (301). Insert the Parallel Pin (341) into the pin groove of the Rear Flange (301). Apply grease on the fitting surface of the Timing Plate (109) with the Rear Flange (301).
  • Page 730 Insert the Rear Flange (301) into the Spindle[2], aligning the pin groove on the Rear Flange (301) and the two Parallel pins inserted in the Spindle (2). Tighten the ten hex-grooved Bolts (343) to the Spindle (2) temporarily, using hex-wrench. Figure 113 16.
  • Page 731 Tighten the Plug (352) by specified torque. ± ± Torque : 12.3 2.45 N•m (1.25 0.25 kgf•m) Figure 117 Tighten the Plug (357) by specified torque. ± ± Torque : 98.1 19.6 N•m (10.0 2.0kgf•m) Figure 118 17. Assembling the Relief Valve Assembly Mount the two Relief Valve Assemblies (including 203).
  • Page 732 18. Assembling the 2-Step Gears Turn the work bench so that the Reduction Gear faces upwards. Assemble the Sun Gear(2, 8) with the Carrier (2, 7). Install eye bolts in the three M12 tabs for hanging on the Carrier(2, 7), use a crane to insert the Carrier Assembly (2).
  • Page 733 Insert the Sun Gear (1, 4) into the Coupling (15), aligning the splines. NOTE: In the event that the Sun Gear (1, 4) cannot be inserted because the spline of the Sun Gear touches the teeth end of the Planetary Gear, gears positioned such, slowly lift the Carrier...
  • Page 734 Apply Locktite 242 on the tip of the hex-grooved Bolt (35), and tighten with specified torque. ± ± Torque : 66.7 3.92 N•m (6.8 0.4 kgf•m) Figure 129 22. Lubricant Supply lubricant through the lubricating port. NOTE: Supply 2.1 liter of lubricant. Figure 130 Mount Plug (30) on each port and tighten with specified torque.
  • Page 735 Performance Test • When the maintenance work of the GM Travel Motor has been completed, conduct performance testing as follows. Required Instruments Pressure Gauge 3.43 MPa (35 kgf / cm Mass Cylinder (5 liter) Stop Watch Test procedures Mount the GM Motor on the frame and connect piping. GM Motor mounting Do not put on cover.
  • Page 736 Travel Moter SP001346 Page 72...
  • Page 737 SP001945 MAIN PUMP SP001945 Main Pump Edition 1 Main Pump SP001945 Page 1...
  • Page 738 MEMO Main Pump SP001945 Page 2...
  • Page 739 Table of Contents Main Pump Safety Precautions ..........5 Applicable Models ..........5 Disassembling and Reassembling Procedures ..6 Tool ................. 6 Disassembling Procedures..........7 Reassembling procedures..........11 Pump Maintenance Criteria ........ 15 Worn Part Replacement Criteria ........15 Installation of Tandem Type Double-pump ....16 Construction of Tandem Type Double-Pump ....
  • Page 740 Main Pump SP001945 Page 4...

  • Page 741: Main Pump

    SAFETY PRECAUTIONS CAUTION Follow safety recommendations 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.

  • Page 742: Disassembling And Reassembling Procedures

    DISASSEMBLING AND REASSEMBLING PROCEDURES Tool The tools necessary to disassemble / reassemble K7V pump are shown in the following list. The size of the bolts and plugs depend on the pump type. FG015033 Figure 1 Ο Necessary Tool Name & Size Part Name Hexagon ROH plug...

  • Page 743: Disassembling Procedures

    Disassembling Procedures For disassembling the pump, read this section thoroughly and then disassemble it in the following sequence. The figures in parentheses after part names show the items in Attached Dwg.1 Construction of tandem type double-pump. Select place for disassembling. CAUTION Select clean place.
  • Page 744 In case the pump is provided without the PTO unit (05), remove the cover (326) with the hexagon socket head cap screws (414). Figure 4 Remove flange socket (435) and remove gear-pump (04). Figure 5 Loosen hexagon socket head bolts (401) which tighten pump casing (271, 272) and valve block (312).
  • Page 745 Pull out cylinder (141), pistons (151), set plate (153), spherical bush (156) cylinder springs (157) simultaneously from pump casing (271, 272) straightly over drive shaft (111, 113) CAUTION Take care not to damage sliding surfaces of cylinder (141), spherical bush (156), shoes (152), swash plate (212), etc.
  • Page 746 13. Remove valve plates (313, 314) from valve block (312). CAUTION These may be removed in Work 8. Figure 12 14. If necessary, remove stopper (L, 534), Qmin.plug (533), servo piston (532) and tilting pin (531) from pump casing (271, 272), and needle bearing (124) from valve block. CAUTION When removing tilting pin, use a protector to prevent pin head from being damaged.

  • Page 747: Reassembling Procedures

    Reassembling procedures For reassembling reverse the disassembling procedures, paying attention to the following items. not fail to repair the parts damaged during disassembling, and repair replacement parts in advance. Clean each part fully with cleaning oil and dry it with compressed air.
  • Page 748 In assemble of front pump, assemble seal cover (F, 261) to pump casing (271) and fix it with hexagon socket head bolts (406). Figure 15 10. Assemble piston cylinder subassembly [cylinder (141), piston subassembly (151, 152), set plate (153), spherical bush (156) and cylinder spring (157)].
  • Page 749 13. Fit valve block (312) to pump casing (271, 272) with hexagon socket head bolts (401). Figure 19 14. Fit gear-pump (04) to pump casing (272) with hexagon socket head bolts (435). Figure 20 15. Attach the PTO unit (05) by fastening the flange socket (435) to the valve block (312).
  • Page 750 16. Putting feedback lever (611) of regulator into feedback pin (548) of tilting pin (531), fit regulator with hexagon socket head bolts (415). CAUTION Take care not to mix up regulator of front pump and that of rear pump. 17. Fit drain port plug (468). Figure 23 This is the end of reassembling procedures.

  • Page 751: Pump Maintenance Criteria

    PUMP MAINTENANCE CRITERIA Worn Part Replacement Criteria When a part exceeds any of the following criteria, replace of readjust it. However, when a part is damaged seriously in appearance, replace it without fail. Standard Dimension / Recommended replacement vale Part name & inspection Countermeasures Pump type K7V63...
  • Page 752 Installation of Tandem Type Double-pump Figure 25 Main Pump SP001945 Page 16...
  • Page 753 Construction of Tandem Type Double- Pump Figure 26 Main Pump SP001945 Page 17...
  • Page 754 Reference Reference Description Description Number Number Gear Pump Plug Drive Shaft (F) Plug Drive Shaft (R) Tilting Pin 1st Gear Servo Piston Roller Bearing Qmin.Plug Needle Bearing Stopper (L) Bearing Spacer Stopper (S) Cylinder Block Feedback Pin Piston O-ring Shoe O-ring Set Plate O-ring...
  • Page 755 SP001029 MAIN CONTROL VALVESP001029 Main Control Valve Edition 1 Main Control Valve SP001029 Page 1...
  • Page 756 MEMO SP001029 Main Control Valve Page 2...
  • Page 757 Table of Contents Main Control Valve Safety Precautions ..........5 Applicable Models ..........5 General Description ..........7 Theory of Operation ............8 Composite Operation ............ 19 Anti-drift Valve ............... 20 Disassembly ............22 Precautions for Disassembly ......... 22 Disassembling Procedures..........22 Washing..............
  • Page 758 MEMO SP001029 Main Control Valve Page 4...

  • Page 759: Safety Precautions

    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.

  • Page 760: General Description

    GENERAL DESCRIPTION Figure 1 Main Control Valve SP001029 Page 6...

  • Page 761: Theory Of Operation

    Theory of Operation Service Spool Movement Remove the stopper plug of both pilot caps before using this section. When necessary, replace the shut-off valve with an overload relief valve and remove the plug at port (P4). When the spool is moved by being pressurized through the pilot port (pb2) (pa2) of the first service (Section 2), the neutral path (L1) will be closed.
  • Page 762 Swing Spool Movement When the swing spool is moved by being pressurized through the pilot port (pb3) (pa3) of the swing (Section 3), the neutral path (L1) will be closed. The oil supplied through port P1 flows from the parallel path (L3), via the load check valve (S3-1), path (S3-2), and the spool head to the (B3) (A3) port.
  • Page 763 Boom Spool Movement Neutral This valve incorporates an anti-drift valve on the bottom of the cylinder of boom 1. In a neutral state, the poppet (AD1) is fully seated by the pressure at port (A8) which is applied to the spring chamber (AD5) through the path (AD2), poppet (AD3), and path (AD4).
  • Page 764 Upward When the boom1 spool is moved by being pressurized through the pilot port pa8 of the boom1 (Section 8, Figure 5), the neutral path (R1, Figure 5) will be closed. The oil supplied through port P1 flows from the parallel path (R3, Figure 5) to port (A8, Figure 5) via the load check valve (S8-1, Figure 5) and spool head.
  • Page 765 Downward (recycle) When the boom1 (Section 8) spool is moved by being pressurized through the pilot port pb8 of the boom1, the neutral path (R1) will be closed.The oil supplied through port P2 flows from the parallel path (R3) to port B8 via the load check valve (S8-1) and spool head.
  • Page 766 Arm Spool Movement Dump (2 speed convergence) When the arm1 (Section 5) spool is moved by being pressurized through the pilot port pa5 of the arm1, the oil supplied through the P1 port flows from the neutral path (R1)to the A5 port via load the check valve (S5-1), path (S5-2) and spool head.
  • Page 767 Crowd (2 speed convergence) When the arm1 spool is moved by being pressurized through the pilot port pb5 of the arm1 (Section 5), the oil supplied from port P1 flows from the parallel path (L1) to port B5 via the load check valve (S5-1), path (S5-2), and spool head.
  • Page 768 Variable Recycle (at crowd control) In arm crowd operation, the spool (S5-6) will stroke according to the pressure in the path (S5-2) induced through the path (S5-5), to change the position of the arm variable recycle orifice (Lc8). When the pressure in path (S5-2) is high, the stroke of the spool (S5-6) will be increased, which will increase the opening of the orifice (Lc8).
  • Page 769 Parallel Orifices for Arm In the arm parallel circuit of this valve, both arm1 (Section 5) and arm2 (Section 9) are equipped with orifices, which control the arm speed even in composite operation. The parallel circuit of arm2 (section 9) is throttled at the orifice (Rc6) of the sleeve (S9-3) in the parallel path (R3), and connected with path (S9-2) through the poppet (S9-4).
  • Page 770 Neutral Cut Spool Movement (First Service convergence) This valve is equipped with a neutral cut spool at the downstream end (upstream of the low pressure relief valve) of the neutral path (R1). When port (pcc) is pressurized to move the neutral cut spool (R), the neutral path (R1) will be closed. Accordingly, the flow to the negacon relief valve (Rc1) is shut- off, changing the pressure of the ps2 signal.
  • Page 771 Relief Valve Main Relief Valve in the Body The oil supplied through ports P1 and P2 is guided to the main relief valve via the poppet (LP), and via the poppet (RP) and path (3) respectively. The maximum pressure of the P1 and P2 side pumps is controlled by activation of the main relief valve.

  • Page 772: Composite Operation

    Composite Operation Travel Composite Operation During simultaneous operation of traveling and left-right turn (forward, backward or spin turn), when an operation other than travel is carried out at the same time, or during any operation except travel, when simultaneous operations of travel and left- right turn are carried out, the oil supplied from port PP is isolated from the tank path (Ta) at the signal land part of a section except the travel moved by the land (Lc4), (Lc7), (Rc3), and (Rc5),...

  • Page 773: Anti-Drift Valve

    Anti-drift Valve An anti-drift valve is installed in the cylinder port on the side of the arm load (arm bottom) which prevents the unwanted self- lowering of the arm (boom) cylinder. In the neutral state (Figure 14), cylinder port pressure is guided to the spring chamber (AD5) through path (AD2), poppet (AD3) gap, and path (Ad4).
  • Page 774 Figure 19 Figure 20 Main Control Valve SP001029 Page 20...

  • Page 775: Disassembly

    DISASSEMBLY Precautions for Disassembly On a level surface, place the main equipment on the level and place all other working devices on the ground. Ensure that neither the traveling nor the swing motion is self-activated. Stop the engine and release the pressure from all actuators.
  • Page 776 CAUTION Spools must be picked out straight so that they are not dented or scratched. Dents or scratches may damage the wall of the body hole when picking out, making reassembly difficult or impossible. Furthermore, when assembled, it may cause malfunction. Each spool has to be tagged so that it can be reassembled in the correct place.
  • Page 777 Disassembly of Sub-Spool Unscrew the spool end (width across flats: 5) of the spool, remove the spring seat and spring. Adhesive is applied on the thread connecting the spool and spool end. Refer to (Caution: 3) when disassembling them. Disassembly of Sub-Spool Disassemble the plug (width across flats: 32), remove the O-ring.
  • Page 778 CAUTION When disassembling this part with the control valve mounted on the equipment, parts may be ejected by the inner pressure. Unscrew the plug slowly, and then disassemble when it is certain that the inner pressure has been fully released. Remove the sleeve and poppet.
  • Page 779 Disassembly of the External Convergence Check Valve of the First Service Disassemble the plug (width across flats: 32), remove the O-ring from the plug. Take out the spring and poppet. Disassemble the plug assembly (width across flats: 27), remove the O-ring. Disassembly of the Common Check Valve Disassemble the plug (width across flats: 27) of the check valve, remove the O-ring from the plug.
  • Page 780 Disassembly of Other Plugs Disassemble the plug assembly (width across flats: 19) of PP port, remove the O-ring. Disassemble the plug (width across flats: 19) in the preliminary section cap part, remove the O-ring. Disassemble the G1/8 plug (width across flats: 5, 3 in all) remove the O-ring.

  • Page 781: Washing

    WASHING All disassembled parts have to be washed clean with mineral oil. Dry with compressed air. Place them on a clean sheet of paper or a vinyl sheet. INSPECTION Carry out a visual inspection on all parts for any foreign matter, scratches, or other defects.

  • Page 782: Assembling

    ASSEMBLING CAUTION Check number parts, assembling position, necessary tools before starting assembly. Sub-Assembly Before assembling the parts into valve housing, sub-assemble the necessary parts. Main Spool Apply adhesive on the threads of spool. Fix spring seat, spring, and spool end then fix spool with wooden vise and tighten spool end.
  • Page 783 Torque: 9.8~11.8 N•m. Insert poppet and spring into the hollow of the spool. Apply adhesive to the thread of the spool for plug fitting. Insert the plug assembled with an O-ring and back-up ring. Torque: 9.8~11.8 N•m. Apply adhesive to the thread of the spool which is assembled with the spool end.
  • Page 784 Fix the body at the contacting surface on the O-ring side using a wooden vise to prevent scratching. CAUTION It is recommended to apply grease on the spring and spring seat so that both can be correctly positioned on the poppet. If the spring is not correctly positioned on the spring seat, it may be damaged and spring debris may surround the oil path, resulting in malfunction.

  • Page 785: Assembling Control Valve

    Assembling Control Valve Assembling Add-on Section Install tie rod in the main body valve housing. CAUTION Tighten the tie rod to effectively thread the end. If the thread cannot perform its proper function, an oil leak may occur at the contact surfaces due to the insufficient jointing force of the add-on section, causing malfunction.
  • Page 786 CAUTION The hex nut must be tightened to the specified torque. At smaller torque, oil may leak at the contact surface due to insufficient tightening force. At too strong torque, the spool may be stuck due to the torsion of spool section valve...
  • Page 787 Assembling Travel Orifice (left travel section) Check Valve Insert the poppet and spring into the valve housing. Insert the plug assembled with the O-ring and tighten. Torque: 103~113N•m CAUTION When installing the plug [19], the spring [17] must be inserted into the plug completely. If the spring is not fully inserted, it may be broken.
  • Page 788 CAUTION Insert the spring carefully so that it is located in the spacer position correctly. If the spring is not located in the spacer position correctly, it may be broken by the poppet, and its debris may clog the oil path, causing malfunction.
  • Page 789 Assembling Sub Spool Insert the spool assembly into the original place. Insert the spring. Insert the plug [attached with the O-ring, and tighten the plug. Torque: 103~113N•m. Assembling Main Spool Insert the O-ring into the valve housing. Install the short cap] in the straight travel spool. Install to other spools.
  • Page 790 CAUTION When assembled, check for any omitted or loose parts. If loose, oil may leak. Specified torque values are all in wet condition (applied with oil). Main Control Valve SP001029 Page 36...

  • Page 791: Relief Valve

    RELIEF VALVE Main Relief Valve Body Main Relief Valve Operation This relief valve is inserted between the neutral path "HP" and low pressure path "LP", oil is filled in the inner space (C) through the orifice of the main poppet (1). The sleeve (2) and main poppet (1) are securely seated by the areal difference between "A"...
  • Page 792 Disassembling / Reassembling Body Main Relief Valve Figure 24 Disassembling This part is replaced by assembly. When replacing, unscrew plug <width across flats: 32> with spanner, remove O-ring. If oil leaks at the adjuster kit, disassemble adjuster kit and replace O-ring. CAUTION When disassembling the adjuster kit, parts may be ejected by the spring.
  • Page 793 Add-on Main Relief Valve Operation This relief valve is inserted between the neutral path "HP" and the tank path "LP". Oil is filled into the inner space (C) through the orifice of the main poppet . The sleeve (2) and main poppet (1) are securely seated by the areal difference between "A"...
  • Page 794 Disassembling / Reassembling Add-on Main Relief Valve Figure 28 Disassembling This part is replaced by assembly. When replacing, unscrew the plug (width across flats: 32) with a spanner, then remove the O-ring. If oil leaks at the adjuster kit, disassemble the adjuster kit and replace the O-ring.

  • Page 795: Overload Relief Valve

    Overload Relief Valve Relief Valve Operation This relief valve is inserted between the neutral path "HP" and tank path "LP". Oil is filled in the inner space (G) through the orifice of the piston (C). The sleeve (K) and main poppet (D) are securely seated by the areal difference between "A"...
  • Page 796 For the oil flow through the path "HP" and poppet (D), the pressure difference increases due to throttling by the poppet (D), circular gap of piston (C), and orifice. The poppet (D) is opened by the differential pressure and oil flows directly through path "LP".
  • Page 797 Disassembling / Reassembling Overload Relief Valve Figure 34 Disassembling This part is designed to be replaced by assembly. When replacing, unscrew the cap (hex, width across the flats: 32) with spanner, and remove the O-ring. If oil leaks at the adjuster kit, unscrew the adjuster kit and replace the O-ring.

  • Page 798: Negacon Relief Valve

    Negacon Relief Valve Negacon Relief Valve Operation Figure 35 Generation of Signal Pressure The oil supplied through the pump port (P1) flows to the tank path through the neutral path (L1) and the negacon orifice (D) at the neutral downstream path (A). In this process, pressure is generated in the path (B) by the negacon orifice (D), and the pressure is induced in the negacon signal pressure port (Ps1) through path (E).
  • Page 799 Disassembling / Reassembling Negacon Relief Valve Figure 36 Disassembly This part is designed to be assembly-replaced without disassembly, in order for the press-in at the "D" part. Assembling Check for dust, paint or any dirt on the threaded part of the plug , and insert a new O-ring.

  • Page 800: Adjusting Relief Valve

    Adjusting Relief Valve Main Relief Valve (common for body and add-on) This part is designed for non-disassembly and is not subject to readjustment. If pressure is adjusted, we cannot guarantee its proper operation. Install a precise pressure gauge at the circuit inlet. Run the pump at the rated rpm.

  • Page 801: Installation

    Turn the adjuster clockwise until the desired pressure is reached. 21.2MPa of pressure is increased by each turn of the adjuster. When the specified pressure is reached, press the adjuster so that it does not rotate, and tighten the lock nut. Torque: 27~31N.m Raise the pressure again to check the rated pressure has been obtained.

  • Page 802: Control Valve Specification

    CONTROL VALVE SPECIFICATION Item Specification 160L/min Rated Flow(main body) (At neutral: 30L/min) Max. Pressure(main body) 35MPa Rated Flow(Add-on Pr) 70L/min Max. Pressure(Add-on Pr) 28MPa Allowable Back-pressure Peak Pressure: 1.5MPa max. (Operating Pressure: 0.5MPa max.) Allowable Oil Temperature Operating: -25~80°C Instantaneous: 100°C max. (seal: nitrile rubber) Main Control Valve SP001029...

  • Page 803: Troubleshooting

    TROUBLESHOOTING Control Valve: overall Problem Possible Cause Remedy Spool does not stroke. Oil temperature is too high. Remove obstructions in the piping line, which may resist oil flow. Hydraulic oil is contaminated. Replace hydraulic oil, wash circuit. Piping port joint is loose. Check torque.

  • Page 804: Hydraulic System: Overall

    Relief valve Problem Possible Cause Remedy Pressure does not rise at all Main poppet, sleeve or pilot poppet Replace relief valve. is stuck open; or there is dust in the valve seat. Relief pressure is unstable Pilot poppet seat is scratched. Piston or main poppet is stuck.
  • Page 805 SP001646 REMOTE CONTROL VALVE (WORK LEVER / JOYSTICK) SP001646 Remote Control Valve (Work Lever / Joystick) Edition 1 Remote Control Valve (Work Lever / Joystick) SP001646 Page 1...
  • Page 806 MEMO Remote Control Valve (Work Lever / Joystick) SP001646 Page 2...
  • Page 807 Table of Contents Remote Control Valve (Work Lever / Joystick) Safety Precautions ..........5 Applicable Models ..........5 General Description ..........7 Theory of Operation ............7 Parts List ................. 8 Specifications ..............10 Torques ................. 10 Tools and Materials ..........10 Disassembly ............
  • Page 808 MEMO Remote Control Valve (Work Lever / Joystick) SP001646 Page 4...
  • Page 809 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.
  • Page 810 Remote Control Valve (Work Lever / Joystick) SP001646 Page 6...
  • Page 811 GENERAL DESCRIPTION Theory of Operation Structure The remote control valve contains four push rods, spring holders, spools and return springs, which are in the valve casing. The valve works as a pressure reduction valve. The housing has six ports, which include input port P, tank port T, and four secondary pressure ports.
  • Page 812 Parts List Figure 1 Remote Control Valve (Work Lever / Joystick) SP001646 Page 8...
  • Page 813 Reference Reference Description Description Number Number Case Boot Plug Joint Assembly Bushing Swash Plate Spool Hex Nut Shim Spring Handle Assembly (RH) Spring Seat Handle Assembly (LH) Stopper Handle Bar Spring Spring Pin Stopper Bellows Spring Bushing Push Rod Connector Assembly Spring Switch Kit Spring Seat...

  • Page 814: Torques

    Specifications Performance (2, 4) (1, 3) (20) (19.6) (19) Operating Torque (17.5) Operating Torque 15.9 15.4 Secondary Pressure Secondary Pressure 6.5 7 (6.2) 7.5 8 Push Rod Strike (mm) Push Rod Stroke (mm) FG013492 Figure 2 Torques Tool Standard Remark Plug PT 1/8 370 kg...

  • Page 815: Disassembly

    DISASSEMBLY Remove lead wire from bushing (29). Figure 3 Remove lever assembly from case (1). Figure 4 Remove hex nut (23) and swash plate (22) from case (1). Figure 5 Remove joint assembly (21) from case (1). Figure 6 Remote Control Valve (Work Lever / Joystick) SP001646 Page 11...
  • Page 816 Remove plate (19) from case (1). Figure 7 Remove plug kit assembly, stopper and spring (11) from case (1). Figure 8 Figure 9 Figure 10 Remote Control Valve (Work Lever / Joystick) SP001646 Page 12...
  • Page 817 Remove four spool kit assemblies from case (1). Figure 11 Figure 12 The bushing (3) and plug cannot be removed from case (1). Figure 13 FG013505 Figure 14 Remote Control Valve (Work Lever / Joystick) SP001646 Page 13...

  • Page 818: Cleaning And Inspection

    Figure 15 Figure 16 CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section. Remote Control Valve (Work Lever / Joystick) SP001646 Page 14...

  • Page 819: Reassembly

    REASSEMBLY Install four plugs (2) into case (1). Figure 17 Figure 18 Install bushing (3) into case (1) using jig. Figure 19 Figure 20 Remote Control Valve (Work Lever / Joystick) SP001646 Page 15...
  • Page 820 Take care when assembling spool kit assemblies (1 and 3, 2 and 4). (They should be assembled in same way). The assembly order is; spool (4), shim (5), spring (6), spring seat (7), and stopper (8). Figure 21 Figure 22 Install spring (9) into case (1).
  • Page 821 Assemble plug kit insert rod seal (18), O-ring (17), and push rod (12) into plug (16) in proper order. Figure 25 Figure 26 Assemble four springs (11) and stoppers and insert assembled set in case (1) to form a plug kit assembly. NOTE: Pay attention to measurement specifications of stoppers (1 and 3, 2 and 4).
  • Page 822 Install plate (19) into case (1). Figure 29 Install joint assembly (21) into case (1). Figure 30 10. Install boot and swash plate (22) and hex nut (23) into case (1). Figure 31 Figure 32 Remote Control Valve (Work Lever / Joystick) SP001646 Page 18...
  • Page 823 11. Insert bar and tighten it with a spanner to check balance of joint assembly. Figure 33 12. Install bushing (29) into case (1). Figure 34 13. Install lever assembly into case (1). Figure 35 14. Put lead wire in bushing (29), tie it, and arrange boot. Figure 36 Remote Control Valve (Work Lever / Joystick) SP001646...
  • Page 824 15. Install lead wire terminal into connector terminal pressing them together. Figure 37 16. Assemble connector assembly (30), and connect it to lead wire terminal, and properly route wiring. Figure 38 Figure 39 Remote Control Valve (Work Lever / Joystick) SP001646 Page 20...

  • Page 825: Start-Up Procedures

    START-UP PROCEDURES Start engine and set throttle at "LOW IDLE." Set safety lever on "UNLOCK" position. HAOB290L Figure 40 Slowly cycle boom, arm, bucket cylinders and swing motor about five times without a load to vent air from pilot lines. Do this for five minutes.
  • Page 826 Remote Control Valve (Work Lever / Joystick) SP001646 Page 22...
  • Page 827 SP002262 TRAVEL CONTROL VALVE (WITH DAMPER) SP002262 Travel Control Valve (with Damper) Edition 1 Travel Control Valve (with Damper) SP002262 Page 1...
  • Page 828 MEMO Travel Control Valve (with Damper) SP002262 Page 2...
  • Page 829 Table of Contents Travel Control Valve (with Damper) Safety Precautions ..........5 Applicable Models ..........5 General Description ..........7 Theory of Operation ............7 Pressure Reducing Valve ..........8 Operating Theory of Damper Mechanism ....... 9 Causes of Faults and Measures......11 Parts List ...............
  • Page 830 MEMO Travel Control Valve (with Damper) SP002262 Page 4...
  • Page 831 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.
  • Page 832 Travel Control Valve (with Damper) SP002262 Page 6...
  • Page 833 GENERAL DESCRIPTION Theory of Operation The damper valve is divided into two areas of operation. There is the pressure reducing valve (a) and the damper mechanism (b). The following hydraulic circuit is an example of a remotely located control valve. ARS1810L Figure 1 Reference...
  • Page 834 Pressure Reducing Valve Neutral Condition If pedal is in neutral, spool is pushed up by return spring and spring seat. Port (P) is blocked by bottom part of spool and four operating ports (left forward and backward, right forward and backward) are connected to port (T) through inner hole of spool.
  • Page 835 Operating Theory of Damper Mechanism Operation When Operating Lever When pushing pedal, pushing force pushing push rod and spool presses cylinder, return spring and hydraulic oil in cylinder is compressed, piston coming down with push rod compresses vibration prevention chamber of lower part, oil of vibration prevention chamber of lower part is flowed through orifice to oil pressure vibration prevention chamber of upper part of low pressure, at this time, ball check valve...
  • Page 836 Travel Control Valve (with Damper) SP002262 Page 10...
  • Page 837 CAUSES OF FAULTS AND MEASURES At times it may be difficult to pinpoint the source of the problem. The following table lists some of the possible problems, possible causes and remedies. Refer to this table for possible causes and remedies to assist in correcting the sometimes difficult problems.
  • Page 838 Parts List Figure 3 Travel Control Valve (with Damper) SP002262 Page 12...
  • Page 839 Reference Reference Description Description Number Number Body (1) O-ring Body (2) Rod Seal Plug Dust Seal Plug Cover Spring Seat Hex Socket Head Bolt Spring Shim Bushing Spool Camshaft Stopper Set Screw Spring Set Screw Spring Pin Hex Nut O-ring Bellows Push Rod Piston...

  • Page 840: Specification

    Specification 112.6 25 1.5 Operating Torque 91.8 46.4 7.5 1 Secondary Pressure 1 0.5 4.8 0.5 5.5 Rush Rod Strike (mm) FG013534 Figure 4 Travel Control Valve Specification Type Pilot Control (With Damper) 25 kg/cm @ 4.8 mm Stroke Pressure / Stroke (356 psi @ 0.1890 in Stroke) Weight 7.8 kg (17 lb)

  • Page 841: Removal

    REMOVAL Park on firm and level ground. Lower front attachment (bucket) to ground. Shut down engine. Set safety lever on "RELEASED" position. Turn starter switch to "I" (ON) position. WARNING when performing inspection WARNING 190-00695A FG014348 engine must running while performing Figure 5 maintenance, always use extreme caution.

  • Page 842: Disassembly

    DISASSEMBLY Remove bellows (32). Figure 7 Remove set screw (29) from cam (26). Figure 8 Remove cam shaft (28) from cam (26). Figure 9 Remove hex nut (31) and set screw (30) from cam (27). Figure 10 Travel Control Valve (with Damper) SP002262 Page 16...
  • Page 843 Remove hex socket head bolt (25) and cover (24) from each body (1 and 2). Figure 11 Figure 12 Remove push rod assembly from body (2). Figure 13 Remove body (2) from body (1). Figure 14 Travel Control Valve (with Damper) SP002262 Page 17...

  • Page 844: Cleaning And Inspection

    Remove damper spool assembly and spring (10) from body (1). Figure 15 Figure 16 Remove plug (3 and 4) and O-rings (12 and 34). Figure 17 CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures"...

  • Page 845: Reassembly

    REASSEMBLY Insert spring (10) into body (1). Figure 18 Assemble in proper order, damper spool (8), shim (7), spring (6), spring seat (5) and stopper (9). Figure 19 Install damper spool assembly into body (1). Figure 20 Assemble body (2) onto body (1). Figure 21 Travel Control Valve (with Damper) SP002262...
  • Page 846 Assemble rod seal (22), dust seal (23) and O-ring (21) into plug (20). Figure 22 Figure 23 Assemble seal (15), piston (33), steel ball (16), plate (18), spring (17) and snap ring (19) into push rod (13). Figure 24 Assemble push rod and plug. Figure 25 Travel Control Valve (with Damper) SP002262...
  • Page 847 Install push rod assembly into body (2). Figure 26 Install bushing (27) in cover (24) using jig. Figure 27 10. Assemble cover (24) onto each body (1 and 2) and install hex socket head bolt (25) using torque wrench. Figure 28 Travel Control Valve (with Damper) SP002262 Page 21...
  • Page 848 11. Install set screws (30) and hex nut (31) into cam (26) and tighten it. Figure 29 Figure 30 12. Position cam (26) on cover (24) and insert cam shaft (29) using hammer. Figure 31 13. Install set screw (29) in cam (26) and tighten it using torque wrench.
  • Page 849 14. Check cam balance. Figure 33 15. Install bellows. Figure 34 Figure 35 Travel Control Valve (with Damper) SP002262 Page 23...

  • Page 850: Installation

    INSTALLATION Position pedal valve (1, Figure 36) on cabin floor plate and install four bolts and washers (2). FG003016 Figure 36 Install pedal brackets (3) and levers (4, Figure 37) on pedal valve and install four bolts and washers (2). Install rubber boots (1, Figure 37).

  • Page 851: Start-Up Procedures

    START-UP PROCEDURES Start engine and set throttle at "LOW IDLE." Set safety lever on "UNLOCK" position. HAOB290L Figure 39 Slowly push and pull both travel lever about five times without a load to vent air from pilot lines. HAOB903L Figure 40 Travel Control Valve (with Damper) SP002262 Page 25...
  • Page 852 Travel Control Valve (with Damper) SP002262 Page 26...
  • Page 853 SP001944 SOLENOID VALVE ASSEMBLYSP001944 Solenoid Valve Assembly Edition 1 Solenoid Valve Assembly SP001944 Page 1...
  • Page 854 MEMO Solenoid Valve Assembly SP001944 Page 2...
  • Page 855 Table of Contents Solenoid Valve Assembly Safety Precautions ..........5 Applicable Models ..........5 Parts List............... 6 Functions of 5-Solenoid Valve Assembly Package ................7 Functions of Solenoid Valve Assembly Package .... 7 Assembly Diagram and Tools Required ......9 Solenoid Valve Diagram ..........
  • Page 856 MEMO Solenoid Valve Assembly SP001944 Page 4...

  • Page 857: Solenoid Valve Assembly

    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.

  • Page 858: Parts List

    PARTS LIST Components used for the solenoid valve package are the same as in the parts list below. FG015005 Figure 1 Reference Description Sizes Quantity Remarks Number Block Body 95x110x200 1-A1073-05-0 Solenoid valve TF-S3A-00 C1, C2, C3, C4, C5 Check Valve FD-DCP-0-A Plug PF 1/4"...

  • Page 859: Functions Of 5-Solenoid Valve Assembly Package

    FUNCTIONS OF 5-SOLENOID VALVE ASSEMBLY PACKAGE Functions of Solenoid Valve Assembly Package This solenoid valve assembly package have the following functions. Pilot cut-off Breaker pressure supply High travel speed Main pressure increase Work modes control - Swing Priority Functions and Operations of Solenoid Valves Reference Function Operations...
  • Page 860 Breaker pressure supply Pressing the breaker switch on the joystick operates the breaker solenoid valve (C2) to supply pilot pressure to the option valve of the main control valve. The pressure switches the spool of the option valve, which transfers pressure and oil from the main pump to the breaker system for excavation.II High travel speed control...

  • Page 861: Assembly Diagram And Tools Required

    Assembly Diagram and Tools Required Table 1 shows assembly torques recommended for components of the solenoid valve package. Designated tools and torques should be followed. FG015154 Figure 2 Reference Torques Components Screw Sizes Tools Number (kg/cm) Hex torque 200 ± 25 Solenoid valve UNF7/8 - 14"...
  • Page 862 Cautions During Disassembly and Reassembly Wipe dust and dirt in the area where disassembly and reassembly will be performed. For disassembly and reassembly, standard torques and tools stated in Table in should be used. The directions of disassembly and reassembly are same "Disassembly Direction"...

  • Page 863: Solenoid Valve Diagram

    Solenoid Valve Diagram Figure 3 Solenoid Valve Assembly SP001944 Page 11...

  • Page 864: Check Points And Solutions For Problems

    Check Points and Solutions for Problems Symptoms Causes How to Check Solutions Remove Disassemble the solenoid valve concerned and Foreign substance, contaminant, check if there are any contaminant such as dirt, dust in solenoid wash, and foreign substance and sludge between the valve assemble caseand the spool.
  • Page 865 Checking of Pilot Pressure for Defects Port where pressure gage set up Screw size Remark Operate the solenoid valve P1, P3, P4, P5, P6, TR2, PH, HO, SP PF1/4" O ring BOSS concerned (ON). Solenoid Valve Assembly SP001944 Page 13...
  • Page 866 Solenoid Valve Assembly SP001944 Page 14...
  • Page 867 SP000192 BREAKER EPPR VALVE (OPT)SP000192 Breaker EPPR Valve (Opt) Edition 1 Breaker EPPR Valve (Opt) SP000192 Page 1...
  • Page 868 MEMO Breaker EPPR Valve (Opt) SP000192 Page 2...
  • Page 869 Table of Contents Breaker EPPR Valve (Opt) Safety Precautions ..........5 Applicable Models ..........5 Structure ............... 6 Numbers and Names of Parts ......... 6 Functions and Operation ........7 Cautions for Operation ......... 7 Maintenance Instructions........8 Maintenance ..............8 Disassembly ..............
  • Page 870 MEMO Breaker EPPR Valve (Opt) SP000192 Page 4...

  • Page 871: Safety Precautions

    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.

  • Page 872: Structure

    STRUCTURE Numbers and Names of Parts Figure 4 Reference Reference Description Description Number Number Solenoid Valve casing Spring Sleeve O-ring Spool O-ring Breaker EPPR Valve (Opt) SP000192 Page 6...

  • Page 873: Functions And Operation

    FUNCTIONS AND OPERATION The proportional reducing valve shall be adjusted that its reduced pressure is proportional to the current of the solenoid. The proportional solenoid shall be changed with pressure proportional to the electrical input signal. Flow increases corresponding to the force of the solenoid. As the solenoid (1) receives pressure, the spool (4) opens and oil flows from P to A.

  • Page 874: Maintenance Instructions

    MAINTENANCE INSTRUCTIONS Maintenance Bolt Tightening Torque Table 1 shows torques used to tighten bolts of the motor. Make sure that assembly work should be done according to Table 1. Used Torques Bolt Sizes Names (kgf.cm) M 35 Hex bolt 450 ± 50 M 10 Hex bolt 200 ±...

  • Page 875: Disassembly

    Disassembly Determine a place for disassembly. • It should be clean. • Lay a rubber board or a cloth on the table and take care not to damage parts. Remove dust and rust of the proportional pressure reducing valve with cleansing oil. Disassemble the solenoid •...

  • Page 876: Assembly

    Assembly Assembly shall be done in the reverse order of disassembly described above, taking into consideration the following points. • Parts damaged during disassembly should be repaired without fail and spare parts should be prepared in advance. • Every part should be cleaned enough with cleaning oil and dried with compressed air before starting assembly.
  • Page 877 Assemble the spool, the spring, and the pin. FG003693 Figure 10 • The spring and the pin should not be fell off. FG003696 Figure 11 Assemble the solenoid correctly. 426-00266 PART No.: SERIAL No.: FG003697 Figure 12 Breaker EPPR Valve (Opt) SP000192 Page 11...
  • Page 878 • Take care not to damage O-rings of the solenoid. FG003698 Figure 13 Breaker EPPR Valve (Opt) SP000192 Page 12...
  • Page 879 SP002383 HYDRAULIC SCHEMATIC (DX140LCR) SP002383 Hydraulic Schematic (DX140LCR) Edition 1 Hydraulic Schematic (DX140LCR) SP002383 Page 1...
  • Page 880 MEMO SP002383 Hydraulic Schematic (DX140LCR) Page 2...
  • Page 881 Table of Contents Hydraulic Schematic (DX140LCR) Safety Precautions ..........5 Applicable Models ..........5 DX140LCR ............7 Hydraulic Schematic (DX140LCR) SP002383 Page 3...
  • Page 882 MEMO SP002383 Hydraulic Schematic (DX140LCR) Page 4...
  • Page 883 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.
  • Page 884 Hydraulic Schematic (DX140LCR) SP002383 Page 6...
  • Page 885 DX140LCR OPTION APPLIED PART 1. PUMP 2. PILOT FILTER LOCK VALVE 3. SOLENOID VALVE(CUT OFF) 4. ACCUMULATOR ONE-WAY ; JOYSTICK BOTTON 5. SOLENOID VALVE (PACKAGE) ONE/ T WO- W AY 6. JOYSTICK VALVE(L) 7. JOYSTICK VALVE(R) ROTATING 8. PEDAL VALVE 9.
  • Page 886 Electrical System...
  • Page 888 SP001949 ELECTRICAL SYSTEMSP001949 Electrical System Edition 1 Electrical System SP001949 Page 1...
  • Page 889 MEMO SP001949 Electrical System Page 2...
  • Page 890 Table of Contents Electrical System Safety Precautions ..........6 Applicable Models ..........6 Introduction ............7 Electrical Supply System ........8 Engine Starting Circuit ........10 Engine Preheating System ......... 14 Engine Stop ............16 Charging System ..........18 Monitoring System ..........19 Operation ............
  • Page 891 Air Conditioner System ........81 Troubleshooting ..........94 Weight of R134a Gas Used In Machines ... 96 Refrigerant System Repairs ....... 97 Wiper System ........... 105 Lighting System ..........108 Overload Warning Device......... 110 Audio Controller ..........111 Electrical System SP001949 Page 4...
  • Page 892 MEMO SP001949 Electrical System Page 5...

  • Page 893: Safety Precautions

    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.

  • Page 894: Introduction

    INTRODUCTION The electrical system for this equipment is DC 24 volts. The rated voltage for all electric components is 24 volts with the exception of the stereo and the air-conditioning control actuator. The system contains two 12 volt batteries connected in series and a three phase AC generator with a rectifier.

  • Page 895: Electrical Supply System

    ELECTRICAL SUPPLY SYSTEM The electric power circuit supplies electric current to each electric component. It consists of a battery, battery relay, starter switch, circuit breaker, fusible link and fuse box. The negative terminal of the battery is grounded to the vehicle body.
  • Page 896 0.5G 12V 100AH 12V 100AH STARTER SWITCH CONNECTION REGULATOR START FG015054 Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM Reference Reference Description Description Number Number Battery Fuse Box Battery Relay Alternator Fusible Link Diode Circuit Breaker Relay Starter Switch Electrical System SP001949 Page 9...

  • Page 897: Engine Starting Circuit

    ENGINE STARTING CIRCUIT 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) →...
  • Page 898 CN2-1 CN2-1 STARTER SWITCH CONNECTION REGULATOR PREHEAT START FG015055 Figure 3 STARTER CIRCUIT (1) - WHILE STARTING Reference Reference Description Description Number Number Battery Starter Relay Battery Relay Starter Fusible Link Alternator Circuit Breaker Diode Starter Switch Starter Relay 2 Fuse Box e-EPOS Controller Starter Controller...
  • Page 899 After Start Once the engine has been started, the belt driven alternator (10) generates a current. The output generated by the alternator (10) is a square wave pulse voltage through the "P" terminal and the frequency of the pulse voltage is proportional to the rotation of the alternator. The starter controller (7) monitors the frequency of the output current.
  • Page 900 Operation of the Start Circuit (2) - Immediately After Start CN1-15 CN2-1 STARTER SWITCH CONNECTION REGULATOR PREHEAT START FG015056 Figure 4 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START Reference Reference Description Description Number Number Battery Starter Relay Battery Relay Starter Fusible Link Alternator...

  • Page 901: Engine Preheating System

    ENGINE PREHEATING SYSTEM An air heater (8) is installed in the intake manifold of the engine. When the starter switch (5) is turned "ON," the current flows from the battery (1) → fusible link (3) → fuse box (6) → "B" terminal of starter switch (5) →...
  • Page 902 CN6-1, 2 CN7-4, 5, 6 PREHEAT CN4-4, 5, 6 CN2-1 STARTER SWITCH CONNECTION 1-37, 46, 47 1-39 1-40 1-42 START FG015057 Figure 5 ENGINE PREHEAT CIRCUIT Reference Reference Description Description Number Number Battery Preheat Relay Battery Relay Air Heater Fusible Link Preheat Indicator Light Circuit Breaker Diode...

  • Page 903: Engine Stop

    ENGINE STOP When starter switch (5) is turned "ON" the engine controller (8) is activated. The engine controller monitors and controls the engine including the injector solenoid (9). It controls the fuel deliver rate and the injection timing for each cylinder. There is an individual injector solenoid (9) for each of NOTE: the six cylinders.
  • Page 904 STARTER SWITCH CONNECTION START 0.5G 1-12 1-34 1-39 FG015058 Figure 7 ENGINE STOP CIRCUIT Reference Reference Description Description Number Number Battery Fuse Box Battery Relay Diode Fusible Link Engine Controller Circuit Breaker Injector Solenoid Starter Switch Emergency Stop Switch Electrical System SP001949 Page 17...

  • Page 905: Charging System

    CHARGING SYSTEM When the starter switch (5) is turned to the "ON" position, an initial excited current flows to the field coil of the alternator (7) through the battery relay (2) and circuit breaker (4). When the engine is started from this condition the alternator (7) starts charging.

  • Page 906: Monitoring System

    MONITORING SYSTEM ENGINE PORT OEM PORT FG015089 Figure 9 Reference Reference Description Description Number Number Instrument Panel Warning Buzzer Battery Pump Discharge Pressure Sensor Light Switch Hydraulic Oil Temperature Return Filter Switch Sensor Pilot Filter Switch Fuel Sensor e-EPOS Controller Air Cleaner Indicator Alternator Engine Controller...
  • Page 907 Instrument Panel CHECK < CONNECTOR AND TERMINAL NO.> AMP 040 28P 5 4 3 2 1 (CN7) (CN6) FG013521 Figure 10 Electrical System SP001949 Page 20...
  • Page 908 Gauges Warning Lights Mode Selector Switches Fuel Gauge Charge Warning 14. Power Mode Selector Button Engine Coolant Temperature Engine Oil Pressure Warning 15. Economy Mode Selector Gauge Button Engine Coolant Temperature Warning 16. Auto Idle Selector Button Hydraulic Oil Temperature Gauge 10.
  • Page 909 Monitoring System Schematic CN6-1 CN6-3 ILL. CN6-2 CN6-12 CN6-11 CN6-9 CN6-10 R2 B CN6-4 CN6-5 CN2-1 CN6-6 CN6-7 LCD DISPLAY PANEL WATER TEMPERATURE FUEL LEVEL OIL TEMPERATURE CN3-1 CN3-2 CN3-3 GRAPHIC DISPLAY CN5-7 CN3-4 CN2-17 CN7-4 WARNING LAMP CN4-4 CN7-5 CN4-5 CAN A CN2-18...
  • Page 910 Reference Reference Description Description Number Number Instrument Panel Return Filter Switch Pilot Buzzer Alternator Light Switch e-EPOS Controller Starter Switch Battery Front Pump Pressure Sensor Battery Relay Rear Pump Pressure Sensor Circuit Breaker Hydraulic Oil Temperature Fusible Link Sensor Fuse Box Fuel Sensor Check Connector Pedal Pressure Switch (Optional)

  • Page 911: Operation

    OPERATION Instruments Sensor Specification Function Display Input Terminal Input Specification Blue Coolant ECU-CAN 61 C 102 C Temperature Communication 41 C 107 C White FG013527 Blue 1/10 LCD (Red Zone) CN3-7 Blinking → over 5K ohms Fuel Level CN3-8 FULL → under 525 ohms 1/10 Full FG013528...
  • Page 912 Sensor Specification Function Display Input Terminal Input Specification N = 146 f / 60 ECU-CAN N = Engine speed (rpm) Tachometer 1750 E/G SPEED Communication f = Frequency of engine speed sensor (Hz) 28.0 BATTERY VOLT Voltmeter CN2-14 0 - 32 VDC FG000050 Main pump CN3-1...

  • Page 913: Warning And Indicator Lights

    WARNING AND INDICATOR LIGHTS Indication of Warning Lights Input Description Symbol Operation Remarks Terminal This symbol appears in case of no charge [voltage of "R(I)" Normally, it lights terminal is below when starting engine Charge CN2 - 14 12 ±1V] or and is out after engine overcharge [voltage starts.
  • Page 914 Input Description Symbol Operation Remarks Terminal This symbol appears Work Light CN2 - 6 when work light turns "ON" (24V applied). HB4O2003 Indication of Multifunction Gauge Input Description Symbol Operation Remarks Terminal When hydraulic oil CN3-9 Hydraulic Oil temperature is above Temperature CN3-10 about 96°C.
  • Page 915 When pilot filter pressure is above Pilot Filter CN2-18 about 1 kg/cm² (14 psi) FG000055 Warning buzzer also It flickers in case of starts when boom 2.71V and above and pressure sensor CN3-5 Overload lights continuously in output voltage is Warning case of 2.8V and CN3-6...

  • Page 916: Initial Operation

    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" •...

  • Page 917: Graphic Information Area Display

    GRAPHIC INFORMATION AREA DISPLAY Overview Many kinds of condition of machine are displayed on the letter information display department. 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.
  • Page 918 Main Menus for the Graphic Display Area Main menu: Language setting, Time setting, Filter/Oil information, Brightness adjustment, Password Special menu: Information of machine status, failure information, Information of machine operation. Menu Selector Buttons Up Arrow Button ( , 1 on Figure 12): Move the cursor to up, left and previous screen.

  • Page 919: Main Menu

    MAIN MENU When the "ESC" button is pressed for more than 3 seconds, the MAIN MENU main menu screen is displayed. 1. Language Main menu offers sub-menus (language setting, time setting, or filter/oil information, brightness adjustment, password) to the 2. Set Clock operator.
  • Page 920 Set Clock MAIN MENU It is used to adjust time of the digital clock. 1. Language Pressing the Enter Button ( , 3 on Figure 12) in the Main 2. Set Clock Menu after putting cursor on Set Clock brings Set Clock display. 3.
  • Page 921 Menu Display Order and Icon Explanation 1. Fuel Filter 2. Air Cleaner 3. Engine Oil Filter 4. Hyd. Oil Filter 5. Pilot Filter 6. Engine Oil 7. Hydraulic Oil 8. Coolant Water FG001358 Figure 20 Adjust Display MAIN MENU Pressing the Enter Button ( , 3 on Figure 12) in the main 1.
  • Page 922 Day Mode Adjust Display The default brightness is set to 50%. Brightness lllll l l l l l l ll ll l l l l l l l ll l The default contrast is set to 50%. The default back light is set to 90%. Contrast l l l ll l l...

  • Page 923: Special Menu

    SPECIAL MENU In this menu, many types of operating conditions and functions can be accessed and displayed, including the e-EPOS controller. This menu is mainly used for machine testing and failure diagnostics. The special menu offers three sub-menus: Machine status. Failure information.
  • Page 924 Special Menu Screen SPECIAL MENU Displayed language on the special menu screen NOTE: consists of Korean and English. 1. Machine Information If any language except for Korean is selected during language selection mode of main menu, only English 2. Failure Information will be displayed on special menu screen.
  • Page 925 Analog Inputs Description Analog Input Items Display Remark 1. Pump P/V Current in pump proportional valve. 2. Cooling Fan P/V N.A. Current in flow control proportional 3. Flow Control P/V valve. 4. Dial Indicating dial voltage. 5. TPS N.A. 6. E/G Control Motor N.A.
  • Page 926 Digital Inputs Descriptions Digital Inputs Items Mark Remark Lights up when output at alternator 1. Alternator "R(I)" terminal is above 12 ±1V. 2. Travel Select SW N.A. (only for wheel type equipment) Lights up when the travel speed 3. High Speed Sel. SW (M) selector switch is set to the "I"...
  • Page 927 Menu Select 1. Alternator 7. E/G Oil Press.SW 2. Travel Select SW 8. Air Cleaner Clogged 3. High Speed Sel. (M) 9. Return Filter Clogged 4. High Speed Sel. (A) 10. Pilot Filter Clogged 5. Pressure SW (Py) 11. OWD Warning SW 6.
  • Page 928 Digital Outputs Descriptions Digital Outputs Items Mark Remark Lights up when the relief press up 1. Relief Press. Up S/V solenoid valve is "ON." Lights up when the high speed 2. High Speed S/V solenoid valve is "ON." ON / OFF 3.
  • Page 929 Current failure information REALTIME FAILURE Current status of failure is displayed (Failure code, failure contents). 1/2 CODE : V204 - 05 When a number of failures are produced, failure 2/2 CODE : E011 - 04 information can be checked using "UP" ( , 1 on Figure 25) or "DOWN"...
  • Page 930 Input your password with one of No. 1 - 8 switches. DELETE FAIL LOG When "NO" (ESC, 4 on Figure 25) button is pressed, the screen will recover to previous menu without deletion. ENTER PASSWD : YES ESC : NO FG013618 Figure 38 Delete Completed screen will appear 3 seconds and...
  • Page 931 Failure Information Code at Machine Side Correct Value Measuring Code Failure Component Remarks Points Active Passive CN7-4 It is a Gauge Panel Communication R = 60 ± 5 Ω V201 composite Error CN7-5 resistance of CAN line. This value has to be CN4-4 measured by R = 60 ±...
  • Page 932 Correct Value Measuring Code Failure Component Remarks Points Active Passive R = 2.45 ± 0.25 kΩ (25°C CN3-9 Hyd. Temperature (77°F)) V222 Sensor CN3-10 R = 320 ± 32 Ω (80°C (176°F)) V223 N.A. Water Temperature Sensor V224 N.A. Engine Speed Sensor Empty: 5 ±...
  • Page 933 Failure Information Code at Engine Side Measuring Operation Code Failure Component Trouble shooting Points when failure occurs Check power supply E0111 ECU internal circuit defect Engine start failure circuit, reinstall program, replace ECM Engine output Check engine position Crank/Cam sensor signal 1-27, 1-48 E0115 abnormality, engine...
  • Page 934 Measuring Operation Code Failure Component Trouble shooting Points when failure occurs Excess of engine E0234 Crank/Cam sensor defect Operator’s training permitted rpm Sensor supply circuit 3 E0238 1-16 defect Engine output fall, Check related circuit, E0271 Fuel pump circuit defect 1-2, 1-32 abnormal operation connector and sensor...
  • Page 935 Measuring Operation Code Failure Component Trouble shooting Points when failure occurs Engine protecting Check related circuit, E0435 Engine oil pressure defect 1-17 function loss connector and sensor 3-1, 3-2 Check related circuit E0441 Battery voltage defect Engine hunting 3-3, 3-4 and connector (OEM) 3-1, 3-2 Check related circuit...
  • Page 936 1. Active value: Starter switch has to be turned "ON" NOTE: Measuring points between component and wire harness have to be connected. 2. Passive value: Starter switch has to be turned "OFF" Measuring points between component and wire harness have to be disconnected. 3.
  • Page 937 FMIs (Failure Mode Identifier) Above normal range (DATA VALID but ABOVE NORMAL OPERATIONAL RANGE) Below normal range (DATA VALID but BELOW NORMAL OPERATIONAL RANGE) Incorrect signal (DATA ERRATIC, INTERMITTENT OR INCORRECT) Voltage above normal (VOLTAGE ABOVE NORMAL OR SHORTED TO HIGH SOURCE) Voltage below normal (VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE) Current below normal (CURRENT BELOW NORMAL OR OPEN CIRCUIT) Current above normal (CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT)
  • Page 938 Operating Hours Screen OPERATING HOURS Exiting Sub-menus: If escape button (ESC, 4 on Figure 25) is pressed for more than 1 second, this : 00042 Hr 1. Power information screen will be returned to previous 2. Economy 00120 Hr screen. 3.
  • Page 939 Menu Selection of Operation Hour Information 3. Auto Idle 1. Power Mode 2. Economy Mode 4. Travel Speed 1st, 2nd 6. Coolant Temperature Distribution 5. Hydraulic Oil Temperature Distribution FG013856 Figure 44 Example of Machine Operation Info Screen OPERATING HOURS OPERATING HOURS : 00042 Hr 1.
  • Page 940 Reset screen of operation hour OPERATING HOURS Exiting Sub-menus: If escape button (ESC, 4 on Figure 25) is pressed for more than 1 second, this information screen will be returned to previous All Opearting hours screen. will be DELETED. When "YES" ( , 3 on Figure 25) button is NOTE: pressed, operation hours will reset.

  • Page 941: Electronic Hydraulic Control System (E-Epos)

    ELECTRONIC HYDRAULIC CONTROL SYSTEM (e-EPOS) Control System Schematic ENGINE PORT OEM PORT Work Mode Auto Idle Machine Info E/G speed order 20 18 FG015090 Figure 51 Electrical System SP001949 Page 54...
  • Page 942 Reference Reference Description Description Number Number Instrument Panel Solenoid Valve (Boost) e-EPOS Controller Solenoid Valve (High Speed) Engine Controller (ECU) Solenoid Valve (Breaker) Main Pump Travel Motor Aux Pump Main Relief Valve Control Valve Engine Control Dial Pressure Switch Breaker/Boost/Shear Selector Switch Pump Pressure Sensor Auto Travel Selector Switch...

  • Page 943: Power Mode Control

    POWER MODE CONTROL ENGINE PORT OEM PORT FG015091 Figure 52 Reference Reference Description Description Number Number Instrument Panel (Power Mode Electromagnetic Proportional Selector Switch) Pressure Reducing Valve (Mode Control) e-EPOS Controller Engine Control Dial Engine Controller (ECU) Aux Mode Switch Main Pump Aux Mode Resistor Aux Pump...
  • Page 944 The power mode switch permits the selection of the appropriate engine power depending on the working condition. One of the two, Power Mode or Standard Mode, setting can be selected. When the engine starter switch is turned "ON," the power mode is automatically defaulted to standard mode.
  • Page 945 Operation 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.
  • Page 946 Standard Mode Standard Mode is used for general work. When this mode is selected it will reduce noise and fuel consumption in comparison with Power Mode. The 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.
  • Page 947 FG013633 Figure 57 Reference Reference Description Description Number Number Engine Horsepower (hp) Pump Discharge Volume (lpm) Engine Speed (rpm) Pump Discharge Pressure (kg/cm Operation in case of failure in the control system (Aux mode operation) Though it is impossible to control current of the E.P.P.R (Electromagnetic Proportional Pressure Reducing) Valve controlling the discharge volume of pump due to fault in control system, the machine can be operated in the aux...
  • Page 948 Electrical System SP001949 Page 61...

  • Page 949: Power / Economy Mode Control - Circuit Diagram

    POWER / ECONOMY MODE CONTROL - CIRCUIT DIAGRAM CN6-1 CN6-2 CN6-9 CN6-10 CN1-1 CN7-4 CN4-4 CN1-2 CN7-5 CN4-5 CN7-6 CN4-6 CN1-8 CN1-9 CN1-10 P/V-(A) 1-46 1-47 CN1-21 VEHICLE 1-37 CONN (CONN.1) CN3-15 +(5V) CW LOW 1-51 CN3-16 1-52 CN3-17 HIGH 1-54 1-53 1-39...

  • Page 950: Engine Control Dial

    Reference Reference Description Description Number Number Instrument Panel Aux Mode Resistor Engine Controller Battery e-EPOS Controller Battery Relay E.P.P.R. Valve (Electromagnetic Fuse Proportional Pressure Reducing) Fusible Link Engine Control Dial Starter Switch Aux Mode Switch Electrical System SP001949 Page 63...
  • Page 951 ENGINE CONTROL SYSTEM ENGINE PORT OEM PORT (Drive Signal) (Command Signal) FG015092 Figure 59 Reference Reference Description Description Number Number Engine Controller Engine Control Dial e-EPOS Controller When the engine control dial is moved the output voltage changes according to the dial position. The e-EPOS controller converts this output voltage of dial to digital signal and sends it to the engine controller by CAN line.
  • Page 952 ENGINE CONTROL DIAL 7th STEP 1st STEP 13th STEP ( 10 ) ( 10 ) MECHANICAL MECHANICAL STOP STOP 4.0V 2.5V 1.0V SETUP 1ST 2nd 12th 13th STOP STOP VIEW ( POTENTIOMETER BOTTOM) FG000866 Figure 60 Reference Reference Description Description Number Number Knob...
  • Page 953 ENGINE CONTROL CIRCUIT DIAGRAM CN6-1 CN6-2 CN6-9 CN6-10 CN1-1 CN7-4 CN4-4 CN1-2 CN7-5 CN4-5 CN7-6 CN4-6 CN1-8 CN1-9 1-46 1-47 VEHICLE 1-37 CONN CN2-15 (CONN.1) CN3-15 +(5V) CW LOW 1-51 CN2-16 CN3-16 1-52 CN3-17 HIGH 1-54 1-53 1-39 AMP 070 18P AMP MIC 21P AMP 070 16P AMP 040 12P...
  • Page 954 Reference Reference Description Description Number Number Instrument Panel Fuse Engine Controller Starter Switch e-EPOS Controller Fusible Link Engine Control Dial Pressure Switch (Py) Battery Pressure Switch (Px) Battery Relay Electrical System SP001949 Page 67...
  • Page 955 AUTOMATIC DECELERATION CONTROL (AUTO IDLE CONTROL) ENGINE PORT OEM PORT FG015093 Figure 62 Reference Reference Description Description Number Number Instrument Panel Engine Controller (Auto Idle Switch) Engine Control Dial e-EPOS Controller Pressure Switch Electrical System SP001949 Page 68...
  • Page 956 If the machine is idling without the controls being operated or is waiting for a dump truck the engine speed is automatically lowered. Once the controls are operated and work is being started the machine will be restored to the previous settings. As a result, noise and fuel consumption will be reduced.
  • Page 957 ENGINE OVERHEAT PROTECTION SYSTEM ENGINE PORT OEM PORT (Pump control signal) (E/G overheating signal) (E/G overheating signal) FG015094 Figure 63 Reference Reference Description Description Number Number Instrument Panel Control Valve e-EPOS Controller E.P.P.R. Valve (Electromagnetic Proportional Pressure Reducing Engine Controller Valve) Main Pump Warning Buzzer...
  • Page 958 When the engine coolant temperature increases to over 107°C (225°F), the engine controller detects it from the sensor mounted in the coolant line and will send a signal to the e-EPOS controller. The e-EPOS controller sends a overheat signal to the instrument panel turning "ON"...
  • Page 959 POWER BOOST MODE Operation ENGINE PORT OEM PORT FG015095 Figure 64 Reference Reference Description Description Number Number Instrument Panel Solenoid Valve (Boost) e-EPOS Controller Main Relief Valve Engine Controller Breaker/Boost/Shear Selector Switch Main Pump Power Boost Switch Aux Pump (Top of Right Work Lever) Control Valve Electrical System SP001949...
  • Page 960 The Power Boost function is used to temporarily increase the main relief pressure to enhance excavation ability. When the breaker/boost/shear selector switch is set to "BOOST" and the power boost button on the center of the right-hand work lever (joystick) is pressed during work, the e-EPOS controller will activate the power boost solenoid valve and increase the relief valve pressure from 330 - 350 kg/cm (4,700 - 5,000 psi).
  • Page 961 Power Boost Control - Circuit Diagram CN6-1 CN6-2 CN6-9 CN6-10 CN1-1 CN7-4 CN4-4 CN1-2 CN7-5 CN4-5 PRESS CN7-6 CN4-6 SHEAR BREAKER (C4) CN1-11 (POWER MAX) CN2-2 CN1-8 CN1-9 (Center) (POWER MAX / BREAKER) AMP 070 18P AMP MIC 21P AMP 070 16P AMP 040 12P AMP 040 20P 6 5 4...
  • Page 962 Electrical System SP001949 Page 75...
  • Page 963 AUTOMATIC TRAVEL SPEED CONTROL ENGINE PORT OEM PORT FG015096 Figure 66 Reference Reference Description Description Number Number e-EPOS Controller Pump Pressure Sensor Engine Controller Solenoid Valve (High speed) Main Pump Travel Motor Aux Pump Engine Control Dial Control Valve Selector Switch For Automatic Travel Pressure Switch (Py Port) Electrical System...
  • Page 964 If the automatic travel speed control switch is set to the "OFF" position, the travel motor will run in the I-speed (low speed) range. If the selector switch is set to the "I" position, the travel motor will run in the II-speed (high speed) range. If the selector switch is set to the "II"...
  • Page 965 Automatic Travel Speed Control - Circuit Diagram CN1-1 CN1-2 CN3-1 CN3-2 (C3) CN1-12 CN3-3 CN3-4 CN2-4 CN2-5 CN3-15 CN1-8 +(5V) CN3-16 CN1-9 CN3-17 HIGH AMP 070 18P AMP MIC 21P AMP 070 16P AMP 040 12P AMP 040 20P 6 5 4 19 18 15 14 11 10 9...
  • Page 966 SELF-DIAGNOSTIC FUNCTION e-EPOS Controller The system operation status and malfunction codes can be checked through the display on top of the e-EPOS controller box the rear cover behind the operator's seat. FG000588 Figure 68 Reference Reference Description Description Number Number Upper Digit Power Monitor (Stays "ON"...
  • Page 967 Normal Operation Display Readout Display Readout Mode Selection Operation Status Upper Digit Lower Digit Normal Operation Power Mode Power Mode HAOH370L HAOH340L Normal Operation Power Mode Standard Mode Standard Mode HAOH370L HAOH350L Normal Operation Economy Mode Economy Mode HAOH370L FG013637 Communication Monitor What are shown in the 7-SEGMENT LED are same as those in the Error Codes.

  • Page 968: Air Conditioner System

    AIR CONDITIONER SYSTEM Outline FG014384 Figure 69 Solid-type heater and air conditioner are installed in the cover below the operator's seat. Temperature of the operator's room is adjusted automatically to the temperature set by operator. SP001949 Electrical System Page 81...
  • Page 969 Internal and External Filters Internal and external air purification filters are installed for the operator's room. Filters should be cleaned every 500 hours. machine operates excessively contaminated environment, filters should be cleaned more frequently and if necessary, replaced with new ones. How to Check Internal Air Filter Open cover by turning knob indicated and mounted on the lower end of operator’s seat.
  • Page 970 Air-Conditioning System Layout Figure 72 FG015075 Reference Reference Description Description Number Number Air Conditioner/heater Unit Suction Hose Condenser Liquid Hose (1) Compressor Liquid Hose (2) Receiver Dryer Control Panel Discharge Hose SP001949 Electrical System Page 83...
  • Page 971 Air Conditioner/heater Circuit Diagram SWITCH STARTER SWITCH BATTERY RELAY FUSIBLE LINK A/C CONTROL PANEL SWITCH CN8-11 INTAKE ACTUATOR BATT. STARTER SWITCH CN8-13 0.5GrG CN8-18 CN8-22 OPEN COMPRESSOR BATTERY RELAY 0.5GrY CN8-19 FUSIBLE LINK CLOSE RELAY RECEIVER DRIER 0.85BW 0.85LW DEFROSTER ACTUATOR A/C CONTROL PANEL CN8-20 0.5OrR...
  • Page 972 Air Conditioner/heater Unit Air Flow Diagram Aircon Unit Blower Motor Blower Register FG015097 Figure 74 SP001949 Electrical System Page 85...
  • Page 973 REFRIGERANT CIRCULATION HBOI020L Figure 75 Reference Reference Description Description Number Number Evaporator Compressor Expansion Valve Blower Fan Condenser Receiver Dryer Condenser Fan Electrical System SP001949 Page 86...
  • Page 974 Shading Temperature Refrigerant State High High-pressure Gas High High-pressure Liquid Low-pressure Liquid High High-pressure Gas/Liquid Low-pressure Gas • Refrigerant (R134a) is compressed to approximately 15 kg/cm (210 psi) within the compressor. • The compressed refrigerant flows into the condenser at high temperature (approximately 80°C (176°F)). •...
  • Page 975 Air Flow Control Air flow control motor (B) Air flow control motor (C) Air flow control motor (A) FG015098 Blower Motor Figure 76 Air flow control motor (A) Air flow control motor (B) Air flow control motor (C) Close Open Close Close Open...
  • Page 976 Air Flow Control Motor Circuit Connector and Terminal Number FG015099 Figure 77 Blower Motor Circuit Blower Motor Temperature Fuse FG015100 Figure 78 SP001949 Electrical System Page 89...
  • Page 977 Coolant Flow Control Valve Circuit Connector and Terminal Number FG015101 Figure 79 Electrical System SP001949 Page 90...
  • Page 978 Temperature Level Control And Display Position Step LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 Sensor Remark Voltage Green Green Green Green Green Green Green 4.50V ± 0.2 MAX. COOL Green Green Green Green Green Green Green...
  • Page 979 Control Panel Appearance and Terminal Arrangement FG015072 Figure 80 Refer to "Air Conditioner and Heater" of operation manual. Compressor Categories Specifications Relief Valve Output 155.3 cc/rev Oil Level 120 cc (ND-OIL8) Refrigerant R134a Rated Voltage Open: 35 - 42.2 kg/cm Relief Valve Close: 28.1 kg/cm Compressor sucks in refrigerant which evaporates completely in...
  • Page 980 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.

  • Page 981: Troubleshooting

    TROUBLESHOOTING Refrigerant Pressure Check Open all doors and windows. Install manifold gauge set. Start engine and maintain engine speed at 1,800 - 2,000 rpm. HDA6074L Figure 84 Check high / low-pressure of refrigerant. High-pressure: 8.0 - 10.0 kg/cm (114 - 142 psi) Low-pressure: Approximately 1.0 kg/cm (14 psi) Possible Cause: Low Refrigerant Level...
  • Page 982 High-pressure: Over 6 kg/cm (85 psi) Low-pressure: Approximately 760 mmHg (Negative Pressure) Possible Cause: Refrigerant does not circulate Step Inspection Item Remedy Connect manifold gauge and start engine. Turn on air conditioner. Moisture in system, replace receiver dryer. Set blower switch to HIGH position. Turn air conditioner OFF and wait 10 minutes.

  • Page 983: Weight Of R134A Gas Used In Machines

    WEIGHT OF R134a GAS USED IN MACHINES Model Weight of Gas DX140LCR 550 ± 20 grams (19.3 ± 0.7 oz) DX140LC 800 ± 20 grams (28 ± 0.7 oz) DX225LC 800 ± 20 grams (28 ± 0.7 oz) DX225NLC 800 ± 20 grams (28 ± 0.7 oz) DX300LC 800 ±...

  • Page 984: Refrigerant System Repairs

    REFRIGERANT SYSTEM REPAIRS WARNING Always wear protective glasses and gloves when handling refrigerant. If refrigerant comes in contact with the skin or eyes, immediately flush with clean, running water and consult a physician. Select a clean and well ventilated area to work. The refrigerant container is under high-pressure and should be stored below 40°C (104°F).
  • Page 985 Do not over tighten connections when working on refrigerant system. The new refrigerant system standards require new tools, equipment and parts. DO NOT attempt to use equipment use in servicing the old refrigerant system. The new refrigerant oil (PAG type) has a high moisture absorption characteristic.
  • Page 986 INSTALL REPAIR TOOL RECOVER REFRIGERANT REPAIR / REPLACE DEFECTIVE PARTS VACUUM SYSTEM (OVER 5 MINUTES) CHECK SYSTEM FOR AIR LEAKAGE REPAIR VACUUM SYSTEM (OVER 20 MINUTES) CHARGE SYSTEM (APPROXIMATELY 100 g) CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHARGE SYSTEM TO PROPER LEVEL (Standard Capacity less Initial Charge) CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHECK FOR PROPER REFRIGERANT LEVEL...
  • Page 987 Refrigerant Recovery Reference Description Number To Compressor Low-pressure Side High-pressure Side From Receiver Refrigerant Recovery Tank Attach the manifold gauges and the refrigerant recovery unit to the refrigerant lines as shown. HDA6067L Figure 87 Be careful not to switch the connections for the NOTE: low and high-pressure valves.
  • Page 988 Check system for vacuum leak. Allow system to sit for 10 minutes and check whether the system is holding the pressure. If the pressure has dropped, it must be repaired before proceeding to the next step. Vacuuming Procedure If the system is holding the pressure and it has not changed for 10 minutes, vacuum out the system for an additional 20 minutes.
  • Page 989 Leakage Check Perform leakage check after completing NOTE: vacuuming process. After attaching the manifold gauge, open the high side valve. Charge system until the low side gauge dial indicates a pressure of 1 kg/cm (14 psi) and close the high side valve. Using a refrigerant leak detector or soapy water check each joint for leakage.
  • Page 990 If refrigerant does not flow freely into system, try starting engine first before operating air conditioner. • Temperature control switch setting: Maximum Cooling Blower Speed Setting: Hi (3 step) Engine Speed: 1,300 - 1,500 rpm WARNING When charging refrigerant system with the engine running: •...
  • Page 991 Inspecting System For Leakage After completing charging procedures, clean all joints and connections with a clean dry cloth. Using a refrigerant leak detecting device or soapy water, inspect system for leaks starting from the high-pressure side. When the refrigerant circulation has been stopped NOTE: the high-pressure will start to decrease and the low- pressure will start to increase until they are...

  • Page 992: Wiper System

    WIPER SYSTEM Wiper Circuit (Continuous mode) (Intermittent 1 mode) (Intermittent 2 mode) (Washer mode) AMP MIC 13P CN12 CN13 KET 8P AMP MIC 13P (CN12) (Wiper Motor) (CN13) FG000589 Figure 94 Reference Reference Description Description Number Number Battery Wiper Controller Battery Relay Wiper Switch Panel Fusible Link...
  • Page 993 Wiper operation Continuous operation - Operation of wiper motor Pressing the successive operation switch on the wiper switch panel (7) changes the voltage of the "5" terminal of the wiper controller (6) from HIGH (about 5.5 ± 0.5V) to LOW (0+0.5V) and also current flows via the "3"...
  • Page 994 - 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. The wiper system does not work when the wiper NOTE: cutoff switch (9) is "ON." SP001949 Electrical System Page 107...

  • Page 995: Lighting System

    LIGHTING SYSTEM Lighting System Circuit Diagram CN6-1 CN6-2 CN6-9 CN6-10 CN2-6 CN7-4 CN4-4 CN7-5 CN4-5 CN7-6 CN4-6 CN1-1 CN1-2 CN1-8 CN1-9 FG000590 Figure 95 Electrical System SP001949 Page 108...
  • Page 996 Reference Reference Description Description Number Number Battery Front Cabin Light / Rear Work Light Relay Battery Relay Instrument Panel Fuse Box e-EPOS Controller Light Switch Headlight (2 ea.) Cabin Light Switch Work Light (2 ea.) Headlight Relay (Work Light Indicate Light) Front Cabin Light (4 ea.) Work Light Relay Rear Cabin Light (2 ea.)

  • Page 997: Overload Warning Device

    OVERLOAD WARNING DEVICE Overload Warning Device Circuit Diagram ARS1260L Figure 96 Reference Reference Description Description Number Number Battery e-EPOS Controller Battery Relay OWD Selector Switch Fuse Box Pressure Sensor Electrical System SP001949 Page 110...

  • Page 998: Audio Controller

    AUDIO CONTROLLER Audio Controller Circuit Diagram ANTENNA MODULE Vcc(+5V) (LH) (RH) MICOM Vcc(+5V) DC/DC CONVERTER 1 9 10 13 14 15 1 2 3 4 (Audio Control Panel) (STEREO) FG000591 Figure 97 Reference Reference Description Description Number Number Battery Audio Control Panel Battery Relay Stereo Fuse Box...
  • Page 999 Operations Via Audio Control Panel Connected Terminal of Switch Measured values Operations switch 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 Electrical System SP001949 Page 112...
  • Page 1000 SP002271 ELECTRICAL SCHEMATIC (DX140LCR)SP002271 Electrical Schematic (DX140LCR) Edition 1 Electrical Schematic (DX140LCR) SP002271 Page 1...
  • Page 1001 MEMO Electrical Schematic (DX140LCR) SP002271 Page 2...

  • Page 1002: Table Of Contents

    Table of Contents Electrical Schematic (DX140LCR) Safety Precautions ..........5 Applicable Models ..........5 DX140LCR ............7 Electrical Schematic (DX140LCR) SP002271 Page 3...
  • Page 1003 MEMO Electrical Schematic (DX140LCR) SP002271 Page 4...
  • Page 1004 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.
  • Page 1005 Electrical Schematic (DX140LCR) SP002271 Page 6...
  • Page 1006 DX140LCR WIPER WIPER AUDI O CONTROLLER ROTATING BEACON (OPT) SWITCH PANEL CONTROL PANEL 6-LAMP ASS’Y (OPT) STARTER SWITCH CONNECTION 155B 155A 159A (CONT) 0.5LR 159B 0.85LW 129B 129C TELESCOPIC BEACON 0.85RG 1.25RG 0.85RG 160A (INT-1) 0.5LY 160B CONT. POWE R 0.85Or 156A 0.85LB...
  • Page 1007 Attachments...
  • Page 1009 SP002378 Boom and Arm Edition 1 Boom and Arm SP002378 Page 1...
  • Page 1010 MEMO SP002378 Boom and Arm Page 2...
  • Page 1011 Table of Contents Boom and Arm Safety Precautions ..........5 Applicable Models ..........5 Front Attachment Pin Specifications..... 6 One-Piece Boom ............. 6 Two-Piece Boom ............. 7 Front Attachment - Removal and Installation..8 Arm Removal Procedure ..........8 Boom Removal Procedure ..........10 Installation ............
  • Page 1012 MEMO SP002378 Boom and Arm Page 4...

This manual is also suitable for:

Dx140lcrDx235lcr

Table of Contents

Save PDF