Page 1 K1009096E Serial Number 5001 and Up Doosan reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products.
Page 3 Product Label Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine Pub. No. K1009096E...
Page 5 Table of Contents Safety Track Excavator Safety................. SP000256 Speciﬁcations Specification for DX420LC..............SP000257 General Maintenance General Maintenance Procedures ............SP000016 Standard Torques ................. SP000017 Upper Structure Cabin ....................SP000018 Counterweight..................SP000265 Fuel Tank....................SP000264 Swing Bearing..................SP000262 Swing Reduction Gear................SP000249 Lower Structure and Chassis Track Assembly ..................
Page 6 Breaker EPPR Valve (Opt) ..............SP000192 Fan Motor (Vane Type)................. SP000209 Gear Pump (Fan Cooling Drive) ............SP000208 Fan Cooling Flow In-Out Change Valve ..........SP000207 Hydraulic Schematic (DX420LC) ............SP000274 Electrical System Electrical System .................. SP000269 Electrical Schematic (DX420LC) ............SP000275 Attachments Boom and Arm..................
Page 7 Safety...
Page 9 SP000256 TRACK EXCAVATOR SAFETYSP000256 Track Excavator Safety Edition 1 Track Excavator Safety SP000256 Page 1...
Page 10 MEMO SP000256 Track Excavator Safety Page 2...
Page 11: Table Of Contents
Table of Contents Track Excavator Safety Safety Precautions..........5 Applicable Models..........5 To the Operator of a DOOSAN Daewoo Excavator ................6 General Safety Essentials ........10 Location of Safety Labels ........11 Summary of Safety Precautions for Lifting in Digging Mode .............
Page 12 MEMO SP000256 Track Excavator Safety Page 4...
Page 13: Track Excavator Safety
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up SP000256 Track Excavator Safety Page 5...
Page 14: To The Operator Of A Doosan Daewoo Excavator
TO THE OPERATOR OF A DOOSAN DAEWOO EXCAVATOR DANGER! Unsafe use of the excavator could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
Page 15 In no event should you or others engage in prohibited uses or actions as described in this manual. DOOSAN delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in...
Page 16 SAFETY ALERT SYMBOL Be Prepared - Get to Know All Operating and Safety Instructions. This is the Safety Alert Symbol. Wherever it appears in this manual or on safety signs on the machine you should be alert to the potential for personal injury or accidents. Always observe safety...
Page 17 Safety precautions are described in SAFETY from page -11 on. DOOSAN cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not speciﬁcally recommended or allowed in this manual...
Page 18: 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 19: 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. 11 9 11 2190-3311 FG001823 Figure 1 SP000256 Track Excavator Safety Page 11...
Page 20: 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 SP000256 Page 12...
Page 21: Unauthorized Modifications
UNAUTHORIZED MODIFICATIONS Any modiﬁcation made without authorization or written approval from DOOSAN can create a safety hazard, for which the machine owner must be held responsible. For safety's sake, replace all OEM parts with the correct authorized or genuine DOOSAN part. For example, not taking...
Page 22 Inside Operator's Compartment When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If you operate the travel pedal with mud or oil stuck to your shoes, your foot may slip and this may cause a serious accident. After using the ashtray, make sure that any matches or cigarettes are properly extinguished, and be sure to close the ashtray.
Page 23 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 24 • Slow down if it is necessary when passing rough terrain. • Drive around obstacles and excessive rough terrain conditions. Keep the terrain on work sites where the machine is working and traveling in good condition. • Remove any large rocks or obstacles. •...
Page 25 Fuel, Oil and Hydraulic Fluid Fire Hazards Fuel, oil and antifreeze will catch ﬁre if it is brought close to a ﬂame. Fuel is particularly ﬂammable and can be hazardous. Always strictly observe the following. Add fuel, oil, antifreeze and hydraulic ﬂuid to the machine only in a well ventilated area.
Page 26 Asbestos Dust Hazard Prevention Asbestos dust can be HAZARDOUS to your health if it is inhaled. Materials containing asbestos ﬁber can be present on work site. Breathing air that contains asbestos ﬁber can ultimately cause serious or fatal lung damage. To prevent lung damage from asbestos ﬁber, observe following precautions: •...
Page 27 Reinstallation, recertiﬁcation and/or replacement of the system may be necessary. Contact your DOOSAN distributor for available safety guards and/or recommendations if there is any danger of getting hit by objects that could strike the operator's cabin. Make sure that all other work site crew members are kept well away from the excavator and safe from possible hazards.
Page 28 Attachment Precautions Option kits are available through your dealer. Contact DOOSAN for information on available one-way (single-acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because DOOSAN cannot anticipate, identify or test all of the attachments that owners may wish to install on their machines, please contact DOOSAN for authorization and approval of attachments, and their compatibility with options kits.
Page 29 Emergency Exit This machine is equipped with a glass breaking tool. It is behind the operator seat in the upper right corner of the cabin. This tool can be used in case of an emergency situation that requires the breaking of glass to exit from the operator's cabin. Grip the handle ﬁrmly and use the sharp point to break the glass.
Page 30: 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 the ground surface as hard and horizontal as possible before carrying out operations.
Page 31 areas. If the ground should collapse, the machine could fall or tip over and this could result in serious injury or death. Remember that the soil after heavy rain, blasting or after earthquakes, is weakened in these areas. Earth laid on the ground and the soil near ditches is loose. It can collapse under the weight of vibration of your machine and cause your machine to tip over.
Page 32 Look around the work site area for potential hazards, people or properly that could be at risk while operation is in progress. NEVER start the engine if there is any indication that maintenance or service work is in progress, or if a warning tag is attached to controls in the cabin.
Page 33 • Warm up the engine and hydraulic oil before operating machine. • Before moving the machine, check the position of undercarriage. The normal travel position is with idler wheels to the front under the cabin and the drive sprockets to the rear. When the undercarriage is in the reversed position, the travel controls must be operated in opposite directions.
Page 34: 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 the direction of travel from forward to reverse or from reverse to forward, reduce speed early and stop the machine before changing the HAOA190L...
Page 35 Travel Precautions TRAVEL POSTURE Never turn the starting switch to the "O" (OFF) position when traveling. It is dangerous if the engine stops when the machine is traveling. It will be impossible to operate the steering. Attachment control levers should not be operated while traveling.
Page 36 Traveling on Slopes Never jump onto a machine that is running away to stop it. There is danger of serious injury. Traveling on slopes could result in the machine tipping over or slipping. On hills, banks or slopes, carry the bucket approximately 20 - 30 cm (8 - 12 in) above the ground.
Page 37 Do not carry out deep digging under the front of the machine. The ground under the machine may collapse and cause the machine to fall. Working heavy loads over loose, soft ground or uneven, broken terrain can cause dangerous side load conditions and possible tipover and injury.
Page 38 Avoid High Voltage Cables Serious injury or death can result from contact or proximity to high voltage electric lines. The bucket does not have to make physical contact with power lines for current to be transmitted. Use a spotter and hand signals to stay away from power lines not clearly visible to the operator.
Page 39 In a work site where falling rocks can cause damage and possibly crush personnel, or in a mining operation, be sure to install the falling object protective structure (Figure 26). Be sure to install any other additional protective structures required for work site conditions. When the falling object protective structure is installed, and the front window needs to be cleaned, loosen the bolts marked with an arrow.
Page 40 Parking Machine Avoid making sudden stops, or parking the machine wherever it happens to be at the end of the work day. Plan ahead so that the excavator will be on ﬁrm, level ground away from trafﬁc and away from high walls, cliff edges and any area of potential water accumulation or runoff.
Page 41: Maintenance
DO NOT OPERATE a length of chain or cable to keep the safety lever in the fully lowered, nonactive position. when performing inspection or maintenance Warning tags, for controls are available from DOOSAN 190-00695 distributors. ARO1320L Figure 30 Clean Before Inspection or Maintenance Clean the machine before carrying out inspection and maintenance.
Page 42 Proper Tools Use only tools suited to the task. Using damaged, low qualify, faulty, or makeshift tools could cause personal injury. There is danger that pieces from, chisels with crushed heads, or hammers, may get into your eyes and cause blindness. HDO1037L Figure 32 Use of Lighting...
Page 43 ﬂuids. Before you weld on pipes or on tubes or before you ﬂame cut on pipes or on tubes, clean the pipes or tubes thoroughly with a nonﬂammable solvent. Burn Prevention When checking the radiator coolant level, shut down engine, let the engine and radiator cool down, then check the coolant recovery tank.
Page 44 When carrying out welding repairs, carry out the welding in a properly equipped place. The welding should be performed by a qualiﬁed worker. During welding operations, there is the danger of, generation of gas, ﬁre, or electric shock, so never let an unqualiﬁed worker do welding.
Page 45 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 46 Precautions When Working on Machine When carrying out maintenance operations on the machine, keep the area around your feet clean and tidy to prevent you from falling. Always do the following: • Do not spill oil or grease. • Do not leave tools laying about. •...
Page 47 In particular, if the machine is used when there are still problems with the brake or work equipment systems, it may lead to serious injury. If necessary depending on the type of failure, please contact your DOOSAN distributor for repairs. SP000256 Track Excavator Safety Page 39...
Page 48 Precautions with High-pressure Lines, Tubes and Hoses When inspecting or replacing high-pressure piping or hoses, check that the pressure has been released from the circuit. Failure to release the pressure may lead to serious injury. Always do the following: • Wear protective glasses and leather gloves.
Page 49 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 50: 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 51 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 52: Towing
Shackle • If the engine on the problem machine will not start or there is a failure in the brake system. always contact your DOOSAN distributor. Towing Wire FG000669 • Never go between the towing machine and the towed Figure 47 machine during the towing operation.
Page 53: 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 54 Track Excavator Safety SP000256 Page 46...
Page 55 Speciﬁcations...
Page 57 SP000257 SPECIFICATION FOR DX420LCSP000257 Speciﬁcation for DX420LC Edition 1 Speciﬁcation for DX420LC SP000257 Page 1...
Page 58 MEMO SP000257 Speciﬁcation for DX420LC Page 2...
Page 59 Specification for DX420LC Safety Precautions..........5 Applicable Models..........5 General Description..........7 Component Locations........... 8 General Dimensions (DX420LC) ......10 Working Range ........... 12 General Speciﬁcations........14 Engine Performance Curves (Per DIN 6270 Standard) ............16 Approximate Weight of Workload Materials ..18 Performance Tests ..........
Page 60 MEMO SP000257 Speciﬁcation for DX420LC Page 4...
Page 61: Specification For Dx420Lc
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up SP000257 Speciﬁcation for DX420LC Page 5...
Page 62 Speciﬁcation for DX420LC SP000257 Page 6...
Page 63: General Description
The excavator has three main component sections: • The Upper Turntable • The Lower Undercarriage and Track Frames • The Excavator Front-end Attachment The following illustration identiﬁes main components and their locations. (See Figure 1 on page -8.) SP000257 Speciﬁcation for DX420LC Page 7...
Page 64: Component Locations
COMPONENT LOCATIONS 9 10 11 12 13 14 15 16 17 18 FG001806 Figure 1 Speciﬁcation for DX420LC SP000257 Page 8...
Page 65 Air Cleaner Lower Roller Swing Bearing Center Joint Cabin Upper Roller Seat Sprocket Work Lever (Joystick) Controls Travel Motor Travel Lever Track Link and Shoe Boom Cylinder Suction Filter Arm Cylinder Return Filter Boom Pumps Speciﬁcation for DX420LC SP000257 Page 9...
Page 66: General Dimensions (Dx420Lc)
2,750 mm (9' 0") 3,350 mm (11' 0") 600 mm (2' 0") 540 mm (1' 9") * 555 mm (1' 10") 3,154 mm (10' 4") * 3,270 mm (10' 9") * Indicates double grouser shoes installed dimension. Speciﬁcation for DX420LC SP000257 Page 10...
Page 67 Speciﬁcation for DX420LC SP000257 Page 11...
Page 68: Working Range
Digging too far underneath the excavator if soil conditions are wet, loose or unstable can collapse ground support, which could cause injury and/or equipment damage. FG001799 Speciﬁcation for DX420LC SP000257 Page 12...
Page 69 (24' 6") (25' 7") (26' 11") (25' 5") 4,385 mm 4,380 mm 4,445 mm * 4,380 mm Min. swing radius (14' 5") (14' 4") (14' 7") (14' 4") * Indicates double grouser shoes installed dimension. SP000257 Speciﬁcation for DX420LC Page 13...
Page 70: General Specifications
Standard 600 mm (24.0") shoe - 0.74 kg/cm (10.5 psi) Optional 750 mm (30.0")shoe- 0.61kg/cm (8.7 psi) Optional 800 mm (32.0") shoe - 0.57 kg/cm (8.1 psi) Optional 900 mm (35.0")shoe- 0.50 kg/cm (7.1 psi) Transport Dimensions Speciﬁcation for DX420LC SP000257 Page 14...
Page 71 Track Shipping Length 5,200 mm (17' 1") Transport Trailer Capacity 41.0 metric tons (45.2 tons) minimum load capacity Transport Loading Ramp 15˚ angle CAUTION: Refer to Transport Maximum Allowable Slope Procedure for Safe Shipping Instructions. SP000257 Speciﬁcation for DX420LC Page 15...
Page 72: Engine Performance Curves (Per Din 6270 Standard)
ENGINE PERFORMANCE CURVES (PER DIN 6270 STANDARD) Figure 3 Speciﬁcation for DX420LC SP000257 Page 16...
Page 73 DIN 6270 297 ps @ 1,800 rpm Power (293 hp @ 1,800 rpm) 140 kg•m @ 1,300 rpm Max. Torque (1013 ft lb @ 1,300 rpm) 160 g/ps•h Fuel Consumption (MIn. Rated) (5.64 oz/hp•h) SP000257 Speciﬁcation for DX420LC Page 17...
Page 74: Approximate Weight Of Workload Materials
1,362 kg/m --------------------- --------------------- clinkers (2,295 lb/yd 1,522 kg/m Dolomite, crushed --------------------- --------------------- (2,565 lb/yd 1,202 kg/m Earth, loamy, DRY, loose --------------------- --------------------- (2,025 lb/yd 1,522 kg/m Earth, DRY, packed --------------------- --------------------- (2,565 lb/yd Speciﬁcation for DX420LC SP000257 Page 18...
Page 75 1,522 kg/m Sand, DRY, loose --------------------- --------------------- (2,565 lb/yd 1,922 kg/m Sand, WET, packed --------------------- --------------------- (3,240 lb/yd 1,362 kg/m Shale, broken --------------------- --------------------- (2,295 lb/yd 529 kg/m Sulphur, broken --------------------- --------------------- (1,620 lb/yd SP000257 Speciﬁcation for DX420LC Page 19...
Page 76: Performance Tests
36.4 ±2.0 High 15.3 ±1.0 14.3 ±1.0 Travel Speed 20 m (65.62 ft) 26.1 ±1.5 24.3 ±1.5 High mm (in) 150 (5.91) 150 (5.91 Travel Deviation 20 m (65.62ft) mm (in) 150 (5.91) 150 (5.91) Speciﬁcation for DX420LC SP000257 Page 20...
Page 77: Excavator Performance Standards
Travel Speed and Travel Motor Balance (Steering Deviation) Tests Speed Test Prepare the excavator for travel speed tests by extending all hydraulic cylinders - boom, arm and bucket - to the fully extended position, shown in Figure 4. SP000257 Speciﬁcation for DX420LC Page 21...
Page 78 Rotate the turntable 180°. Both tests should be repeated three times. Average all results to obtain a ﬁnal value. 3M - 5M 3M - 5M (10' - 15') (10' - 15') (65' 7-1/2'') FG000467 Figure 5 Speciﬁcation for DX420LC SP000257 Page 22...
Page 79: Swing Speed And Deceleration Force Test
3 full 360° rotations. The time required for 3 revolutions should be between 19.5 and 22.5 seconds in Standard Mode, 18.1 and 21.1 seconds in Power Mode. SP000257 Speciﬁcation for DX420LC Page 23...
Page 80 1000 mm (39.4"), in both Power Mode and Standard Mode. Reference Description Number Start Swing 90˚ Swing FG005122 Swing Force Figure 7 Swing Stop Maximum Less than 1,000 mm Distance (39.4 in) Speciﬁcation for DX420LC SP000257 Page 24...
Page 81: Cylinder Performance Tests
5 mm (0.20"). Cylinder Location Maximum Drop Boom Cylinder Less Than 5 mm (0.20 in) Arm Cylinder Less Than 5 mm (0.20 in) Bucket Cylinder Less Than 20 mm (0.79 in) SP000257 Speciﬁcation for DX420LC Page 25...
Page 82 3 full rotations, during both high speed and low speed operation. Operation Standard Mode Power Mode High Speed seconds 22.9±1.5 21.4±1.5 Low Speed seconds 39.1±2.0 36.4±2.0 Speciﬁcation for DX420LC SP000257 Page 26...
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 SP000016 General Maintenance Procedures 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 SP000016 General Maintenance Procedures 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 or any other type of troubleshooting or service is being performed, it's important to remember that the hydraulic system - including both the interior and exterior surfaces of assemblies, and every drop of operating ﬂuid - must be protected from contamination.
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
any seal lip will seriously impair its efﬁciency. Apply a thin coat of Loctite #120 to outer diameter, of metal casing, on oil seals to assure an oil tight ﬁt into retainer. Use extreme care not to get Loctite on lips of oil seals. If this happens, that portion of the seal will become brittle and allow leakage.
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 caused...
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 SP000017 STANDARD TORQUESSP000017 Standard Torques Edition 1 Standard Torques SP000017 Page 1...
Page 106 MEMO SP000017 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 ......11 Torque Wrench Extension Tools ......
Page 108 MEMO SP000017 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 Fasteners
TORQUE VALUES FOR STANDARD METRIC FASTENERS NOTE: The units for the torque values are kg•m (ft lb). Grade Dia. x Pitc h (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...
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 the measuring capacity of the torque wrench.
Page 117: Other Uses For Torque Wrench Extension Tools
extension and torque wrench. Readings may also be inaccurate: • If the extension itself absorbs some of the tightening force and starts to bend or bow out. • If an extension has to be fabricated that is not perfectly straight (for example, an extension made to go around an obstruction, to allow access to a difﬁcult to tighten fastener), the materials and methods used must be solid enough to transmit full tightening...
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 SP000018 CABIN SP000018 Cabin Edition 1 Cabin SP000018 Page 1...
Page 124 MEMO SP000018 Cabin Page 2...
Page 125 Table of Contents Cabin Safety Precautions..........5 Applicable Models..........5 Removal..............6 Installation ............8 Cabin SP000018 Page 3...
Page 126 MEMO SP000018 Cabin Page 4...
Page 127: Cabin
The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 5001 and Up DX340LC 5001 and Up DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up SP000018 Cabin...
Page 128: 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 129 12. Remove ﬂoor mat. 13. Remove operator's seat (1, Figure 2). NOTE: Be careful not to damage seat covering. 14. Remove duct covers (2, 3 and 4, Figure 2). When removing cover (2) disconnect hour meter connector and cigar lighter connector.
Page 130: Installation
24. Remove four mounting nuts from four corners of cabin ﬂoor (2, Figure 6). 25. Remove four hex bolts (3, Figure 6) from door side of cabin ﬂoor. 26. Remove two hex bolts (1, Figure 6) from right side of cabin ﬂoor and one bolt (4) from front of cabin ﬂoor.
Page 131 Install four mounting nuts on four corners of cabin ﬂoor (2, Figure 9). NOTE: Mounting nut torque 20.2 kg•m (146 ft lb) Install four hex bolts (3, Figure 9) in door side of cabin ﬂoor. Install two hex bolts (1, Figure 9) in right side of cabin ﬂoor and one bolt (4) in front of cabin ﬂoor.
Page 132 14. Install air duct (3, 2 and 1, Figure 12) at right side of cabin. NOTE: Connect wire connector of duct (2 , Figure 12 ). FG000667 Figure 12 15. Install side panel (6, Figure 13) and pocket (5). 16. Install cover (4, Figure 13) and connect main harness. Install cover (3).
Page 133 SP000265 COUNTERWEIGHT SP000265 Counterweight Edition 1 Counterweight SP000265 Page 1...
Page 134 MEMO SP000265 Counterweight Page 2...
Page 135 Table of Contents Counterweight Safety Precautions..........5 Applicable Models..........5 General ..............6 Warning for Counterweight and Front Attachment Removal ................. 6 Removal..............8 Installation ............10 Counterweight SP000265 Page 3...
Page 136 MEMO SP000265 Counterweight Page 4...
Page 137: Safety Precautions
Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up SP000265 Counterweight Page 5...
Page 138: 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 139 WARNING! If the turntable deck has been unbalanced by removal of weight from one end only, traveling the excavator, swinging the turntable, movement over bumps or sloping and uneven surfaces could cause loss of control and possible accidents or injuries. To maintain stability the counterweight should be removed whenever the front attachment is taken off the machine.
Page 140 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 WARNING DON'T TOUCH WHEN WARNING! PERFORMING INSPECTION OR MAINTENANCE FG003015 If engine must be run while performing maintenance, Figure 3...
Page 141 12. Remove two caps (1, Figure 4) from counterweight (2). 13. Install two lifting eyes in lifting holes (3, Figure 4). Model Lifting Eye Size DX420LC M48x5.0 14. Using a suitable lifting device capable of handling a heavy load, partially support counterweight (2, Figure 4) before loosening four bolts (4).
Page 142 Torque bolts (4, Figure 5) to values shown in following table. Model Bolt Torque DX420LC 250 kg•m (1,807 ft lb) Remove lifting device and lifting eyes from counterweight lifting holes (3, Figure 5). Install two caps (1, Figure 5) in lifting holes (3).
Page 143 SP000264 FUEL TANK SP000264 Fuel Tank Edition 1 Fuel Tank SP000264 Page 1...
Page 144 MEMO SP000264 Fuel Tank Page 2...
Page 145 Table of Contents Fuel Tank Safety Precautions..........5 Applicable Models..........5 General Description..........6 Parts List ................. 8 Speciﬁcations ..............9 Removal.............. 10 Installation ............14 Start-up Procedures ........... 16 Fuel Tank SP000264 Page 3...
Page 146 MEMO SP000264 Fuel Tank Page 4...
Page 147 Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up SP000264 Fuel Tank Page 5...
Page 148 GENERAL DESCRIPTION WARNING! Engine fuel is highly ﬂammable and potentially explosive. To prevent possible injury and/or damage to equipment, extinguish or move to a safe distance all potential ﬁre hazards. Fuel Tank SP000264 Page 6...
Page 149 Fuel Tank SP000264 Page 7...
Page 150 Parts List Figure 1 Fuel Tank SP000264 Page 8...
Page 151 Reference Reference Description Description Number Number Fuel Tank Spring Washer Fuel Sender Screw O-ring Bolt Cover Clip Bolt Housing Bracket Spring Washer Spring Washer Drain Cock Screw Bolt Plug Shim O-ring Shim Hose Fuel Strainer Filter Hose Clamp O-ring Harden Spacer Plug Level Gauge Speciﬁcations...
Page 152: Removal
REMOVAL Look at fuel level display (Figure 2) on instrument panel in operator's cabin to see what it displays. The display is Green 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 153 12. Clean area around fuel tank ﬁll cap (12, Figure 5). Open fuel cap. FG005137 Figure 5 13. Place a large enough container under fuel tank to collect remaining fuel. Open drain cock (7, Figure 6) at bottom of tank and drain. NOTE: Fuel tank capacity is 550 liters (145 U.S.
Page 154 17. Remove eight bolts (30, Figure 9) and cover (31) from fuel tank. FG005134 Figure 9 18. Remove eight bolts (32 and 33, Figure 10) and stay (34) from fuel tank and frame. Remove four bolts (35 and 36) and fuel tank cover (37) from fuel tank.
Page 155 20. Install two 12 mm eyebolts in threaded holes (42 and 43, Figure 12). Using a suitable lifting device, sling eyebolts. 21. Remove six bolts and spacers (8 and 13, Figure 12) holding tank (1) to frame. Lift tank 25 mm (1") and make sure it is balanced.
Page 156 INSTALLATION Install two 12 mm eyebolts in threaded holes (42 and 43, Figure 13). Using a suitable lifting device, sling eyebolts. Set fuel tank (1, Figure 13) into position. Install six bolts and spacers (8 and 13, Figure 13) ﬁnger tight, to secure tank to frame.
Page 157 Install eight bolts (30, Figure 16) and cover (31) on fuel tank. FG005134 Figure 16 Connect components to fuel ﬁller pump port (29, Figure 17) on side of fuel tank (1). FG005132 Figure 17 Connect as tagged, fuel supply line (26, Figure 18) and fuel return line (27) to fuel tank (1).
Page 158 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 left side door and then there is fuel ﬁlter. FG004960 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 159 SP000262 SWING BEARING SP000262 Swing Bearing Edition 1 Swing Bearing SP000262 Page 1...
Page 160 MEMO SP000262 Swing Bearing Page 2...
Page 161 Table of Contents Swing Bearing Safety Precautions..........5 Applicable Models..........5 Swing Bearing Maintenance......... 6 Operating Recommendation ........... 6 Measuring Swing Bearing Axial Play....... 6 Measuring Bearing Lateral Play ........6 Swing Bearing Basic Operation........7 Disassembly ..............7 Assembly ................. 9 Swing Bearing SP000262 Page 3...
Page 162 MEMO SP000262 Swing Bearing Page 4...
Page 163: Swing Bearing
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up SP000262 Swing Bearing Page 5...
Page 164: 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 165: 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 166 Turn inner ring and use magnet bar (C, Figure 5) to remove steel balls (5). Figure 5 Turn inner ring and use wire (D, Figure 6) to remove retainers (6). Figure 6 Swing Bearing SP000262 Page 8...
Page 167: 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 7 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 168 Swing Bearing SP000262 Page 10...
Page 169 SP000249 SWING REDUCTION GEARSP000249 Swing Reduction Gear Edition 1 Swing Reduction Gear SP000249 Page 1...
Page 170 MEMO SP000249 Swing Reduction Gear Page 2...
Page 171 Table of Contents Swing Reduction Gear Safety Precautions..........5 Applicable Models..........5 General Description..........7 Theory of Operation ............7 Parts List ................. 8 Speciﬁcations ..............10 Troubleshooting, Testing and Adjustment ... 11 Removal.............. 12 Disassembly ............13 Assembly ............17 Shaft and S/R Bearing Shrinkage Fitting ......
Page 172 MEMO SP000249 Swing Reduction Gear Page 4...
Page 173: Swing Reduction Gear
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX340LC 5001 and Up DX420LC 5001 and Up SP000249 Swing Reduction Gear Page 5...
Page 174 Swing Reduction Gear SP000249 Page 6...
Page 175: General Description
GENERAL DESCRIPTION Theory of Operation The swing reduction gearbox is a two-step planetary gearbox with three planet gears, one sun gear and 2-step output reduction. The planetary gear engages with the ring gear. The pinion gear is connected with the output shaft and spline. The gearbox reduces swing motor rpm to increase swing motor output torque.
Page 176: Parts List
Parts List Figure 1 Swing Reduction Gear SP000249 Page 8...
Page 177 Reference Reference Description Description Number Number Drive Shaft Plate Gear Case Lock Ring Carrier No. 2 Spherical Roller Bearing Sun Gear No. 2 Spherical Roller Bearing Planetary Gear No. 2 Oil Seal Side Plate No. 2 Spring Pin No. 2 Shaft for Pin Plug No.
Page 178: Specifications
Speciﬁcations DX340LC DX420LC Swing Reduction Gearbox Drive Type Two Stage Planetary Gear Reduction Ratio 19.565 21.968 Maximum Output Speed 57.3 rpm 59.9 rpm 2,100 kg•m 2,360 kg•m Maximum Output Torque (15,189 ft lb) (17,070 ft lb) 275 kg Weight (606 lb)
Page 179: Troubleshooting, Testing And Adjustment
TROUBLESHOOTING, TESTING AND ADJUSTMENT Symptoms Possible Causes Remedies 1. No rotation and – a. Pressure at swing motor inlet Swing brake not releasing Check brake engagement and disengagement, increases check release pressure Internal damage to gearbox Replace broken gears, drive train drive train assemblies Overload Reduce load weight...
Page 180: 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 WARNING DON'T TOUCH WHEN WARNING! PERFORMING INSPECTION OR MAINTENANCE FG003015 Figure 2 engine must...
Page 181: Disassembly
DISASSEMBLY NOTE: Clean all exterior surfaces of the gearbox before beginning disassembly. Remove the drain plugs and allow all oil to drain from the gearbox. IMPORTANT Use a clean, dry container (with at least 11 liters, or 2.9 gallons capacity) to catch gear oil. A clean container allows an evaluation to be made of the used oil.
Page 182 Use a ﬂat tipped punch to drive the spring pin back into the shaft, so that the shaft can be pulled out of the gear housing. Drive back the spring pins on the other two shafts. Figure 7 Hold the planetary gear and thrust plate with one hand and slide the gear shaft out of the housing.
Page 183 11. Insert the gear case into a hydraulic press. Position the gear case so that the input end of the shaft is facing up. Insert a metal spacer into the bore of the shaft. Press down on the shaft until the shaft, with the spacer, plate, and roller bearing attached, is pressed out of the gear case.
Page 184 14. Set the shaft down into a metal pipe that has an inside diameter of 145 mm. The pipe should contact the bearing inner race only. Place a metal spacer on top of the shaft. Use a hydraulic press to press down on the spacer until the bearing is free of the shaft.
Page 185: Assembly
ASSEMBLY Shaft and S/R Bearing Shrinkage Fitting Washing of the shaft Remove liquid like anti-corrosion liquid on the shaft and then use an air gun to remove all of remaining foreign substance. Insert the spacer in the prepared shaft as shown in the ﬁgure below and put and heat the bearing on the speciﬁed heater.
Page 186 Figure 17 Lift the bearing when the temperature of the heater reaches 90° - 100˚C (194° - 212°F) and put it into the shaft with both hands holding it horizontally. To do so, insert it slowly about 4 to 5 mm that the bearing takes its seat by itself and then push it with force that it sticks to the spacer assembled into the shaft.
Page 187: Assembly Of The Carrier Subassembly
Figure 19 After completing the assembly of the bearing, allow the bearing to air dry for one to two hours. Figure 20 Assembly of the Carrier Subassembly Washing of the Carrier Use a dipping washer to wash the carrier which was got rid of burr through a corner end ﬁnishing (shaping) process, check again if foreign substance is removed completely, and put it on the assembly die.
Page 188 Assembly of the Carrier Subassembly 1 Put the carrier No.1 on the assembly jig as shown in the ﬁgure below. Figure 21 Put the pin assembly No.1 on the pin hole correctly and insert it with a press. Figure 22 Figure 23 Swing Reduction Gear SP000249...
Page 189 After its pressure insert, check its state visually. Figure 24 Insert the pin assembly 1 in the 3 remaining parts with a pressure in the same way. Figure 25 Turn over the carrier in which the pin is inserted and put the thrust washer No.1 on 4 pins as shown in the ﬁgure below.
Page 190 Figure 27 Assemble the planetary gear No.1. Figure 28 Put thrust washer No.3 as shown in the ﬁgure below. Figure 29 Swing Reduction Gear SP000249 Page 22...
Page 191 Engage the snap ring (for φ 40 axis) to each thread of the pin 1 and turn the gear to check if it rotates smooth. Figure 30 Figure 31 Assembly of the Carrier Subassembly 2 Put the carrier No.2 on the assembly die as shown in the ﬁgure below.
Page 192 Insert the bush No.2 in the planetary gear No.2 and put the thrust washer No.2 on it. Figure 33 Figure 34 Hold the gear with both hands and the thrust washer facing downward, insert it in the carrier, and arrange both gauges of the carrier and the bush.
Page 193 Erect the pin 2 above the pin hole (ø10) of the gear inserted carrier that the pin and the spring pin hole of the carrier are in the line, and push it with a hand or tap it with a hammer. Figure 37 Figure 38 Assemble the remaining 3 parts in the same way.
Page 194 Figure 41 Use a caulking punch to tap three areas around the spring pin hole. Figure 42 Figure 43 Assemble the 3 remaining parts in the same way and turn the gear to check if it rotates smooth. Figure 44 Swing Reduction Gear SP000249 Page 26...
Page 195: Assembly Of Main Case
Assembly of Main Case Washing of the Casing and Other Components Use supersonic waves to wash out foreign substance remaining on the casing and other components mentioned in the Parts List after casting and processes. • Cleaning ﬂuid: PK6540 (alkali) •...
Page 196 Figure 48 Remove the bearing press ﬁtting jig and assemble the plate with its stepped part facing downward. Figure 49 Figure 50 Insert the lock ring into the groove in the casing. CAUTION! Care should be taken not to have drive shaft drop to ﬂoor when it is pressed out of case.
Page 197 Figure 52 Insert the collar in the shaft, keep it horizontal, put the piston on it, put the press ﬁtting jig on it, and use a press to insert it. Figure 53 Figure 54 Put the lock plate on it, engage the bolt applied Loctite #262 (M16x40, torque: 2,700 kgf •...
Page 198 Figure 56 Figure 57 Figure 58 Figure 59 Swing Reduction Gear SP000249 Page 30...
Page 199 Figure 60 Figure 61 Figure 62 Swing Reduction Gear SP000249 Page 31...
Page 200 Assembly of the Seal and the Bearing Put the assembled casing in the turnover machine and turn it over. Figure 63 Figure 64 Check if there is any foreign substance on the seal assembly, apply grease and Loctite #609 to the seal and the outside of the oil seal (TC5001300), respectively, push it into the case while keeping it horizontal, put the seal press ﬁtting jig, and use a press to insert it.
Page 201 Figure 67 Figure 68 Figure 69 Figure 70 Swing Reduction Gear SP000249 Page 33...
Page 202 Figure 71 Figure 72 Put out the inner part of the prepared bearing (23024CD) and assemble them again that its trade mark is visible, insert it in the shaft as shown in the ﬁgure below, put the bearing press ﬁtting jig on it, and use a press to insert it. Figure 73 Figure 74 Swing Reduction Gear...
Page 203 Figure 75 Figure 76 Hold the pinion with both hands and turn it to check if it rotates smooth. Figure 77 Insert plugs in the PT3/8 and PT1/8 taps of the drain port. Figure 78 Swing Reduction Gear SP000249 Page 35...
Page 204 Figure 79 Figure 80 Assembly of the Ring Gear Press ﬁtting of the lock pin Insert lock pins (ø13 x 31.5) in 4 reamer holes of the casing and use a hammer to tap them. FG000936 Figure 81 FG000937 Figure 82 Swing Reduction Gear SP000249 Page 36...
Page 205 Apply liquid gasket (Three Bond 1104) to the area where the ring gear of the casing is assembled. FG000938 Figure 83 Use a hoist to lift the prepared ring gear, wipe the Aim at holes. assembled part with a cloth, put it on the hole considering its assembly direction, tighten speciﬁc bolts (M16 x 160), to which Loctite is not applied, in the symmetrical order, and be sure that the assembled parts are pressed each other...
Page 206 Assembly of the Carrier Use a hoist to lift the prepared No.2 carrier assembly and turn it clockwise or anticlockwise lightly for it to engage with the spline of the ring gear and the shaft naturally. Use a rubber hammer to tap the top of the carrier that it sticks to the bearing during the assembly.
Page 207 Figure 90 Put the prepared carrier assembly No.1 on the assembling part and turn it clockwise or anticlockwise lightly for it to engage with the low toothed shaft end of the ring gear and the sun gear No.2. Figure 91 Figure 92 Insert the sun gear No.1 in the middle of the carrier No.1.
Page 208 Figure 94 Loosen the retaining bolt and apply liquid gasket to the assembling part. Figure 95 FG000950 Figure 96 Swing Reduction Gear SP000249 Page 40...
Page 209 Figure 97 Lift the cover and check if there remains any foreign substance, put the level pipe on the hole of the case ø11, and use an impact wrench to tighten bolts (M16x180) applied Loctite by pulling it to your breast slowly, which should be repeated once more to ensure its torque after the ﬁrst torque engagement is heard.
Page 210 Figure 100 Assemble the plug with caution to prevent the inﬂow of foreign substance into the tap (PT1/4) used for the assembly of the level pipe of the cover during the test. Figure 101 Swing Reduction Gear SP000249 Page 42...
Page 211: Test
Test Pneumatic Test After the completion of the cover assembly, engage the pneumatic test jig as shown in the ﬁgure below. Figure 102 Figure 103 Supply air when the pressure gauge indicates 2 kgf • cm and check if the gauge indicates any change of pressure for 3 minutes.
Page 212 Noise and Abnormal Sound Test Upon the completion of the pneumatic test, pour gear oil of 5 ℓ into the reduction gear and engage the test motor. Figure 105 Figure 106 Start the motor up to 1400 RPM and use a noise measuring machine to carefully measure its noise level which should be below 90 dB and not include abnormal sound.
Page 213: Assembly Of The Motor
Figure 108 Assembly of the Motor Supply of Gear Oil Upon the completion of the noise test, remove the test motor and pour gear oil of 2.5 ℓ more. Figure 109 Figure 110 Swing Reduction Gear SP000249 Page 45...
Page 214 Assembly of the Motor Apply liquid gasket to the assembling part of the cover. Figure 111 Use a hoist to lift the motor, wipe its assembling part with a clean cloth, check the O-ring of the motor shaft, and assemble it at the tap of the PT3/4 of the cover with the brake valve of the motor facing to the left.
Page 215 Engage bolts (M16x40, torque: 2,700 kgf • cm) applied Loctite using a L wrench, check the standard torque using a torque wrench, and mark using a paint marker. FG000973 Figure 114 Figure 115 Figure 116 SP000249 Swing Reduction Gear Page 47...
Page 216 Engage the plug at the PT3/4 tap. Figure 117 Remove the plug, engage the level pipe sealed with Teﬂon tape, and check the oil level. Figure 118 Figure 119 Swing Reduction Gear SP000249 Page 48...
Page 217 Figure 120 Supply of Grease Assemble the caulk in the grease inlet, and put the nipple to supply grease until it ﬂows out of the opposite hole. FG000978 Figure 121 FG000979 Figure 122 Swing Reduction Gear SP000249 Page 49...
Page 218 After the completion of supplying grease, release and remove the caulk, assemble the plug sealed with Teﬂon tape, tighten it with a torque wrench, and ﬁnish the procedure by wiping out grease and other foreign substance remaining on the surface. FG000980 Figure 123 FG000981...
Page 219: Installation
INSTALLATION Coat pinion gear with grease. Refer to operation manual for speciﬁcations. Make sure two alignment pins (6) are installed in ﬂange of swing reduction gearbox (5). Using a suitable lifting device, sling swing motor (1, Figure 3) and position swing motor and reduction gearbox (5) as an assembly on unit.
Page 220 Swing Reduction Gear SP000249 Page 52...
Page 221 Lower Structure and Chassis...
Page 223 SP000263 TRACK ASSEMBLY SP000263 Track Assembly Edition 1 Track Assembly SP000263 Page 1...
Page 224 MEMO SP000263 Track Assembly Page 2...
Page 225 Table of Contents Track Assembly Safety Precautions..........5 Applicable Models..........5 General Description..........6 Track Tension ............6 Cleaning and Inspection (Wear Limits and Tolerances) ............9 Track Shoe..............10 Lower Roller ..............12 Upper Roller ..............13 Front Idler ..............14 Track Shoes and Links........
Page 226: Track Assembly
Track Spring Disassembly Diagram....... 34 Disassembly of the Track Spring Assembly....35 Assembly of the Track Spring ........37 Track Assembly SP000263 Page 4...
Page 227: Safety Precautions
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up SP000263 Track Assembly Page 5...
Page 228: 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 229 "D" on below table. The clearance should be approximately distance "E" on below table for operation over gravel, rocky terrain, or over sand or snow. Distance "A" Terrain Type DX420LC Normal "B" 380 - 430 mm (14.96 - 16.93 in) Minimum "C" 380 mm (14.96 in)
Page 230 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 231: 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 232: Track Shoe
Track Shoe FG004347 Figure 4 Track Assembly SP000263 Page 10...
Page 233 Limit for Use Recommended Limit for Check Item Standard Dimension (Repair - P or Maintenance Replace - R) 215.9 mm Link Pitch (8.50") Bushing Outside 71.0 mm 68.0 mm 66.0 mm [R] Diameter (2.80") (2.68") (2.60") 129 mm 126 mm 122 mm [P] Link Height (5.08")
Page 234: Lower Roller
Lower Roller FG004351 Figure 5 Limit for Use Recommended Limit for Check Item Standard Dimension (Repair - P or Maintenance Replace - R) Outside Diameter of 250 mm ﬂange (9.84") Outside Diameter of 200 mm 194 mm 190 mm [P] Tread (7.87") (7.64")
Page 235: Upper Roller
Upper Roller FG004352 Figure 6 Limit for Use Recommended Limit for Check Item Standard Dimension (Repair - P or Maintenance Replace - R) Outside Diameter of 210 mm ﬂange (8.27") Outside Diameter of 180 mm 171 mm 162.5 mm [P] Tread (7.09") (6.73")
Page 236: Front Idler
Front Idler FG000510 Figure 7 Limit for Use Recommended Limit for Check Item Standard Dimension (Repair - P or Maintenance Replace - R) Outside Diameter of 640 mm ﬂange (25.2") Outside Diameter of 590 mm 578 mm Tread (23.23") (22.76") 102 mm Width of Protrusion (4.02")
Page 237: 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 238: 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 239 Track Assembly SP000263 Page 17...
Page 240: Front Idler Roller
FRONT IDLER ROLLER Parts List FG004357 Figure 14 Track Assembly SP000263 Page 18...
Page 241: Front Idler Roller Disassembly
Reference Reference Description Description Number Number Idler Assembly Idler Floating Seal Bearing O-ring Shaft Plug Bushing Front Idler Roller Disassembly Remove plug (9, Figure 15) from roller assembly (3), and drain into a suitable container. FG004358 Figure 15 Separate the pin (6, Figure 16) from the bearing (3). FG004359 Figure 16 Use a press to remove the bearing from the axle (4).
Page 242: Front Idler Roller Reassembly
Detach the ﬂoating seal (7, Figure 18) from the idler (2) and bearing (3). FG004361 Figure 18 Use a press to separate the axle (4, Figure 19), O-ring (8) and bearing (3). FG004362 Figure 19 Remove bushing (5, Figure 20) with the press and special tool.
Page 243 Install ﬂoating seal (7, Figure 22) inside the idler (2) and bearing (3). NOTE: Apply clean engine oil to the joint side of the ﬂoating seal. Apply grease to the ﬂoating seal O-ring. FG004361 Figure 22 Install idler (2, Figure 23) on the axle. Install bearing (3, Figure 23) and pin (6) to the axle.
Page 244: Lower Roller
LOWER ROLLER Parts List FG004392 Figure 24 Track Assembly SP000263 Page 22...
Page 245: Lower Roller Removal
Reference Reference Description Description Number Number Roller Collar Floating Seal Shaft O-ring Bushing Plug 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.
Page 246: Lower Roller Reassembly
Separate the collar (2, Figure 27) from the axle, using press. Figure 27 Detach O-rings (7, Figure 28) from the axle. Separate ﬂoating seals (6, Figure 28) from the collar and roller (1). Detach collar (2, Figure 28) and O-rings (7) from the axle, using press.
Page 247: Lower Roller Installation
Insert ﬂoating seals (6, Figure 31) into the roller (1) and collar (2). NOTE: Apply clean engine oil to the joint side of the ﬂoating seal. Apply grease to the ﬂoating seal O-ring. Slide the axle inside the roller. FG004393 Figure 31 Install the collar (2, Figure 32), O-ring (7, Figure 31), and pin (5) on the remaining side.
Page 248: Upper Roller
UPPER ROLLER Parts List Figure 34 Track Assembly SP000263 Page 26...
Page 249: Upper Roller Removal
Reference Reference Description Description Number Number Roller O-ring Shaft Plug Thrust Ring Cover Bushing Washer Bushing Bolt Floating Seal Blot O-ring 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 250 Remove the bolts (13, Figure 37) and cover (10). Detach o- ring (14), bolts (12) and washer (11). FG004404 Figure 37 Separate the roller (1, Figure 38) from the axle (2). FG004406 Figure 38 Separate the ﬂoating seal (6, Figure 39) from the roller and coller(1).
Page 251 Separate the bushing (4 and 5, Figure 41) from the roller with a press. ST-1919 FG001502 Figure 41 SP000263 Track Assembly Page 29...
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). FG004419 Figure 42 Insert ﬂoating seal (6, Figure 43) into the roller (1) and coller. NOTE: Apply clean engine oil to the joint side of the ﬂoating seal.
Page 253 Track Assembly SP000263 Page 31...
Page 254: Track Spring And Track Adjusting Cylinder
TRACK SPRING AND TRACK ADJUSTING CYLINDER FG004444 Figure 45 Track Assembly SP000263 Page 32...
Page 255 Reference Reference Description Description Number Number Body Dust Seal Bracket Plate Bolt Spring Spring Washer Tie Bar Stopper Spring Pin Rod Packing Body Assembly Backup Ring UNDER CARRIGE TRACK SPRING Track Spring Assembly Diagram Figure 46 Track Assembly SP000263 Page 33...
Page 256 Track Spring Disassembly Diagram Figure 47 Reference Reference Description Description Number Number Bolt Spring Pin Lock Plate Body Lock Nut Rod Packing Bracket Back up Rinf Spring Dust Seal Sotpper Tie Bar Track Assembly SP000263 Page 34...
Page 257 Disassembly of the Track Spring Assembly CAUTION! The track spring assembly is assembled with strong force that more care should be taken for its disassembly. Use a 27 mm spanner to remove the grease valve from the rod (13). CAUTION! When supplying air, the operator should stand beside, not behind, the rod for it may be sprung forth suddenly with a blasting sound.
Page 258 CAUTION! Remember that spring has a very high elasticity that it might sprung forth during assembly disassembly. Recommended load of press is higher than 28 ton. Compress the track spring slowly until the lock nut (3) has clearance of more than 10 mm from the bracket (4) CAUTION! The lock nut (3) can be removed easily by means of heating, as it is attached with a special adhesive.
Page 259 CAUTION! Take care not to damage the inside of the body and screw threads after the disassembly of the tie bar. Figure 51 Use a 10 drill to remove the spring pin (8) retaining the tie bar (7) and the body (9). Disassemble the tie bar (7) and the body (9) after oxygen heating them, as they are attached with a special adhesive.
Page 260 Erect the body and engage the tie bar by 390 mm after checking the presence of any foreign substance in screw threads of the tie bar (7) and the body (9). It may not be used unless there is a special adhesive (Loctite 277 threadlocker) available.
Page 261 Figure 54 CAUTION! Remember that spring has a very high elasticity that it might sprung forth during assembly disassembly. Make sure that, after the assembly, the range of the right angle made by the bracket ﬂoor and the external side of the body should be within 3 mm.
Page 262 13. Seat the dust seal (3) on the body and use a hammer to tap it to stick it. 14. Apply grease in the body and carefully push the rod completely. 15. Use a 27 mm spanner to install the grease valve and supply grease.
Page 263 SP000025 AIR CONDITIONER SP000025 Air Conditioner Edition 1 Air Conditioner SP000025 Page 1...
Page 264 MEMO SP000025 Air Conditioner Page 2...
Page 265 Table of Contents Air Conditioner Safety Precautions..........5 Applicable Models..........5 Air Conditioner System ......... 6 Outline ................6 Internal and External Filters ..........7 Air-Conditioning System Layout ........9 Air Conditioner/Heater Circuit Diagram ......10 Air Conditioner/Heater Unit ........... 11 Relay - Blower ...............
Page 266 MEMO SP000025 Air Conditioner Page 4...
Page 267: Safety Precautions
The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 5001 and Up DX340LC 5001 and Up DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up SP000025 Air Conditioner...
Page 268: Air Conditioner System
AIR CONDITIONER SYSTEM Outline FG000784 Figure 1 Solid-type heater and air conditioner are installed in the cover behind the driver's seat. Temperature of the driver's room is adjusted automatically to the temperature set by operator. Air Conditioner SP000025 Page 6...
Page 269: Internal And External Filters
(Please refer to the Operation Manual for detailed whole automatic control. Vent mode selects the direction of discharged air. Outlets by vent modes Modes Outlets Internal and External Filters Internal and external air puriﬁcation ﬁlters are installed for the driver's room. Filters should be cleaned every 500 hours.
Page 270 Turn marked knobs (1, Figure 4) at the rear side of the cabin to open the cover. FG000441 Figure 4 Remove the ﬁlter attached to the cover and clean the contaminated ﬁlter using compressed air. Close the cover, replace the knobs, and secure the cover to the support with butterﬂy bolts.
Page 271: Air-Conditioning System Layout
Air-Conditioning System Layout FG003919 Figure 6 Reference Reference Description Description Number Number Air Conditioner/heater Unit Liquid Hose (1) Condenser Liquid Hose (2) Compressor Ambient Temperature Sensor Receiver Dryer Sun Sensor Discharge Hose Control Panel Suction Hose SP000025 Air Conditioner Page 9...
Page 272: Air Conditioner/Heater Circuit Diagram
Air Conditioner/Heater Circuit Diagram 0.5RW FUSIBLE LINK LAMP SWITCH STARTER SWITCH BATTERY RELAY AIRCON UNIT BATT. A/C CONTROL PANEL 1.25LR CN11-2 LED 1~12 130C CN9-6 0.85LR CN10-8 CN9-11 0.5WR CN10-18 CN9-5 1.25LR 0.85BW 0.85LR RECEIVER DRIER BLOWER RELAY RELAY COMPRESSOR 168B CN8-10 CN10-16...
Page 273: Air Conditioner/Heater Unit
Air Conditioner/Heater Unit Air Flow Diagram External Air Inlet Cold Box Internal Air Inlet Outlet Vent Rear Outlet Vent Front Outlet Foot Outlet Outlet External Air VENT COOL DOOR -INTAKE DOOR -MIX Internal Air WARM Heater Evaporator Core FOOT FG001359 Figure 8 SP000025 Air Conditioner...
Page 274 Door Open by Vent Modes Mode Door Vent Bi-level Foot Def/foot Vent Foot Main Components Air Flow Actuator Blower Blower Duct Control - Internal/external Relay Motor Actuator Sensor Module Air Exchanger - Temp Relay Control Internal Internal Air Sensor Air Filter Actuator Water Temp Evaporator...
Page 275 FG001361 Figure 10 Actuator - Wind direction control Wind Direction Mode Output Terminal Voltage Vent 0.5 ±0.2V Bi-level 1.3 ±0.2V c(+): CN10-10 Foot 2.45 ±0.2V b(-): CN10-4 Foot/def 3.5 ±0.2V 4.5 ±0.2V Actuator - Temp control Set Temp Output Terminal Voltage Max cooling c(+): CN10-9...
Page 276 Actuator - Internal/external air exchange CN10-20 CN10-2 FG001055 Figure 11 Sel mode Output Terminal Output Internal Air Moving of exchange door P1(+), P2(-) by selecting external air External Moving of exchange door P1(-), P2(+) by selecting internal air Air Flow Control Module Air ﬂow is controlled through the control of voltage between GATE and SOURCE.
Page 277: Relay - Blower
Relay - Blower Power is supplied to the blower motor when the system is turned Speciﬁcations Rated voltage Rated current Figure 13 Relay - A/C Power is supplied to the magnetic clutch of the compressor. Speciﬁcations Rated voltage Rated current FG001058 Figure 14 Duct Sensor...
Page 278 Water Temp Sensor It senses the temperature of coolant water in the heater core. Temp (°C) Resistance (K Ω Ω Ω Ω ) 55.8 ±1.7 32.9 ±0.9 15.76 ±0.5 10.0 ±0.3 6.5 ±0.2 Figure 16 Internal Air Temp Sensor Built in the internal air ﬁlter, it senses the internal temperature. Temp (°C) Resistance (K Ω...
Page 279 Sun Sensor Built beside the socket of spare power, it senses the quantity of the sun radiation to optimize discharge temperature and air ﬂow as set by driver. 83.7 76.2 67.7 58.8 46.6 36.0 21.4 1.0 2.0 3.0 4.0 5.0 6.0 7.0 LUX(x10,000) FG001062 Figure 19...
Page 280: Water Temp Sensor
Term No. Terms Term No. Terms Temp control (warm) Water temp sensor Sensor earth Duct sensor Temp control Power (5V) Sun sensor Mix feedback Ambient air temp sensor Power (KEY ON) Internal air temp sensor Back-up A/C output (LOW) Earth D.P.S CHECK Light Air ﬂow module (gate)
Page 281 Control Logic Categories Inputs System Operation AUTO Set Temp Automatically adjust room temp as set and then next items. Internal air temp sensor Temp/wind direction/internal, external air/air ﬂow/ compressor. Ambient air temp sensor Auto mode is released when manually setting any switch Water temp sensor except.
Page 282 Categories Inputs System Operation Starting Auto mode Prevention of discharge of hot air before discharge temp Control of drops enough in hot summer weather. Duct sensor Cooling Start conditions (AND condition) (1) A/C ON (AUTO or manual) (2) Temperature sensed by the duct sensor is above 30°C (3) Air ﬂow: Auto mode One time control in the cycle of engine OFF →...
Page 283 Categories Inputs System Operation Start condition (AND condition) (1) When wind direction mode is one of the following modes in the Auto or manual control mode - BI-LEVEL, FOOT or FOOT/DEF (2) The Water temp sensor is stable and the water temp < 73°C (3) Air ﬂow: Auto mode (4) Set temp >...
Page 284 Categories Inputs System Operation Initial heating Water temp sensor Entry condition (AND condition) control (2) External temperature (1) Auto Mode sensor (2) External air temp < 5°C and difference between external Internal air temp sensor and internal air temp 5°C Auto mode (3) Failure of water temp sensor Only one time of engine OFF →...
Page 285 Self Diagnosis How to start self diagnosis Starter Switch ON Set temp to 25 C Set temp to 77 F Press the SEL switch more than 3 times in 5 secs while pressing the A/C switch Auto diagnosis starts after every graphic in LCD displays twice every 0.5 sec.
Page 286 Error codes Code Description Normal Internal Air Temp Sensor Short Internal Air Temp Sensor Open Ambient Air Temp Sensor Short Ambient Air Temp Sensor Open Duct Sensor Short Duct Sensor Open Sun Sensor Short Sun Sensor Open Water Temp Sensor Short Water Temp Sensor Open D.P.S OPEN Position Error of Wind Direction...
Page 287: Compressor
Volume of refrigerant by model kgf/cm Model Volume of refrigerant (g) kgf/cm DX300LC 800 ± 20 DX340LC 800 ± 20 FG003921 Figure 25 DX420LC 800 ± 20 DX480LC 800 ± 20 DX520LC 800 ± 20 SP000025 Air Conditioner Page 25...
Page 288: 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 26 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 289 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 290: Weight Of R134A Gas Used In Machines
Model Weight of Gas DX300LC 800 ±20 grams (28 ±0.7 oz) DX340LC 800 ±20 grams (28 ±0.7 oz) DX420LC 800 ±20 grams (28 ±0.7 oz) DX480LC 800 ±20 grams (28 ±0.7 oz) DX520LC 800 ±20 grams (28 ±0.7 oz) Air Conditioner...
Page 291: 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 292: Repair And Replacement Procedure
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 293 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 294: Refrigerant Recovery
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 29 NOTE: Be careful not to switch the connections for the low and high-pressure valves.
Page 295 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 296: Leakage Check
Leakage Check NOTE: Perform leakage check after completing 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 297 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 298: Inspecting System For Leakage
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. NOTE: When the refrigerant circulation has been stopped the high-pressure will start to decrease and the low- pressure will start to increase until they are equalized.
Page 299 Engine and Drive Train...
Page 301 SP000026 DRIVE COUPLING (MAIN PUMP)SP000026 Drive Coupling (Main Pump) Edition 1 Drive Coupling (Main Pump) SP000026 Page 1...
Page 302 MEMO SP000026 Drive Coupling (Main Pump) Page 2...
Page 303 Table of Contents Drive Coupling (Main Pump) Safety Precautions..........5 Applicable Models..........5 Drive Coupling ............6 Installation of Drive Coupling ........ 7 Installation Procedure............7 Drive Coupling (Main Pump) SP000026 Page 3...
Page 304 MEMO SP000026 Drive Coupling (Main Pump) Page 4...
Page 305: Drive Coupling (Main Pump)
The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 5001 and Up DX340LC 5001 and Up DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up SP000026 Drive Coupling (Main Pump)
Page 306: Drive Coupling
DRIVE COUPLING Figure 1 thru Figure 2, show typical drive coupling installations. FG000656 Figure 1 FG000657 Figure 2 Drive Coupling (Main Pump) SP000026 Page 6...
Page 307: Installation Of Drive Coupling
INSTALLATION OF DRIVE COUPLING Always follow the following installation procedure when installing the drive coupling in the main pump. NOTE: Noncompliance with the procedure may cause noise or shortening of life of the drive coupling or the main pump. Installation Procedure Assemble the ﬂange of the coupling (1, Figure 3) in the engine ﬂywheel with bolts (2, Figure 3).
Page 308 Drive Coupling (Main Pump) SP000026 Page 8...
Page 309 Hydraulics...
Page 311 SP000273 HYDRAULIC SYSTEM TROUBLESHOOTING, TESTING AND ADJUSTMENTSP000273 Hydraulic System Troubleshooting, Testing and Adjustment Edition 1 Hydraulic System Troubleshooting, Testing and SP000273 Adjustment Page 1...
Page 312 MEMO SP000273 Hydraulic System Troubleshooting, Testing and Page 2 Adjustment...
Page 313 Table of Contents Hydraulic System Troubleshooting, Testing and Adjustment Safety Precautions..........5 Applicable Models..........5 Hydraulic System - General Notes ....... 6 Hydraulic Schematic ..........8 General Notes ..............8 Operation of Working Components..... 10 Boom Operating Circuit ..........10 Boom Up Circuit ............
Page 314 Control Valve Pressure and Current Adjustments ..21 Pressure Up Valve ..........22 Checks and Adjustments..........22 Pump Input Power Control........24 Pump Regulator Adjustment ......... 24 Flow Meter and Flow Meter Kit Installation and Testing ............... 27 Swing System Troubleshooting......29 Precautions/Initial Checks ..........
Page 315 Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up SP000273 Hydraulic System Troubleshooting, Testing and Adjustment Page 5...
Page 316 HYDRAULIC SYSTEM - GENERAL NOTES CENTER JOINT FG005307 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 mode for most types of general operation.
Page 317 Electronic management of hydraulic control valves assists in optimizing the application speed and overall operator control of hydraulic actuators and functions. SP000273 Hydraulic System Troubleshooting, Testing and Adjustment Page 7...
Page 318: 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 319 • 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 320: 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 321: Boom Down Circuit
Boom Down Circuit When the boom control lever is pushed forward, the right side BOOM pilot valve generates secondary boom down pilot pressure that CYLINDER is transmitted only to the BOOM1 spool of the control valve. When secondary pilot pressure reaches 7 - 9 kg/cm (100 - 130 psi), the BOOM1 spool on the left side of the control valve opens so that oil from only one pump (PUMP (L)) assembly goes to the...
Page 322: Arm Crowd Circuit
Arm Crowd Circuit When the arm control lever is put in the crowd mode, the left side pilot valve generates secondary pressure that is transmitted to the AM1 and AM2 spools of the control valve simultaneously. CYLINDER When secondary pilot pressure reaches 7 - 9 kg/cm (100 - 130 psi), the arm control valve spools AM1 and AM2 open.
Page 323: 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. 360 kg/cm (5,112 psi) overload relief valves at BKT and BKTD 1 ports of the control valve protect the circuit and its components from being damaged.
Page 324: Right Swing Operating Circuit
Right Swing Operating Circuit SWING MOTOR When the swing control lever is pushed to the right swing position, pilot pressure from the left side pilot valve is directed to the right side pump regulator and right half of the control valve. Output ﬂow from the right pump is then directed through the PR and SWR ports of the control valve to the swing motor.
Page 325: Forward Travel Circuit
Forward Travel Circuit TRAVEL TRAVEL MOTOR(R) MOTOR(L) When the right and left travel control levers are pushed forward, output from both of the main pumps is directed through the PR, PL, TRRF, and TRLF ports on the control valve, through the upper works center joint, to the travel motors on each side of the CENTER JOINT machine.
Page 326: 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 327 component or circuit, not the control pressure or system pressure available to the actuator. Poor ﬂow through the individual circuit may indicate that the component is worn beyond tolerance limits, while all other hydraulic functions are adequate. IMPORTANT It is suggested that the troubleshooter maintain the testing sequence of the preceding list.
Page 328: 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 329: 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 330 Mode Engine RPM Current Pressure 2bar Power Mode High Idle: 1,880 RPM 200 ±20 mA (29 psi) 7 bar Standard Mode High Idle: 1,770 RPM 350 mA (102 psi) Hydraulic System Troubleshooting, Testing SP000273 Adjustment Page 20...
Page 331: Boom/Front Priority Valve
BOOM/FRONT PRIORITY VALVE Control Valve Pressure and Current Adjustments WARNING! This procedure should be done with two people. To reduce the chance of accident or unintended start-up, one person should remain at the operator's control stand while checks and adjustments are made. The front priority control valves are located inside the compartment behind the cabin.
Page 332: 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 333 Main Pressure and Pilot Pressure and Power Mode Operation Tolerance Tolerance 20 - 40 bar 30 bar +10 bar Mode Neutral, No Operation (290 - 580 psi) (435 psi +145 psi) 320 bar +5 bar 30 bar +10 bar Mode Cylinder Stall (4,641 psi +75 psi) (435 psi +145 psi)
Page 334: 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 335 adjustment, the pump which supplies output to the track frame toward which the excavator is veering is weak. ASS0320L Figure 12 Refer to the illustration of the pump regulator control valve (Figure 12) for the location of adjustment screws (1, 2 and 3). There are three different adjustments, Qmax, Pi-Q Pd-Q, adjustment screws (1, 2 and 3).
Page 336 Start the engine and turn the engine speed dial to maximum. When normal operating temperature is reached, adjust screw 2 clockwise to shift the Pi-Q control valve curve decrease compensating control pressure. A 1/2 turn on the adjusting screw is equal to approximately -0.7 kg/cm of Pi.
Page 337: Flow Meter And Flow Meter Kit Installation And Testing
ﬂow meter. The After Sales Service department of the nearest local DOOSAN dealer can assist you with these tests or, if you prefer carrying out your own testing, they should be able to help in putting together a hose and ﬁtting kit (or the required dimensions and speciﬁcations for hoses and ﬁttings) to allow you to install a...
Page 338 power mode selector at Power Mode and the work mode selector at digging mode: • Unloaded maximum engine speed baseline test (all controls in neutral). • Front pump test – operate "travel right" lever. Record values at all speciﬁed pressures. •...
Page 339: 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. Turn off engine and disengage control functions until initial tests are ready to be made.. WARNING! Prevent possible injury and/or loss of operating control.
Page 340 • 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. Pressure should be between 250 and 260 bar (3,625 psi and 4,061 psi), with both swing locks engaged.
Page 341 has been restored but if problems with cavitation continues, disassemble the upper swing motor housing and clean or replace assembly components as required. NOTE:If tested pressures above recommended levels, there mechanical problems in the drive train or in the motor/brake assembly, the problem will require further hydraulic troubleshooting.
Page 342: 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 343: 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 344: Troubleshooting - Control Valve
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 345 the required level and free of oil leaks or air in the system that could cause cavitation problems. Problem Possible Cause Remedy Main relief valve. Particulate contamination. Disassemble, clean main poppet. Broken or damaged spring. Replace. Adjusting screw loose. Readjust. Main poppet sticking.
Page 346: Troubleshooting - Travel Control Valve
TROUBLESHOOTING – TRAVEL CONTROL VALVE Problem Possible Cause Remedy Secondary pressure does Low primary pressure. Check primary pressure. not increase. Broken spring. Replace spring. Spool sticking. Clean, repair or replace. Excess spool to casing clearance. Replace spool casing. Worn or loose universal joint Repair or replace U-joint subassembly.
Page 347 Problem Possible Cause Remedy Secondary pressure does Dirt, other interference between Clean, repair or replace. not hold steady. valve parts, or worn spool sticking intermittently. Interference or binding on spool Clean, repair or replace. return spring. Unsteady pressure in tank return Redirect return line.
Page 348 Hydraulic System Troubleshooting, Testing SP000273 Adjustment Page 38...
Page 349 SP000028 ACCUMULATOR SP000028 Accumulator Edition 1 Accumulator SP000028 Page 1...
Page 350 MEMO SP000028 Accumulator Page 2...
Page 351 Table of Contents Accumulator Safety Precautions..........5 Applicable Models..........5 General Description..........6 Speciﬁcations ..............8 Accumulator SP000028 Page 3...
Page 352 MEMO SP000028 Accumulator Page 4...
Page 353: Safety Precautions
The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 5001 and Up DX340LC 5001 and Up DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up SP000028 Accumulator...
Page 354: 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 355 of the diaphragm eventually seals off the lower oil passage. Just after the needle on the gauge reaches its highest point (when there is 0 bar (0 psi) resistance from hydraulic system pressure) pressure on the gauge will drop sharply to zero, as the accumulator is completely emptied of oil and the diaphragm button closes.
Page 356: Specifications
(19.53 in 320 cc 10 kg/cm DX340LC S/N 5001 and Up Pilot (140 psi) (19.53 in 320 cc 10 kg/cm DX420LC S/N 5001 and Up Pilot (140 psi) (19.53 in 320 cc 10 kg/cm DX480LC S/N 5001 and Up Pilot (140 psi) (19.53 in...
Page 357 SP000181 CENTER JOINT (SWIVEL)SP000181 Center Joint (Swivel) Edition 1 Center Joint (Swivel) SP000181 Page 1...
Page 358 MEMO SP000181 Center Joint (Swivel) Page 2...
Page 359 Table of Contents Center Joint (Swivel) Safety Precautions..........5 Applicable Models..........5 General Description..........6 Center Joint Disassembly Diagram ......... 7 Disassembly ............8 Reassembly ............11 Center Joint (Swivel) SP000181 Page 3...
Page 360 MEMO SP000181 Center Joint (Swivel) Page 4...
Page 361: Safety Precautions
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX340LC 5001 and Up DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up SP000181 Center Joint (Swivel)
Page 362: 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) SP000181 Page 6...
Page 363: Center Joint Disassembly Diagram
Center Joint Disassembly Diagram Figure 1 Reference Reference Description Description Number Number Body Wear Ring Shaft Slipper Seal Cover O-ring(1AP 120) Spacer O-ring(1BP 100) Shim O-ring(1BG 120) SP000181 Center Joint (Swivel) Page 7...
Page 364: Disassembly
DISASSEMBLY CAUTION! It is recommended to use a hoist or a similar device for it is heavy. CAUTION! Remove active oil and wash it out before starting disassembly. CAUTION! It should be disassembled after its active oil is cool enough after it is removed from the system for its active oil is very hot.
Page 365 Disassemble the body from the spindle assembly. It can be disassembled easily by ﬁxing the spindle assembly, tightening at least 2-12 mm eye bolts on the body, and lifting it with a hoist slowly. Or, it may be disassembled by setting the continuous thread studs on the spindle drain port as shown in the ﬁgure.
Page 366 Remove foreign substance at every pieces disassembled and wash them out. Replace disassembled O-rings and slipper seals with new ones, for they cannot be reused. CAUTION! The inside of the body should be air washed and rust- proof treated after washing it, as its material is subject to rust.
Page 367: Reassembly
REASSEMBLY CAUTION! Apply active oil to every functional (moving) part before assembly to reduce any assembly friction as much as possible. Figure 7 Wrap the Teﬂon tape around the PT3/8 about 6 times. Assemble the PT and PF plugs into the washed shaft. Internal sealing PF3/4: 12 mm wrench External sealing PT3/8: 8 mm wrench Engagement torque: 15±1.09 Kg m...
Page 368 CAUTION! For any sliper seal which is protruded, press it with ﬁnger to seat it in its position. Care should be taken when using a driver or a metal tool, which may cause damage to it. CAUTION! Applying active oil to the surface of the shaft enables the assembly without any damage to the sliper seal.
Page 369 Set the O-ring (1 BG 120) in its place and assemble the cover in the direction as shown in the ﬁgure. 10. Engage the cover bolt (M 12) at torque of 10 ~ 12.5 kg m. 11. Return the O-ring (1 AP 120) assembled to the outside of the body to its original position.
Page 370 Center Joint (Swivel) SP000181 Page 14...
Page 371 SP000030 CYLINDERS SP000030 Cylinders Edition 1 Cylinders SP000030 Page 1...
Page 372 MEMO SP000030 Cylinders Page 2...
Page 373 Table of Contents Cylinders Safety Precautions..........5 Applicable Models..........5 General Description..........6 Theory of Operation ............6 Parts List ................. 8 Special Tools and Materials ........ 10 Piston Nut..............10 Piston Jig............... 12 Steel Bushing Jig............14 Dust Wiper Jig ............... 16 Slipper Seal Jig .............
Page 374 MEMO SP000030 Cylinders Page 4...
Page 375: Safety Precautions
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 5001 and Up DX340LC 5001 and Up DX420LC 5001 and Up SP000030 Cylinders Page 5...
Page 376: 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 377 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. = S x π (D = S x π...
Page 378: 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 379 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 380: 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 381 12.0 mm 5.0 mm BOOM (5.79 in) (4.21 in) (0.47 in) (0.20 in) 147.0 mm 107.0 mm 12.0 mm 5.0 mm DX420LC (5.79 in) (4.21 in) (0.47 in) (0.20 in) 155.0 mm 115.0 mm 12.0 mm 5.0 mm BUCKET (6.10 in) (4.53 in)
Page 382: 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 383 93.0 mm 165.0 mm BOOM (5.12 in) (0.51 in) (3.66 in) (6.50 in) 130.0 mm 13.0 mm 93.0 mm 165.0 mm DX420LC (5.12 in) (0.513 in) (3.66 in) (6.50 in) 130.0 mm 13.0 mm 93.0 mm 165.0 mm BUCKET (5.12 in) (0.51 in)
Page 384: 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 385 70.0 mm 11.0 mm BOOM (4.33 in) (5.12 in) (2.76 in) (0.43 in) 110.0 mm 130.0 mm 70.0 mm 11.0 mm DX420LC (4.33 in) (5.12 in) (2.76 in) (0.43 in) 110.0 mm 130.0 mm 70.0 mm 11.0 mm BUCKET (4.33 in) (5.12 in)
Page 386: 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 387 6.0 mm 7.0 mm BOOM (4.53 in) (5.16 in) (0.24 in) (2.28 in) 120.0 mm 136.0 mm 6.0 mm 7.0 mm DX420LC (4.72 in) (5.35 in) (0.24 in) (2.28 in) 110.0 mm 126.0 mm 6.0 mm 7.0 mm BUCKET (4.33 in) (4.96 in)
Page 388: Slipper Seal Jig
Slipper Seal Jig (B+40) ARS4770L Figure 10 Cylinders SP000030 Page 18...
Page 389 OPT BUCKET (5.91 in) (1.12 in) 165.0 mm 34.5 mm BOOM OPT BOOM (6.50 in) (1.36 in) 180.0 mm 41.5 mm DX420LC OPT ARM (7.09 in) (1.63 in) 160.0 mm 34.5 mm BUCKET OPT BUCKET (6.30 in) (1.36 in) SP000030...
Page 390: Slipper Seal Straightening Jig
Slipper Seal Straightening Jig ∅ ARS4780L Figure 11 Cylinders SP000030 Page 20...
Page 391 (5.91 in) 170.0 mm DX340LC OPT ARM (6.69 in) 150.0 mm BUCKET OPT BUCKET (5.91 in) 165.0 mm BOOM OPT BOOM (6.50 in) 180.0 mm DX420LC OPT ARM (7.09 in) 160.0 mm BUCKET OPT BUCKET (6.30 in) SP000030 Cylinders Page 21...
Page 392: 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 393 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 394 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 395 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 396 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 397: 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 398 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 399 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 400 Cylinders SP000030 Page 30...
Page 401 SP000261 SWING MOTOR SP000261 Swing Motor Edition 1 Swing Motor SP000261 Page 1...
Page 402 MEMO SP000261 Swing Motor Page 2...
Page 403 Table of Contents Swing Motor Safety Precautions..........5 Applicable Models..........5 General Description..........6 Parts List ................. 6 Speciﬁcations ..............8 Torques................8 Theory of Operation ............9 Makeup Check Valve ............. 12 Operation of Time Delay Valve ........12 Operation of Swing Reactionless Valve......
Page 404 MEMO SP000261 Swing Motor Page 4...
Page 405: Safety Precautions
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX340LC 5001 and Up DX420LC 5001 and Up SP000261 Swing Motor Page 5...
Page 406: General Description
GENERAL DESCRIPTION Parts List FG005164 Figure 1 Swing Motor SP000261 Page 6...
Page 407 Reference Reference Description Description Number Number Body Rear Cover Oil Seal Socket Bolt Roller Bearing Socket Bolt Snap Ring Poppet Shaft Spring Plug Stop Ring O-ring Shoe Plate Relief Valve Assembly Cylinder Time Delay Valve Spring Socket Bolt Ball Guide Seat Plug Ball Guide Swing Reactionless Valve...
Page 408: Specifications
Speciﬁcations Items Units 329 l/min Oil Flow (86.9 gpm) Set Pressure of Relief V/V 270 kg/cm (Cracking) (3,840 psi) 250 cc/rev Motor Displacement (15.26 in /rev) 107.4 kg•m Motor Output Torque (777 ft lb) Motor Speed 1,316 rpm 107 kg•m Brake Torque (774 ft lb) Spool Cracking...
Page 409: Theory Of Operation
Theory of Operation Structure The hydraulic motor consists of the following ﬁve parts: • Rotary part generating rotary power. • Relief valve. • Parking brake. • Makeup check valve. • Time delay valve. • Swing reactionless valve. Circuit Diagram Figure 2 SP000261 Swing Motor Page 9...
Page 410 Generation of Rotary Power High-pressure oil from hydraulic pump ﬂows into the cylinder (9) through the valve casing (1) and the valve plate (20). The motor is designed to only let high-pressure oil to ﬂow into one side with relationship to Y-Y axis (the centerline of top and bottom dead centers of piston (14).
Page 411 Operation of Relief Valve The relief valve performs two functions: It maintains uniform pressure when hydraulic motor starts and bypasses surplus oil at the inlet of the motor to the outlet in relationship with acceleration of the inertia weight. Device is forced to stop by the generation of brake pressure at the discharge side when the inertia weight is stopped.
Page 412: Makeup Check Valve
Makeup Check Valve A makeup check valve is installed to compensate for the lack of supply line oil to prevent cavitation due to the lack of oil being supplied when the motor turns faster than the expected oil ﬂow rate to the inlet of the swing motor. When an excavator suddenly stops swinging, and supply oil stops ﬂowing to the inlet port of the swing motor, the swing motor will try to turn a little further due to inertia force.
Page 413: Tools And Materials
TOOLS AND MATERIALS Tools Tools B Length Tools to Be Used Hex L Wrench 5 mm Wrench bolt (32) 6 mm Plug (33) 12 mm Wrench bolt (24, 25) 17 mm Plug (28) Socket Wrench 36 mm Relief valve assembly (33) Spanner Snap Ring Pliers (For Oriﬁce And Snap Ringp (4)
Page 414: Troubleshooting, Testing And Adjustment
TROUBLESHOOTING, TESTING AND ADJUSTMENT General Precautions Observe any abnormalities and any possible causes that have noting to do with the motor before starting work. Make sure that no foreign substance is involved when disassembling the machine, which is the most frequent cause of its wear.
Page 415 Problem Possible Cause Remedy Low brake torque. Wear of friction and/or separation Replace worn parts. plates. Damage of brake spring. Replace brake spring. No brake operation. Sticking of inner brake parts. Replace parts. Oil leakage. Leakage from oil seal (2). Oil seal or shaft slidway damaged.
Page 416: Disassembly
DISASSEMBLY General Cautions Prepare for a clean place for disassembly. Place a rubber sheet on place to prevent any damage to parts. Wash out dust and foreign substance in motor and deceleration assembly. Take care not to damage connecting parts and ways of O- ring, oil seal, seal surface, gear, pin, and surface of bearings.
Page 417 Use a hexagonal wrench to remove the wrench bolts (24, 25) and disassemble the rear cover (23) assembly from the body (1). Figure 12 Disassemble the spring (19) to remove the break piston (17) and disassemble it from the body (1) using a jig. FG000687 Figure 13 FG000688...
Page 418 Figure 16 Remove shoe plate (8) from body (1). Figure 17 Remove snap ring (4) from body (1) using snap ring pliers jig. Turn body over, and separate shaft (5) assembly using steel bar. FG000693 Figure 18 Figure 19 Swing Motor SP000261 Page 18...
Page 419: Disassembly Of The Cylinder Block Subassembly
Disassembly of the cylinder block subassembly Separate piston assembly (14) and the set plate (13) from cylinder block assembly. FG000696 Figure 20 FG000697 Figure 21 Remove friction plate (15), plate (16), ball guide (12), ball guide seat (11) and spring (10) from cylinder block (9). FG000698 Figure 22 SP000261...
Page 420: Disassembly Of The Rear Cover Subassembly
FG000699 Figure 23 FG000700 Figure 24 Disassembly of the rear cover subassembly 10. Separate valve plate (20) from rear cover (23). FG000701 Figure 25 Swing Motor SP000261 Page 20...
Page 421 Figure 26 11. Remove two relief valve assemblies (30) from rear cover (23) with torque wrench. FG000706 Figure 27 FG000707 Figure 28 12. Remove check valve assemblies from rear cover (23) with L wrench, and disassemble it in order of plug (28), spring (27), and poppet (26).
Page 422 FG000709 Figure 30 13. Remove plug (35) from rear cover (23) with L wrench and disassemble it in order of backup ring (37), O-ring (36), O- ring (38) and anti-inversion valve assembly (34). FG000710 Figure 31 FG000711 Figure 32 FG000712 Figure 33 Swing Motor SP000261...
Page 423: Cleaning And Inspection (Wear Limits And Tolerances)
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section. REASSEMBLY General Cautions Wash and clean each part. Then dry them with compressed air. The friction plate, however, should not be washed with treated oil.
Page 424 Assemble heated roll bearing (3) into the shaft (5). Use a pliers jig to assemble install stop ring (7). FG000716 Figure 36 FG000717 Figure 37 Assemble oil seal (2) in body (1) using bar hammer. FG000719 Figure 38 Figure 39 Swing Motor SP000261 Page 24...
Page 425 Install shaft in body (1) using bar hammer. FG000717 Figure 40 Figure 41 Secure shaft with snap ring (4) using snap ring pliers. FG000722 Figure 42 Figure 43 SP000261 Swing Motor Page 25...
Page 426: Assembly Of Cylinder Block Assembly Subassembly
Coat shoe plate (8) with grease, and assemble it into body. FG000724 Figure 44 Figure 45 Assembly of Cylinder Block Assembly Subassembly Insert nine sets of springs (10) in cylinder block (9). FG000726 Figure 46 FG000727 Figure 47 Swing Motor SP000261 Page 26...
Page 427 Insert ball guide seat (11) and ball guide (12) in cylinder block (9). FG000728 Figure 48 FG000729 Figure 49 FG000759 Figure 50 FG000730 Figure 51 SP000261 Swing Motor Page 27...
Page 428 Insert nine sets of piston assembly (14) in set plate (13) and assemble it into cylinder block (9). NOTE: Coat piston with clean hydraulic oil. FG000731 Figure 52 FG000696 Figure 53 FG000732 Figure 54 10. Assemble cylinder block into body (1). 11.
Page 429 Figure 56 12. Assemble O-ring (18) into brake piston (17). FG000704 Figure 57 FG000687 Figure 58 13. Insert brake piston assembly in body and secure it using jig. 14. Insert eighteen springs (19) into brake piston (17). FG000736 Figure 59 Swing Motor SP000261 Page 29...
Page 430: Assembly Of Rear Cover Assembly Subassembly
Figure 60 Assembly of Rear Cover Assembly Subassembly Insert pins (6 and 21) in rear cover (23) with bar hammer and assemble needle bearing (22) using jig. FG000738 Figure 61 Figure 62 Insert poppet (26), spring (27), and plug (28) in rear cover (23).
Page 431 Figure 64 Assemble anti-inversion valve. Assemble body, spring seat, spring, poppet, poppet seat, stopper, and spring. Then assemble O-ring (36), backup ring (37), and O-ring (38) using jig. FG000745 Figure 65 FG000711 Figure 66 FG000710 Figure 67 Swing Motor SP000261 Page 31...
Page 432 Assemble anti-inversion valve set. Assemble anti-inversion valve set (34) and plug assembly (35) into rear cover (23) and tighten them with L wrench. FG000746 Figure 68 Assemble two relief valve assemblies (30) into rear cover (23) with torque wrench. (Left and right symmetrically.) FG000706 Figure 69 Figure 70...
Page 433 Figure 72 Put the rear cover ass'y on the body (1) and tighten its wrench bolts (24, 25) with impact and then torch wrench. Figure 73 Install time delay valve assembly onto rear cover (23) with wrench bolts (32). FG000682 Figure 74 Figure 75 Swing Motor...
Page 434: Air Pressure Test
Air Pressure Test Apply air pressure into assembled motor, dip it in treated oil for one minute and check any leakage from it. FG000754 Figure 76 Oil Leakage Check Wash motor with Color Check No.1, spray No.3, and check for any oil leakage.
Page 435: Installation Of Test Bench
Installation of test bench Install the motor test bench to test each function. Figure 80 SP000261 Swing Motor Page 35...
Page 436 Swing Motor SP000261 Page 36...
Page 437 SP000266 TRAVEL MOTOR (WITH GEARBOX)SP000266 Travel Motor (With Gearbox) Edition 1 Travel Motor (With Gearbox) SP000266 Page 1...
Page 438 MEMO SP000266 Travel Motor (With Gearbox) Page 2...
Page 439 Table of Contents Travel Motor (With Gearbox) Safety Precautions..........5 Applicable Models..........5 Travel Motor (M3V270/160A) ........ 6 Speciﬁcations ..............6 Structure and Function ............ 8 Disassembly and Assembly........... 15 Disassembly ..............16 Reassembly..............20 Maintenance Standard ..........23 Troubleshooting ............. 25 Reduction Gear (M3V270 / 160A-RG7.5)...
Page 440 MEMO SP000266 Travel Motor (With Gearbox) Page 4...
Page 441: Travel Motor (With Gearbox)
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up SP000266 Travel Motor (With Gearbox) Page 5...
Page 442: Travel Motor (M3V270/160A)
TRAVEL MOTOR (M3V270/160A) Speciﬁcations Outline Dimensions Figure 1 Travel Motor (With Gearbox) SP000266 Page 6...
Page 443 Speciﬁcations Item M3V270 / 160A Major Capacity 273.50 cc/rev (16.69 in /rev) Minor Capacity 160.60 cc/rev (9.80 in /rev) Rated Pressure 355 kg/cm (5,049 psi) Maximum Pressure 420 kg/cm (5,974 psi) Braking Torque Over 65.7 kg•m (644 Nm) Brake Release Pressure Below 15.7 kg/cm (233psi) Allowable Drain Pressure...
Page 444: Structure And Function
Structure and Function Structure Figure 2 Travel Motor (With Gearbox) SP000266 Page 8...
Page 445 Reference Reference Description Description Number Number Case M6 Restrictor (0.6) Rear Cover M6 Restrictor (0.8) Cylinder Block Oil Seal Shoe Retainer Spring for Check Valve Friction Plate Spring for Cylinder Block Brake Piston Brake Spring Separator Platee Bearing HR32209J Valve Plate Bearing HR32207C Shaft C’SK Head Cap Screw M18x50...
Page 446 Explanation of Structure The motor mainly consists of rotary group (producing turning force to drive shaft), negative brake (preventing host machine from self-running during its rest), capacity control parts (that changes the motor capacity consequently rotating speed) and overload valve (attached to the rear cover). There is another valve that plays an important role in controlling the hydraulic circuit.
Page 447 Overload Valve This valve is screwed in the motor rear cover (2) and consists of; Socket (40-1) that Is screwed and ﬁxed in the rear cover (2) and supports the valve seat (40-3) which metallically seated in the hole of rear cover (2). Valve (40-2) that contact with valve seat (40-3) by adjusting spring (40-9) and ﬁtted in the hole of socket (40-1).
Page 448 Function Table 1: Direction of Rotation Inlet Outlet Direction of Rotation Port Port Right (clockwise) Left (counterclockwise) Figure 4 Main Ports Motor High pressure oil delivered from hydraulic pump is routed to inlet port of brake valve (42) and through the rear cover (2) and valve plate (8), to cylinder block (3).
Page 449 Capacity Control Mechanism Figure 7 Figure 7 shows the capacity control mechanism. When high speed pilot line is pressurized at port P , spring (41- 7) is compressed and spool (41-2) shifts to the right to connect ports P and C. Then, the highest pressure is selected by one of the check valves (17) (from inlet and outlet pressure of the motor and high speed pilot line pressure) and pushes control piston (20).
Page 450 Overload Valve Figure 8 There are two overload valves in the cross-over portion of the counterbalance circuit of brake valve. They accomplish the following functions: When starting the hydraulic motor, they keep the driving pressure below a predetermined value while accelerating, and bypasses surplus oil to return line.
Page 451: Disassembly And Assembly
When hydraulically braking, the piston (40-7, Figure 8) is at the left position by the driving pressure, and when "A" port pressure increases, the pressure is applied also to the piston (40-7) through the small hole in the valve (40-2) and piston (40-7) moves right ward until it touches the plug (40- 5).
Page 452: Disassembly
Disassembly General Instructions Select clean disassembling place. Place a rubber pad on the work bench to prevent parts from being damaged. Clean dirt and foreign materials from reduction gear and motor. Be careful not to damage the contact surface of O-ring, oil seal, and seal class and the contact or sliding surface of gear, pin, and bearing class.
Page 453 Disassembly of motor Place motor with shaft horizontal. Remove cap screws (32) holding rear cover (2) leaving two diagonally from each other in the upper and lower positions. Slowly and simultaneously remove remaining two cap screws. Remove rear cover (2) and brake springs (29) taking care cylinder block (3) does not come out from being stuck in rear cover (2).
Page 454 Match mark piston(s) (14) to cylinder block (3), so that they can be reassembled into same position. Paper pipe cleaners can be used to help accomplish this. Remove cylinder block (3), spring seat (13) and cylinder spring (28). Remove separator plates (7) and friction plates (5). Remove nine piston assemblies (14), shoe retainer (4) and spherical coupling (12) as an assembly.
Page 455 NOTE: Shim adjustment should be performed by measuring clearance shim adjusting shim pack meets that clearance. Other jigs and tools are needed to measure and decide the thickness of the shim. NOTE: remove pivots (22) unless necessary. If they must be removed, match mark each pivot (22) with shoe plate (11).
Page 456: Reassembly
Reassembly General Instructions Wash each part thoroughly with kerosene, and blow dry using compressed air. Assemble sliding parts after coating them with clean hydraulic oil. Reassembly Coat outer surface of oil seal (26, Figure 15) and inner face of case (1, Figure 15) with grease. Using jig, press oil seal (26, Figure 15) into case (1).
Page 457 Insert piston assembly (14, Figure 17), shoe retainer (4), spherical coupling (12), spring seat (13), cylinder spring (28) on to cylinder block (3) as shown and then insert the whole assembly to shaft (9). NOTE: Piston assembly (14) should be inserted into the same bore that it was removed from.
Page 458 Figure 19 Mounting Rear Cover Travel Motor (With Gearbox) SP000266 Page 22...
Page 459: Maintenance Standard
Maintenance Standard Maintenance of Parts The followings are the general maintenance standards. However, it is important to determine which parts should be replaced, depending characteristics before disassembling, damages and discoloration of exterior view, the purpose of disassembling, the expected remaining service life, etc.
Page 460 Judging Criteria and Disposition Item and Measuring Method Check Item Criteria Allowable Disposition Roughness After completion Parking brake torque 65.7 kg•m 60.0 kg•m Replace assembly, set the torque separator wrench on the shaft end, friction and measure the braking plates torque generated when the springs shafts starts to rotate.
Page 461: Troubleshooting
Troubleshooting General instructions The followings are the general instructions to be followed when some troubles occur with hydraulic motors. Judge the nature of abnormality before troubleshooting, and ascertain if the same symptom has occurred before or not. Review if the motor itself is actually causing the problem.
Page 462 Problem Possible Cause Remedy Shortage of oil coming in. Check oil ﬂow or hydraulic circuit to Rotation of drive shaft never motor. Large wear or ﬂaw made on shoe, reaches the set value. cylinder block or valve plate. Check, repair or replace the parts. Brake refuses to work Malfunction of negative brake.
Page 463: Reduction Gear (M3V270 / 160A-Rg7.5)
REDUCTION GEAR (M3V270 / 160A-RG7.5) Speciﬁcations Outline Dimensions Figure 21 Speciﬁcations Item M3V270 / 160A-RG7.5 Motor Displacement 273.5 / 160.6 cc/rev (16.69 / 9.80 in /rev) Rated Pressure 355 kg/cm (5,049 psi) Gear Ratio 50.324 Number of Stages Oil Capacity 11.0 liters (2.9 U.S.
Page 464: Structure And Operation
Structure and Operation Structure Figure 22 Travel Motor (With Gearbox) SP000266 Page 28...
Page 465 Reference Reference Description Description Number Number Cover Spring Pin 8x56 Carrier 1 Thrust Washer 2 Carrier Pin 1 Ring Gear Needle Bearing Housing Thrust Washer 1 Angular Bearing Planetary Gear 1 Shim Spring Pin 4x32 Lock Washer Thrust Plate Support Ring Sun Gear 1 Floating Seal 368 Sun Gear 2...
Page 466: Disassembly And Assembly
When the sun gear S1 is driven by input shaft, planetary action occurs among gears S1, a and b and revolution of gear b transfers the rotation of carrier K1 to second sun gear S2, and also evokes planetary action between gear 52, a and d.
Page 467: Disassembling Reduction Unit
Disassembling Reduction Unit Preparation for disassembling The reduction units removed from machine are usually coverer with mud. Wash outside of propelling unit and dry Remove taper screw plug from drain port. Drain oil from reduction gears. CAUTION! While oil is still hot, inside of the unit may be pressurized.
Page 468 Removing Cover Remove lifting eyes and remaining M10 cap screws (24) that secure cover (1). Figure 26 Cover (1) is adhered to ring gear (17). Remove cover (1) by lightly hammering slantwise upward using a wooden bar aiming at projection of cover (1) Figure 27 Removing Carrier 1 Assembly Remove thrust plate (8).
Page 469 Removing Carrier 2 Assembly Remove sun gear 2 (10). Screw three M10 eye bolts into carrier 2 (11) and lift up and remove carrier 2 assembly (11, 12, 13, 14, 15, 16). Figure 29 Removing Housing Assembly Remove support ring (22, Figure 22). Figure 30 Take off lock washers (21) by hammering on chisel or on similar tool placed at parting surface.
Page 470 Figure 32 Disassembling Housing Assembly Place housing assembly on steel stands with ring gear (17) below. Match mark housing (18) and ring gear (17). Remove ﬂoating seal (23) from housing (18). Remove M18 cap screws (25), leaving two 180° apart from each other.
Page 471 Disassembling Carrier 1 Assembly NOTE: When carrier pins 1 (3) are to be re-used, match mark each pin with its mating hole in carrier 1 (2) to assure the same combination as before. Figure 35 Drive spring pins (7) into carrier pins 1 (3). Remove carrier pins 1 (3) from carrier 1 (2).
Page 472: Assembling
Disassembling Carrier 2 Assembly NOTE: When carrier pins 2 (12) are to be re-used, mark each pin wish its mated hole of carrier 2 (11) to assure the same combination as before. Drive spring pins (15) into pins 2 (12). Remove carrier pins 2 (12) from carrier 2 (11).
Page 473 Install spring pins (15) into carrier 2 (11) and carrier pins 2 (12). Figure 41 Assembling Carrier 1 Assembly Install planetary gears 1 (6), needle bearings (4), and thrust washers 1 (5) into carrier 1 (2). Install carrier pins 1 (3) into carrier 1 (2). Align holes for spring pins (7) wish those in carrier 1 (2).
Page 474 Installing Floating Seal Install ﬂoating seal (23) on motor case. Figure 44 Figure 45 Travel Motor (With Gearbox) SP000266 Page 38...
Page 475 Assembling Housing Apply Loctite #515 on mating surfaces of housing (18) and ring gear (17). Figure 46 Install three M20 eye bolts equally apart from each other in housing (18). Using the eye bolts, position housing (18) on ring gear (17), aligning match marks. After applying Loctite #242 on threads of M18x100 cap screws (25), tighten them with torque wrench to 41kg•m.
Page 476 Determining Shim Thickness For Angular Bearings NOTE: This work should be done only when you have changed; motor (case), housing (18), bearing (19) or lock washer (21). Unless otherwise instructed use the same shim removed during disassembly. Pressing inner races of two bearings (19) evenly, measure the assembling width (A) of inner laces.
Page 477 Install support ring (22) over outside of lock washer (21). Figure 52 Installation Carrier 2 Assembly Position three planetary gears 2 (14) as shown, and place carrier 2 assembly into ring gear (17) and engage splines to those of motor. Figure 53 Position sun gear 2 (10) on center.
Page 478 Carrier 1 Assembly Place carrier 1 assembly into ring gear (17). Rotate planetary gears 1 (6) by hand and adjust carrier 1 (2) to mesh with sun gear 2 (10). Install sun gear 1 (7) into center. Figure 55 Place thrust plate (8) on carrier 1 (2). Figure 56 Installing Cover NOTE:...
Page 479: Maintenance
Maintenance Inspection Before Re-assembling Thrust Washer Check if there is seizure, abnormal wear or uneven wear. Check if wear is over allowable wear limits. Gears Check if there are pitching or seizure on tooth surface. Check if there are cracks on root of tooth by using a die check.
Page 480 Maintenance Standard Figure 58 Mark Item Criteria Allowable Limit Disposition Wear of planetary shaft Smooth, w/out <- Change a set abnormal wear Condition tooth ∅1.6 of pitching, no Change a set for plane or seizure surface cracks at root opinion Thrust clearance -0.08 ~ 0.02...
Page 481: Inspection After Assembling
Inspection After Assembling Lubrication After installing the travel motor and gearbox assembly, position the drain port at its lowest position and check if lubrication oil comes out when loosening the level plug. If not oil is present at the level plug, add oil. Rotating Inspection Place the unit on a test stand and rotate it with no load and check if there are any abnormal noises or oil leaks.
Page 482: Brake Valve (Rbv - 24Dl4)
BRAKE VALVE (RBV - 24DL4) Speciﬁcation Outline Dimensions Figure 59 Number Description O-ring Socket Head Cap Screw Plug O-ring O-ring O-ring Travel Motor (With Gearbox) SP000266 Page 46...
Page 483: Structure And Operation
Speciﬁcations Item M3V270 / 160A-RG7.5 Rated Pressure 355 kg/cm (5,049 psi) Spool changeover pressure 7.8 ~ 13 kg/cm (111 ~ 185 psi) Cracking pressure of check valve 0.3 kg/cm (4.27 psi) Structure and Operation Structure Figure 60 Reference Reference Description Description Number Number...
Page 484 Function Spool By shifting the spool, the discharged oil from hydraulic motor is automatically shut off or restricted according to the operating condition and gives the effect of holding, accelerating, stopping and counterbalance operations. Check Valve (Built into Spool) This valve is located in the oil supplying passage to hydraulic motor, and at the same time functions to block oil displacement.
Page 485 Operation Figures shown in this portion of the manual show the oil ﬂow and the movement of component parts in each operating condition, The ﬁgures are altered for ease of understanding and the correct arrangement of components can be ascertained from Figure 59 and Figure 60.
Page 486 Acceleration Operation When operating control valve, and port VA is connected to pump, and port VB is connected tank, pressurized hydraulic oil from pump, ﬂows through port VA, to push open check valve, inside spool. This allows oil to ﬂow to motor via port MA which then rotates the motor.
Page 487 Stopping Operation When returning control valve to neutral position when running motor, oil supplied ports VA and VB is cut off. These ports are then connected to the tank line. Pressure in each pilot chamber, one located on each end of spool, becomes equal, and spool returns to neutral position by spring force.
Page 488 Counterbalance Operation A counterbalance operation is required to slowly decelerate the hydraulic motor rotation while absorbing inertia force. It also helps during the acceleration process. When hydraulic oil is gradually decreased from pump to port VB, the drive shaft of hydraulic motor tends to rotates faster than the volume of oil supplied by the pump.
Page 489: Disassembling And Reassembling
Disassembling and Reassembling Preparation for Disassembling Select clean disassembling place. Place a rubber pad on the work bench to prevent parts from being damaged. Clean dirt and foreign materials from reduction gear and motor. Be careful not to damage the contact surface of O-ring, oil seal, and seal class and the contact or sliding surface of gear, pin, and bearing class.
Page 490: Reassembling
Reassembling Inspection Before Reassembling. After disassembling, wash all the parts with clean kerosene, and check as the following, and coat them with hydraulic oil. Spool No burrs, no dust, no Indents, no rust should be found on oil groove etc. Sliding parts All parts should easily slide and move.
Page 491 Reassembling Procedure Fix the restrictor (8) and spring (9) with cover (7). Put the O-rings (5 and 6) in body (1). Install spool (2), spring seat (3) and spring (4) with the body (1) in this order. Pay attention to installation direction of spool.
Page 492: Troubleshooting
Troubleshooting Problem Possible Cause Remedy Hydraulic motor never rotates. Malfunction of relief valve built in Pressure never increases. Repair or replace relief valve. hydraulic motor. Malfunction of spool. Stuck between spool and body. Repair or replace. Clogging of restrictor. Pressure increases. Negative brake is not released.
Page 493 SP000186 MAIN PUMP SP000186 Main Pump Edition 1 Main Pump SP000186 Page 1...
Page 494 MEMO SP000186 Main Pump Page 2...
Page 495 Table of Contents Main Pump Safety Precautions..........5 Applicable Models..........5 ectional View............6 A8VO200LA1KH1/63............6 General Repair Guidelines ........8 Seal Kits and Sub-assemblies ......10 Sealing the Drive Shaft ........14 Gear Pump Sealing ..........16 Remove the Control Housing......18 Control Module ...........
Page 496: Main Pump
Bolts (To N 08.001)............55 Plugs with Internal Hexagon and Proﬁle Seal Ring (to N 02.009)..............56 Seal-lock - Sealing Nuts (to N 02.100) ......57 Main Pump SP000186 Page 4...
Page 497: Safety Precautions
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up SP000186...
Page 498: Ectional View
ECTIONAL VIEW A8VO200LA1KH1/63 ASS0010L Figure 1 Main Pump SP000186 Page 6...
Page 499 ASS0020L Figure 2 Main Pump SP000186 Page 7...
Page 500: General Repair Guidelines
GENERAL REPAIR GUIDELINES NOTE: Observe the following cautions when carrying out repairs on hydraulic units. ASS1140L Figure 3 Close off all openings of hydraulic unit. ASS0030L Figure 4 Replace all seals. Use only original spare parts ASS0040L Figure 5 Check all sealing and sliding surfaces for wear. NOTE: Rework of sliding surfaces using crocus cloth or other similar materials, can damage the...
Page 501 Fill hydraulic unit with hydraulic oil before putting into operation. ASS0060L Figure 7 SP000186 Main Pump Page 9...
Page 502: Seal Kits And Sub-Assemblies
SEAL KITS AND SUB- ASSEMBLIES Seal kit for drive shaft. ASS0070L Figure 8 Peripheral seal kit. ASS0080L Figure 9 Rotary group 1, ready to install. ASS0090L Figure 10 Main Pump SP000186 Page 10...
Page 503 Rotary group 2, ready to install. ASS0100L Figure 11 Rotary group, hydraulic component (order rotary groups 1 and 2 separately). NOTE: Adjustment is necessary. Pay attention to direction of rotation. ASS0110L Figure 12 Rotary group 1, mechanical section, ready to install. ASS0120L Figure 13 Rotary group 2, mechanical section, ready to install.
Page 504 Control, pre-adjusted. ASS0140L Figure 15 Gear pump, complete. ASS0150L Figure 16 10. Intermediate gear. ASS0160L Figure 17 Main Pump SP000186 Page 12...
Page 505 11. Auxiliary drive. ASS0170L Figure 18 12. Valve plate with valves. ASS0180L Figure 19 13. Pipe, complete with ﬁttings. ASS0190L Figure 20 SP000186 Main Pump Page 13...
Page 506: Sealing The Drive Shaft
SEALING THE DRIVE SHAFT ASS0200L Figure 21 Protect drive shaft. (e.g. with tape). ASS0210L Figure 22 Remove retaining ring and shim. ASS0220L Figure 23 Main Pump SP000186 Page 14...
Page 507 Screw sheet metal screw(s) into holes ﬁtted with rubber. Pull out seal with pliers. ASS0230L Figure 24 Press in shaft seal ring and shim with bushing to stop. NOTE: Take note of press-in depth. Install mark for press-in depth of safety ring. ASS0240L Figure 25 SP000186...
Page 508: Gear Pump Sealing
GEAR PUMP SEALING ASS0250L Figure 26 Remove gear pump. Visually check: O-ring (1, Figure 27). ASS0260L Figure 27 Main Pump SP000186 Page 16...
Page 509 Sealing surface of housing (2, Figure 28). ASS0270L Figure 28 SP000186 Main Pump Page 17...
Page 510: Remove The Control Housing
REMOVE THE CONTROL HOUSING ASS0280L Figure 29 Main Pump SP000186 Page 18...
Page 511 Place pump into a disassembly / assembly device with a crane and secure it into position. ASS0290L Figure 30 Remove screws holding port plate. Using a suitable lifting device, remove port plate. NOTE: Mark installation position. NOTE: Be careful, control lenses can fall out. ASS0300L Figure 31 SP000186...
Page 512 Remove paper seal, and clean sealing surface. ASS0310L Figure 32 ASS0320L Figure 33 Number Description Setting Screw: Q Setting Screw: Hydraulic Stroke Limitation Setting Screw: Power Characteristic (Begin of Regulation) Main Pump SP000186 Page 20...
Page 513 NOTE: Before carrying out setting or disassembly of regulator, measure distance "X" of adjustment screw and record value. ASS0330L Figure 34 SP000186 Main Pump Page 21...
Page 514: Control Module
CONTROL MODULE Control Module LR ASS0340L Figure 35 Remove and disassemble control module LR. ASS0350L Figure 36 Main Pump SP000186 Page 22...
Page 515: Control Module H
Control Module H ASS0360L Figure 37 Remove and disassemble control module H. ASS0370L Figure 38 SP000186 Main Pump Page 23...
Page 516: Removing The Controller
REMOVING THE CONTROLLER ASS0380L Figure 39 Remove cover. NOTE: Do not change the setting of adjustment screw (1, Figure 39). ASS0390L Figure 40 Main Pump SP000186 Page 24...
Page 517 Remove screws. NOTE: Install control lens - torque support. ASS0400L Figure 41 Remove locking screw and replace with a new one. NOTE: Loosen adhesive with "gentle" ﬂame (approximately 120 ° C). ASS0410L Figure 42 ASS0420L Figure 43 Remove swivel pin. ASS0430L Figure 44 SP000186...
Page 518: Valve Plate With Valves
VALVE PLATE WITH VALVES ASS0440L Figure 45 Pressure relief valve. Electro- proportional pressure reducing valve (EPPR). Main Pump SP000186 Page 26...
Page 519: Remove The Rotary Groups
REMOVE THE ROTARY GROUPS ASS0450L Figure 46 Keep cylinder with device (Remove it completely along with drive shaft). ASS0460L Figure 47 Remove cylinder (Take out the drive shaft without cylinder). ASS0470L Figure 48 SP000186 Main Pump Page 27...
Page 520 Remove cup springs 1 and spring cup 2. ASS0480L Figure 49 Note disassembly position: (1, 2 and 3, Figure 50). Rotary Group 2 Rotary Group 1 ASS0490L Figure 50 Press out rotary group with an appropriate device. 2 2 2 2 2 1 1 1 1 1 ASS0500L Figure 51...
Page 521 Fixing screws are glued Adjustment of measurement D * * * * * 1. Holding device Drive shaft 2 Drive shaft 1 1. Holding device * * * * * Adjustment of measurement D Fixing screws are glued ASS0510L Figure 52 NOTE: 1) Position (*) drive shafts with bearing set are the smallest assembly group.
Page 522: Remove The Intermediate Wheel
REMOVE THE INTERMEDIATE WHEEL Press bolt (*, Figure 53) into gear wheel. (Fixed pressing ﬁt). NOTE: Can only be disassembled with a hydraulic press. * * * * * * * * * * ASS0520L Figure 53 Install sleeve. NOTE: Press out bolt with a hydraulic press.
Page 523 Remove gear wheel through side drive opening. ASS0540L Figure 55 Remove bearing with extraction device. ASS0550L Figure 56 SP000186 Main Pump Page 31...
Page 524: Remove Auxiliary Drive
REMOVE AUXILIARY DRIVE ASS0560L Figure 57 Remove screws and auxiliary drive. ASS0570L Figure 58 Press off bearing cap. ASS0580L Figure 59 Main Pump SP000186 Page 32...
Page 525 In the event of oil leakage, visually check O-ring, housing and groove. ASS0590L Figure 60 Install extractor device. ASS0600L Figure 61 Pull out output pinion. ASS0610L Figure 62 Install bearing extractor device. ASS0620L Figure 63 SP000186 Main Pump Page 33...
Page 526 Completely mount device and pull out bearing. ASS0630L Figure 64 Pull out pinion bearing. ASS0640L Figure 65 Main Pump SP000186 Page 34...
Page 527: Inspection
INSPECTION Check to see that bearing bore is free of scores and that there is no evidence of wear. ASS0650L Figure 66 Visually check: To ensure that bearing seats are free of scores. ASS0660L Figure 67 Visually check: Check to see that bearing bores are free of scores and that there is no evidence of wear.
Page 528 Drive shafts: Check to ensure that cups are free of scores and that there is no pitting (1. Figure 70). Check to see that there is no evidence of corrosion and wear steps (2, Figure 70). ASS0690L Figure 70 Piston: Check to ensure that they are free of scores and that there is no pitting.
Page 529 Check cylinder block / control lens. Bores (1, Figure 74) are free of scores, no evidence of wear. Faces (2, Figure 74) are even, that there are no cracks, no scores. Side guides (3, Figure 74) show no evidence of wear, free of scores.
Page 530 12. Complete rotary group. NOTE: Adjustment of the hydraulic component is necessary. Mechanical component: drive shaft is adjusted with the bearing (1, Figure 77). Hydraulic component (2, Figure 77): Adjustment is necessary (*, Figure 77). ASS0760L Figure 77 Main Pump SP000186 Page 38...
Page 531 13. Rotary group: All of the components. * Adjustment (Figure 78). For adjustment values and torque values, see service information. ASS0770L Figure 78 SP000186 Main Pump Page 39...
Page 532: Re-Fitting The Rotary Group
RE-FITTING THE ROTARY GROUP Threads must be free of oil, grease, dust or any other contaminants which may impair locking of screws. ASS0780L Figure 79 Assemble retaining plate with pistons and center pin in position. Use screws that have a Precoat coating. NOTE: For tightening torques, see service information.
Page 533 Ensure that all parts are assembled in correct order and orientation. ASS0810L Figure 82 Insert pistons into cylinder. Using a soft surface as a support to prevent sliding surfaces from being damaged. Pre-assemble both rotary groups in this manor. ASS0820L Figure 83 SP000186 Main Pump...
Page 534: Pump Assembly
PUMP ASSEMBLY Warm up housing to approximately 80°C. ASS0830L Figure 84 Insert pre-assembled rotary group 2, being sure to align gear tooth marks. ASS0840L Figure 85 Insert rotary group 1. Align the marked gear teeth. ASS0850L Figure 86 Gear tooth marks must align with each other. ASS0860L Figure 87 Main Pump...
Page 535 Adjustment of measurement D. NOTE: Hydraulic control portion. Stop Stop ASS0870L Figure 88 NOTE: Drive shafts with bearing set. The assembly group is adjusted to dimension (A). The tapered roller bearings are adjusted to the stipulated breakaway torque. Assembly Guideline Retaining force: After rotary group has been installed into housing, it has to be pressed in until the end stop is reached.
Page 536 Adjustment of the Hydraulic Component of the Rotary Group The adjustment of dimension "D" is carried out using spring plates of differing thickness, so that the correct clearance is achieved between the rotary group which is installed in housing and center pin, and spring plates. NOTE: Dimension (D) = 0.4 ±0.1 mm.
Page 537: Hydraulic Component - Measurement "D
HYDRAULIC COMPONENT - MEASUREMENT "D" Measuring Device - Hydraulic Component 452 269 Size 140 - 200 Size 80-107 ASS0880L Figure 89 Measuring Centering Intermediate Intermediate Size Shim (5) S.H.C.S (6) Device (*) Device (1) Ring (4) Plate (7) 9452269 9452019 9452014 9083277 9083105...
Page 538: Mounting Position
Mounting Position NOTE: Be sure that the correct mounting position is used. The numbers on the top of the measuring device (*, Figure 89) refer to the piston diameter. ASS0900L Figure 90 Size Mounting Position ASS0890L Figure 91 Install intermediate ring or plates onto the housing. Size 80 - 107 (Figure 92).
Page 539 Only Size 140 - 200 (Figure 93). ASS0920L Figure 93 Zero adjustment - measuring device. Turn using the hand wheel until the stop is reached. Set dial gauge to zero. Size 80 - 107 (Figure 94). Figure 94 Size 140 - 200 (Figure 95). Figure 95 SP000186 Main Pump...
Page 540: Measuring Procedure
Measuring Procedure Turn down by 4 turns on the dial gauge. Check: 2 mm clearance, set dial gauge to "Zero." NOTE: Clearance: Size 28 - 160 0.4 mm ± 0.1. Size 82 - 107 (Figure 96). ASS0950L Figure 96 Size 140 - 200 (Figure 97). ASS0960L Figure 97 Turn down, using the hand wheel, until resistance is met.
Page 541: Installation Of Control Housing
INSTALLATION OF CONTROL HOUSING ASS0990L Figure 100 Install swivel pin into correct position and orientation. Take hardening time and tightening torque into account. NOTE: Tightening Torques (*): M6 = 8.5 Nm (0.87 kg•m (6.27 ft lb)) M8 = 14 Nm (1.43 kg•m (10.33 ft lb)) M10 = 35 Nm (3.57 kg•m (25.81 ft lb)) M12 = 69 Nm (7.04 kg•m (50.89 ft lb)) ASS1000L...
Page 542 Push on piston ring by hand. Fix adjustment piston. Take the tightening torques into account. ASS1010L Figure 102 Install control housing. ASS1020L Figure 103 Install control lens in their correct position using grease to hold them in place. Direction of rotation Direction of rotation clockwise counterclockwise...
Page 543 ASS1040L Figure 105 Install seal and controller. ASS1050L Figure 106 Main Pump SP000186 Page 51...
Page 544: Assembly Of Intermediate Wheel
ASSEMBLY OF INTERMEDIATE WHEEL Press bearing (1, Figure 107) into housing. Install and align intermediate wheel (2, Figure 107) through side drive opening. New Assembly Position Cool down bolt (3, Figure 107) with nitrogen and install it. Press in bearing (4, Figure 107). ASS1060L Figure 107 Press bearing into housing.
Page 545: Installation Of Gear Pump
INSTALLATION OF GEAR PUMP ASS1080L Figure 109 Assemble shaft seal, disc and safety ring. Press-in with assemble sleeve. NOTE: Take care of press-in depth! ASS1090L Figure 110 SP000186 Main Pump Page 53...
Page 546: Installation Of Cover / Auxiliary Drive
INSTALLATION OF COVER / AUXILIARY DRIVE ASS1100L Figure 111 Main Pump SP000186 Page 54...
Page 547: Assembly Guidelines For Tightening Torques
ASSEMBLY GUIDELINES FOR TIGHTENING TORQUES Bolts (To N 08.001) Values stated are valid for bolts with metric ISO threads to DIN 13 part 13, as well as head areas to DIN 912 socked head cap screws, DIN 931 hexagon bolt or DIN 933 hexagon bolts with threads up to the head.
Page 548 Plugs with Internal Hexagon and Proﬁle Seal Ring (to N 02.009). Seal ASS1120L Figure 113 Tightening Torque M In Nm Tightening Torque M In Nm Thread Thread M8 x 1 G 1/8 A M10 x 1 G 1/4 A M12 x 1.5 G 3/8 A M14 x 1.5 G 1/2 A...
Page 549 Seal-lock - Sealing Nuts (to N 02.100) Tightening Torque M Thread M6 x 0.5 M8 x 1 M10 x 1 ASS1130L M12 x 1.5 Figure 114 M14 x 1.5 M16 x 1.5 SP000186 Main Pump Page 57...
Page 550 Main Pump SP000186 Page 58...
Page 551 SP000187 CONTROL VALVE (KVMG-400-DA)SP000187 Control Valve (KVMG-400-DA) Edition 1 Control Valve (KVMG-400-DA) SP000187 Page 1...
Page 552 MEMO SP000187 Control Valve (KVMG-400-DA) Page 2...
Page 553 Table of Contents Control Valve (KVMG-400-DA) Safety Precautions..........5 Applicable Models..........5 General Description..........6 When All Spools are in Neutral ........6 Single Operation............10 Combined Operation ............. 22 Anti Drift Valve ............... 25 Main Relief Valve ............26 Overload Relief Valve ............
Page 554 Cleaning and Inspection (Wear Limits and Tolerances) ............51 Cleaning ................ 51 Inspection ..............51 Reassembly ............52 Subassembly ..............52 Reassembly of Control Valve......... 54 Installation ............60 Start-up Procedures ........... 60 Control Valve (KVMG-400-DA) SP000187 Page 4...
Page 555: Safety Precautions
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up SP000187...
Page 556: General Description
GENERAL DESCRIPTION When All Spools are in Neutral Neutral Passage (Figure 1 and Figure 2) Oil supplied to port (P1) ﬂows through neutral passage (L1) to low pressure relief valve throttle (Lc1), to tank passage (Ta), and returns to ports (T1 and T3). Oil supplied to port (P2) ﬂows through neutral passage (R1), to low pressure relief valve throttle (Rc1), to tank passage (Ta), and returns to ports (T1 and T3).
Page 557 Figure 1 Control Valve (KVMG-400-DA) SP000187 Page 7...
Page 558 Signal Passage (Figure 2) Oil supplied to port (PP, Figure 2), after passing through oriﬁce (Lc3), is divided into two ﬂows. One ﬂow is sent to port (PT), and the other ﬂows through land (Lc4) and passage (5) to land (Rc3) and into tank passage (Ta). The same oil supplied from port (PP), after passing through oriﬁce (Lc5), ﬂows partly to port (PA) and passes partly through passages (L4), (8) and (R4), to boom spool...
Page 559 Figure 2 Control Valve (KVMG-400-DA) SP000187 Page 9...
Page 560: Single Operation
Single Operation Travel Spool Shifting (Figure 3 and Figure 4) When shifting travel spool by increasing pressure of travel (section 1) pilot port (Pb1 (Pa1)), oil supplied to port (P1) ﬂows through neutral passage (L1), to spool, and ﬂows to port (B1 (A1)).
Page 561 Figure 3 Control Valve (KVMG-400-DA) SP000187 Page 11...
Page 562 Swing Spool Shifting (Figure 4) When shifting swing spool by increasing pressure of swing (section 2) pilot port (Pb2 (Pa2)), neutral port (L1) is closed. Oil supplied to port (P1) ﬂows through, parallel passage (L3), load check valve (S2-1), and spool to port (B2 (A2)).
Page 563 Boom Spool Shifting Neutral (Figure 5) This valve also works with anti drift valves that are installed on the bottom side of each boom cylinder. When in neutral, poppet (AD1) is closed by pressure from port (A7), that is sent through passage (AD2), spool (AD3), and passage (AD4) to poppet (AD1).
Page 564 Boom up (2 speed junction) (Figure 6) When boom spool 1 (section 7) is shifted by increasing pressure of boom 1 pilot port (Pa7), neutral passage (R1) is closed. Oil supplied to port (P2) ﬂows through parallel passage (R3), and load check valve (S7-1), to spool and ﬂows into port (A7).
Page 565 Boom down (regeneration) (Figure 7) When boom spool 1 (section 7) is shifted by increasing pressure of boom 1 pilot port (Pb7), neutral passage (R1) is closed. Oil supplied to port (P2), ﬂows through parallel passage (R3), and load check valve (S7-1), to spool, and ﬂows into port (B7).
Page 566 Spare Spool Shifting (Figure 8) When spare spool is shifted by increasing pressure of spare (section 4) pilot port (Pb4 (Pa4)), neutral passage (L1) is closed. Oil supplied to port (P1) ﬂows through, parallel passage (L3), load check valve (S4-1), passage (S4-2), and spool, into port (B4 (A4)).
Page 567 Arm Spool Shifting Arm dump (2 speed junction) (Figure 9) When arm spool 1 is shifted by increasing pressure of arm 1 (section 5) pilot port (Pb5), oil supplied from port (P1) ﬂows through, neutral passage (L1), load check valve (S5- 1), passage (S5-2), and spool, into port (B5).
Page 568 Arm crowd (2 speed junction) When arm spool 1 is shifted by increasing pressure of arm 1 (section 5) pilot port (Pa5), oil supplied from port (P1) ﬂows through, neutral passage (L1), load check valve (S5- 1), passage (S5-2), and spool, into port (A5). When arm 2 spool is shifted by increasing pressure of arm 2 (section 9) pilot port (pa9) also, oil supplied from port (P2) ﬂows through neutral passage (R1), load check valve (S9-1),...
Page 569 Figure 10 SP000187 Control Valve (KVMG-400-DA) Page 19...
Page 570 Neutral-cut Spool Shifting (Figure 11) This valve has a neutral-cut spool that is installed in lowest ﬂow side (the upper ﬂow side of low pressure relief valve). When spool (L (R)) is shifted by increasing pressure of port (pa10 (pa11)), neutral passage (L1 (R1)) is closed. Oil supplied to port (P1) ﬂows through passage (7) and poppet (S8-3, Figure 8), it then joins with bucket (section 8) passage (S8-2, Figure 8).
Page 571 Relief Valve Main relief valve (Figure 12) Oil supplied to port (P1) ﬂows through poppet (LP), oil supplied from port (P2), ﬂows through poppet (RP), and passage (3) also, it then joins with the main relief valve. The highest pressure of pump (P1) and (P2) is controlled by actuating of main relief valve.
Page 572: Combined Operation
Combined Operation Travel Combined Operation (Figure 13) When applying simultaneously the operation except travel while travel left and right simultaneous operating (while forward traveling, backward traveling, or pivot turning) or when applying travel left and right simultaneous operating while applying the operation except travel, oil supplied from port (PP) is disconnected with the tank passage (Ta) at the signal land part of section of exception of travel shifted with the land (Lc4) (Lc7) (Rc3) (Rc5), and the pressure of signal...
Page 573 Figure 13 Control Valve (KVMG-400-DA) SP000187 Page 23...
Page 574 Swing Combined Operation (Figure 14) When applying the combined operation with the swing and another implement, poppet (S2-1) is ﬁxed by increasing port (pc6) pressure, poppet (S2-3) is opened, and pressure supplied to port (L3) is increased through throttle (S2-4). Accordingly, even in the case that the swing load pressure is low, the simultaneous operation character with the other implement can be secured.
Page 575: Anti Drift Valve
Anti Drift Valve The anti drift valve is installed in the cylinder port of arm rod (boom bottom) side to prevent the arm (boom) cylinder from natural lowering. In neutral condition (Figure 15), cylinder port pressure is sent through passage (AD2), spool (AD3), and passage (AD4) to spring chamber (AD5).
Page 576: Main Relief Valve
Main Relief Valve The main relief valve is located between neutral oil passage (HP, Figure 18) and low pressure oil passage (LP). Pressurized oil ﬂows into neutral oil passage (HP) through oriﬁce in the main poppet (C) to ﬁll internal cavity (D).
Page 577: Overload Relief Valve
Overload Relief Valve The overload relief valve is located between cylinder port (HP) and low pressure oil passage (LP). Pressurized oil at cylinder port (HP), ﬂows through an oriﬁce in piston (C), to ﬁll internal cavity (G). Due to the difference in area between (A) and (B) on which the hydraulic pressure acts, main poppet (D) seats on sleeve (K).
Page 578 Sucking operation An anti void unit is installed in cylinder port (HP) to prevent the development of cavitation. If pressure at cylinder port (HP) becomes lower than that of oil passage (LP), sleeve (K) moves so that oil is supplied from the low pressure oil passage (LP) to cylinder port (HP) to eliminate cavitation.
Page 579: Low Pressure Relief Valve
Low Pressure Relief Valve When oil does not pass Figure 27 When spool is in neutral Oil in neutral oil passage (HP) ﬂows through signal oriﬁce (A) into low pressure oil passage (LP). The pressure of the signal port (4Ps (5Ps)) increases by the negacon signal oriﬁce (A).
Page 580: Parts List
Parts List Figure 30 Control Valve (KVMG-400-DA) SP000187 Page 30...
Page 581 Figure 31 Control Valve (KVMG-400-DA) SP000187 Page 31...
Page 582 Figure 32 Control Valve (KVMG-400-DA) SP000187 Page 32...
Page 583 Reference Reference Description Description Number Number Valve Housing Backup Ring Valve Housing Body Spool Assembly (Arm-2) Piston Spool Assembly (Bucket) Flange Spool Assembly (Boom 1) O-ring Spool Assembly (Travel) Poppet Spool Assembly (Straight Travel) Body Assembly Spool Assembly (Arm-1) Relief Valve Assembly Spool Assembly (Service) Relief Valve Assembly Spool Assembly (Boom 2)
Page 584 Spool Assembly (4, Bucket) Reference Description Number Spool Spring Seat Spring Spring Spool End Figure 33 Spool Assembly (5, Boom) Reference Description Number Spool Spring Seat Spring Spring Spool End Poppet Figure 34 Spring Plug O-ring Backup Ring Spool Assembly (6, Travel) Reference Description Number...
Page 585 Spool Assembly (7, Straight Travel) Reference Description Number Spool Spring Seat Spring Spring Spool End Figure 36 Spool Assembly (8, Arm1) Reference Description Number Spool Spring Seat Spring Spring Spool End Poppet Figure 37 Spring Plug O-ring Backup Ring Spool Assembly (9, Service) Reference Description Number...
Page 586 Spool Assembly (10, Boom 2) Reference Description Number Spool Spring Seat Spring Spring Spool End Figure 39 Spool Assembly (11, Swing) Reference Description Number Spool Spring Seat Spring Spring Spool End Figure 40 Spool Assembly (3, Arm 2) Reference Description Number Spool Spring Seat...
Page 587 Spool Assembly (24) Reference Description Number Spool Spool End Figure 43 Poppet Assembly (36) Reference Description Number Poppet Poppet Spring Plug Figure 44 Plug Assembly (51) Reference Description Number Plug O-ring O-ring O-ring Figure 45 Plug Assembly (58) Reference Description Number Plug O-ring...
Page 588 Relief Valve Assembly (48) Figure 47 Item Speciﬁcation Serial No. 1001 thru 1050 1051 and Up Hi: 34.3 ± 0.5 MPa Hi: 34.3 ± 0.5 MPa Relief Valve Pressure Low: 31.4 ± 0.5 MPa Low: 31.4 ± 0.3 MPa Flow 250 liter/min.
Page 589: Specifications
Relief Valve Assembly (50) Reference Description Number Plug Spring Poppet Sleeve O-ring O-ring Figure 49 Speciﬁcations Component Name Speciﬁcation Rated Flow 400 liter/min. 500 liter.min at Neutral Max. Pressure 31.9 MPa Allowable Back Pressure Peak Pressure: Below 1.5 MPa Normal Pressure: Below 0.5 MPa Allowable Working Temperature Range -20 ~ 90°C SP000187...
Page 590: Troubleshooting, Testing And Adjustment
TROUBLESHOOTING, TESTING AND ADJUSTMENT General Problem Possible Cause Remedy Spool does not stroke. Hydraulic oil excessively hot. Remove blockage in oil piping. Hydraulic oil contaminated. Change oil and clean oil passages. Overtightened piping port ﬁttings. Check torque. Valve housing deformed when Remove assembling bolts and assembling.
Page 591: Relief Valve
Relief Valve Problem Possible Cause Remedy Pressure does not rise. Pressure does not rise. Replace relief valve. Pressure unstable Pressure unstable Relief pressure is incorrect. Seat parts worn due to dirt. Lock nut and adjuster deformed. Reset pressure and tighten lock nut in rated torque.
Page 592 High pressure adjustment (See Figure 51 on page -49). Loosen lock nut (5) and tighten plug (6) until piston contacts the end (* mark) of plug (4). Plug (6) should be torqued below 2 kg•m (15 ft lb). While plug (6) is tightened, plug (4) should not be turned.
Page 593: Disassembly
DISASSEMBLY General Instructions for Disassembly Stop engine at low actuator pressure. It is dangerous to disassemble control valve while it is under pressure. High pressure oil can squirt out or components can spring out. When partially disassembling control valve that is on machine, be careful to follow the following caution.
Page 594: Disassembly Of Main Spool (3) - (11)
Disassembly of Main Spool (3) - (11) Remove socket head bolt (63, width across ﬂats: 10 mm) and long cap (12 and 73). Remove O-ring (14) from valve housing. Remove all spool subassemblies from valve housing. WARNING! When removing spool, be careful not to damage it. Attach label to each spool in order to install it in the correct position when reassembling.
Page 595: Disassembly Of Subspool (24)
Disassembly of Subspool (24) Remove plug (27, width across ﬂats: 36 mm), spring (25), spring seat (21), and spool (24). Remove the other spool in a similar manner. Remove O-ring (26) from plug. Spool (24-1) and spool end (24-2) are secured with Loctite. Heat spool end to loosen it (Heating temperature: 200 - 250°C) to prevent damage of thread.
Page 596: Disassembly Of Swing Load Check
Remove plug (47-8, width across ﬂats: 8 mm) and O-ring. Remove plug (47-9, width across ﬂats: 5 mm) and O-ring. NOTE: Steel ball (75) should not be disassembled since it is a press ﬁt. Disassembly of Swing Load Check Remove socket head bolt (68, width across ﬂats: 10 mm) and ﬂange (44).
Page 597: Disassembly Of Other Check Valves
Disassembly of Other Check Valves Remove two common check valves from main relief valve. Remove socket head bolt (64, width across ﬂats: 8 mm) and ﬂange (56). Pull off collar from spacer (17). Remove O-ring (18) and backup ring (19). Remove spring (16) and poppet (15).
Page 598: Disassembly Of Other Flange
Disassembly of Other Flange Remove plug assemblies (60, 61, 62, 58, 52, 59) and O- rings. Reference Size Quantity Number 6 mm 10 mm 12 mm 24 mm 27 mm 8 mm NOTE: Valve housings (1 and 2) should not be disassembled because O-rings and housings can be deformed and mating surfaces can be crisscrossed when reassembling them.
Page 599: Disassembly Of Main Relief Valve
Disassembly of Main Relief Valve This relief valve should be replaced as an assembly. When replacing it, loosen cap (8, width across ﬂats: 41) and O- ring (1, Figure 51). If oil leaks from nut (3), remove nut (3) and plug (4) and replace O-ring and backup ring. Figure 51 SP000187 Control Valve (KVMG-400-DA)
Page 600: Disassembly Of Overload Relief Valve
Disassembly of Overload Relief Valve This relief valve should be replaced as an assembly. When replacing it, loosen cap (1, width across ﬂats: 31.75 mm) and O-ring (2). If oil leaks from nut (3), remove adjusting kit and replace O-ring (4). NOTE: When disassembling adjusting kit, be careful not to allow components to spring out by force...
Page 601: Cleaning And Inspection
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) Cleaning Clean all parts thoroughly using a suitable cleaning ﬂuid and dry them with moisture free compressed air. Put them on a clean paper or a vinyl surface for inspection. Inspection Inspect all parts for scratches, notches and the other defects. Inspect load check seat surface of valve housing for scratches, scores, dirt, notches and corrosion.
Page 602: Reassembly
REASSEMBLY NOTE: Before reassembling, conﬁrm number components, reassembling position, tools and etc. Subassembly Before reassembling valve housing, subassemble parts as needed. Main Spool (3) - (11) Apply Loctite to threads of spools (3, 4, 6, 7, 9, 10 and 11). Assemble spring seat (above parts numbers - 2), spring (above parts numbers - 3, 4) and spool end (above parts numbers - 5), and assemble spool end in spool that is...
Page 603 Subspool (24) Apply Loctite to thread of spool (24-1). IMPORTANT Be careful not to get Loctite into spool by over applying it. Be careful that spool operation does become deteriorated by over torquing spool end. Tighten spool end (24-2) in spool (24-1). Torque is 1.94 - 2.24 kg•m (14 - 16 ft lb).
Page 604: Reassembly Of Control Valve
Reassembly of Control Valve Reassembly of Load Check Valve Assemble travel semiparallel check for P2 port. Assemble poppet (52) and spring (53), and fasten plug (54) with O- ring (55). Torque is 10.50 - 11.52 kg•m (76 - 83 ft lb). Assemble travel load check for P1 port.
Page 605 Reassembly of Other Check Valve Assemble two common check valves of main relief valve. Install poppet (15) and spring (16). Insert spacer (17) with O-ring (18) and backup ring (19). Fasten ﬂange (56) with socket head bolts (64). Torque is 5.91 - 6.53 kg•m (43 - 47 ft lb).
Page 606 Reassembly of Relief Valve Tighten eight over load relief valves (49). Torque is 7.95 - 8.97 kg•m (58 - 65 ft lb). Tighten main load relief valve (48). Torque is 9.48 - 11.01 kg•m (69 - 80 ft lb). Tighten negacon relief valve (50). Torque is 10.50 - 11.52 kg•m (76 - 83 ft lb).
Page 607 Reassembly of Other Plugs Tighten plug assembly (60) with O-ring. Torque is 3.16 - 4.28 kg•m (23 - 31 ft lb). Tighten plug assembly (61) with O-ring. Torque is 11.83 - 13.05 kg•m (86 - 94 ft lb). Tighten plug assembly (62) with O-ring. Torque is 7.44 - 8.06 kg•m (54 - 58 ft lb).
Page 608 Reassembly of Main Relief Valve Check whether there is dirt or paint chips around plug (4, Figure 54) and nut (3). Reassemble with new O-rings. Clean the installation portion of relief valve and install it. Tighten cap (8: Width across ﬂats 41). Torque is 9.48 - 11.01 kg•m (69 - 80 ft lb). When adjusting the position of port (Pi), adjust it before adjusting pressure and tightening plug (2, Width across ﬂats 41 mm).
Page 609 Reassembly of Overload Relief Valve Check whether there is dirt or paint chips around cap (1, width across ﬂats: 31.75 mm) and reassemble with a new O-ring. Clean the installing part of relief valve and install it. Tighten cap (1). Torque is 7.95 - 8.97 kg•m (58 - 65 ft lb). If adjusting kit is disassembled, clean around threads and adjust pressure by referring to “Over Load Relief Valve”...
Page 610: Installation
INSTALLATION Be careful not to work other foreign strength to control valve by pipe laying. Tighten the assembling bolts alternately and evenly to the speciﬁed torque. If welding procedures are being performed near the control valve, the valve could damaged by weld spatter and heat. Use adequate shielding to protect valve.
Page 611 SP000189 REMOTE CONTROL VALVE (WORK LEVER / JOYSTICK) SP000189 Remote Control Valve (Work Lever / Joystick) Edition 1 Remote Control Valve (Work Lever / Joystick) SP000189 Page 1...
Page 612 MEMO SP000189 Remote Control Valve (Work Lever / Joystick) Page 2...
Page 613 Table of Contents Remote Control Valve (Work Lever / Joystick) Safety Precautions..........5 Applicable Models..........5 General Description..........7 Function................7 Parts List ................. 8 Speciﬁcations ..............10 Torques ............... 10 Tools and Materials..........10 Disassembly ............11 Cleaning and Inspection (Wear Limits and Tolerances) ............
Page 614 MEMO SP000189 Remote Control Valve (Work Lever / Joystick) Page 4...
Page 615: Remote Control Valve (Work Lever / Joystick)
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up SP000189...
Page 616 Remote Control Valve (Work Lever / Joystick) SP000189 Page 6...
Page 617: General Description
GENERAL DESCRIPTION Structure The remote control valve contains four push rods, spring holders, spools and return springs, which are in the valve casing. The valve works as a pressure reduction valve. The housing has six ports, which include input port P, tank port T, and four secondary pressure ports.
Page 618: Parts List
Parts List 37 : 24 ~ 28 FG004596 Figure 1 Remote Control Valve (Work Lever / Joystick) SP000189 Page 8...
Page 619 Reference Reference Description Description Number Number Case Swash Plate Plug Bushing Spool Handle Assembly (L) Handle Assembly (R) Shim Spring Handle Bar Spring Seat Spring Pin Stopper Bellows Spring Bushing Push Rod Connector Assembly Plug Switch Assembly O-ring Spool Kit 1, 3 Rod Seal Plug Kit 1, 3 Plate...
Page 620: Specifications
Speciﬁcations Performance Figure 2 Torques Tool Standard Remark 500 kg•cm Plug PF 3/8 (36 ft lb) 1,660 kg•cm Swash Plate 27 mm (120 ft lb) 1,660 kg•cm Hex Nut 22 mm (120 ft lb) 1,660 kg•cm 22 mm (120 ft lb) TOOLS AND MATERIALS Tool Standard...
Page 621: Disassembly
DISASSEMBLY Remove lead wire from bushing (29). FG000804 Figure 3 Remove lever assembly from case (1). FG000805 Figure 4 Remove hex nut (23) and swash plate (22) from case. FG000806 Figure 5 Remove joint assembly (21) from case. FG000807 Figure 6 SP000189 Remote Control Valve (Work Lever / Joystick) Page 11...
Page 622 Remove plate (19) from case (1). FG000808 Figure 7 Remove plug kit assembly from case (1). FG000810 Figure 8 FG000811 Figure 9 Remove four spool kit assemblies from case (1). FG000812 Figure 10 Remote Control Valve (Work Lever / Joystick) SP000189 Page 12...
Page 623 FG000813 Figure 11 The bushing (3) and plug cannot be removed from case (1). FG000814 Figure 12 FG000815 Figure 13 FG000816 Figure 14 Remote Control Valve (Work Lever / Joystick) SP000189 Page 13...
Page 624 FG000817 Figure 15 Remote Control Valve (Work Lever / Joystick) SP000189 Page 14...
Page 625: Cleaning And Inspection (Wear Limits And Tolerances)
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section. REASSEMBLY Install four plugs (2) into case (1). FG000815 Figure 16 FG000817 Figure 17 Install bushing (3) into case (1) using jig. FG000814 Figure 18 SP000189...
Page 626 FG000816 Figure 19 FG000818 Figure 20 Take care when assembling spool kit assemblies (1 and 3, 2 and 4). They should be assembled in same way). The assembly order is; spool (4), shim (5), spring (6), spring seat (7), and stopper (8). FG000819 Figure 21 FG000812...
Page 627 Install spring (9) into case (1). FG000820 Figure 23 Install spool kit assembly into case (1). (The same way is used for four parts.) FG000821 Figure 24 Assemble plug kit insert rod seal (18), O-ring (17), and push rod (12) into plug (16) in proper order. FG000822 Figure 25 FG000810...
Page 628 Assemble plug kit (35) and insert assembled set in case (1) to form a plug kit assembly. FG000811 Figure 27 FG000811 Figure 28 FG000823 Figure 29 Install plate (19) into case (1). FG000808 Figure 30 Remote Control Valve (Work Lever / Joystick) SP000189 Page 18...
Page 629 Install joint assembly (21) into case (1). FG000807 Figure 31 10. Install wash plate (22) and hex nut (23) into case (1). FG000806 Figure 32 11. Insert bar and tighten it with a spanner to check balance of joint assembly. FG000824 Figure 33 12.
Page 630 13. Install lever assembly into case (1). FG000805 Figure 35 14. Put lead wire in bushing (29), tie it, and arrange boot. FG000826 Figure 36 FG000827 Figure 37 15. Install lead wire terminal into connector terminal pressing them together. FG001097 Figure 38 Remote Control Valve (Work Lever / Joystick) SP000189...
Page 631: Start-Up Procedures
16. Assemble connector assembly (30), and connect it to lead wire terminal, and properly route wiring. FG000828 Figure 39 FG000829 Figure 40 START-UP PROCEDURES Start engine and set throttle at "LOW IDLE." Set safety lever on "UNLOCK" position. HAOB290L Figure 41 Slowly cycle boom, arm, bucket cylinders and swing motor about ﬁve times without a load to vent air from pilot lines.
Page 632 Remote Control Valve (Work Lever / Joystick) SP000189 Page 22...
Page 633 SP000070 TRAVEL CONTROL VALVE (WITH DAMPER) SP000070 Travel Control Valve (with Damper) Edition 1 Travel Control Valve (with Damper) SP000070 Page 1...
Page 634 MEMO SP000070 Travel Control Valve (with Damper) Page 2...
Page 635 Table of Contents Travel Control Valve (With Damper) Safety Precautions..........5 Applicable Models..........5 General Description..........7 Theory of Operation ............7 Deceleration Valve............8 Dampening Parts of the Control Section ......9 Causes of Faults and Measures ......11 Parts List ...............
Page 636 MEMO SP000070 Travel Control Valve (with Damper) Page 4...
Page 637: Travel Control Valve (With Damper)
The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 5001 and Up DX340LC 5001 and Up DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up SP000070 Travel Control Valve (with Damper)
Page 638 Travel Control Valve (with Damper) SP000070 Page 6...
Page 639: General Description
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 640: Deceleration Valve
Deceleration Valve In neutral position, the damper spool is pushed to the neutral position by return spring which is seated on the spring seat (and washer. As a result of the damper spool's switching function, the output port is connected to port T and the pressure at the output port and port T is the same.
Page 641: Dampening Parts Of The Control Section
Dampening Parts of the Control Section In the neutral position, the push rod is pushed up to its neutral position by the return spring and damper spring. When the cam is moved in the clockwise direction from the neutral position, the push rod and damper spool of port 1 are moved in a downward direction.
Page 642 When moving lever from the neutral position Moving the lever from the neutral position to the right forces oil in the right damper spool to discharged through the oriﬁce, generating pressure that creates a dampening force. Moving the lever in the opposite direction, causes the left damper spool to assume the function of the right spool.
Page 643: Causes Of Faults And Measures
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 644: Parts List
Parts List 25,26 14,15 FG003925 Figure 5 Travel Control Valve (with Damper) SP000070 Page 12...
Page 645: Specifications
Reference Reference Description Description Number Number Body (1) Retaining Ring Body (2) Plug Plug O-ring Plug Rod Seal Spring Seat Dust Seal Damper Spring Cover Spring Seat Hex Socket Head Bolt Damper Spool Stopper Bushing Return Spring Camshaft Rod Guide Set Screw O-ring Set Screw...
Page 646: 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 WARNING DON'T TOUCH WHEN WARNING! PERFORMING INSPECTION OR MAINTENANCE FG003015 engine must running...
Page 647: Disassembly
DISASSEMBLY Remove bellows (33). ARS1870P Figure 8 Remove set screw (30) from cam (27). FG000985 Figure 9 Remove cam shaft (29) and cover (25) from cam (27). FG000986 Figure 10 Remove hex nut (32) and swash plate (31) from cam. FG000987 Figure 11 SP000070...
Page 648 Remove hex socket head bolt (26) and cover (25) from each body (1 and 2). FG000988 Figure 12 FG000989 Figure 13 Remove push rod assembly from each body (1 and 2). FG000990 Figure 14 Remove retaining ring (13). FG000991 Figure 15 Travel Control Valve (with Damper) SP000070 Page 16...
Page 649 Remove rod guide (11) from each body (1 and 2). FG000992 Figure 16 FG000993 Figure 17 Remove damper spool assembly and spring (10) from each body (1 and 2). FG000994 Figure 18 FG000995 Figure 19 SP000070 Travel Control Valve (with Damper) Page 17...
Page 650: Cleaning And Inspection (Wear Limits And Tolerances)
10. Remove hex socket head bolt (37) from each body (1 and 2). Disassemble each body (1 and 2) and spacer (34). Remove plugs (3 and 4) and O rings (35 and 36). FG000996 Figure 20 FG000997 Figure 21 FG000998 Figure 22 CLEANING AND INSPECTION (WEAR LIMITS AND...
Page 651: Assembly
ASSEMBLY Assemble plugs (3 and 4) and O rings (35 and 36) into each body (1 and 2) and spacer (34). Install hex socket head bolt (37) using torque wrench. FG000996 Figure 23 FG000997 Figure 24 FG000998 Figure 25 Insert spring (10) into each body (1 and 2). FG000995 Figure 26 SP000070...
Page 652 Assemble in proper order, damper spool (8), shim (7), spring (6), spring seat (5), and stopper (9). FG000999 Figure 27 FG001000 Figure 28 Install damper spool assembly into each body (1 and 2). FG000994 Figure 29 Install O-ring (12) on rod guide (11). Coat guide assembly with grease, and slide it into each body (1 and 2).
Page 653 FG000993 Figure 31 Install retaining ring (13). Make sure that it is properly seated. FG000991 Figure 32 Assemble rod seal (23), dust seal (24), and O-ring (22) into plug (21). FG001001 Figure 33 FG001002 Figure 34 Travel Control Valve (with Damper) SP000070 Page 21...
Page 654 Assemble seal (16), piston (38), steel ball (17), plate (19), spring (18), and retaining ring (20) into push rod (14). FG001003 Figure 35 FG001004 Figure 36 Assemble push rod and plug. FG001005 Figure 37 10. Install push rod assembly into each body (1 and 2). FG000990 Figure 38 Travel Control Valve (with Damper)
Page 655 11. Install bushing (28) in cover (25) using jig. FG001006 Figure 39 12. Assemble cover (28) onto each body (1 and 2) and install hex socket head bolt (26) using torque wrench. FG001007 Figure 40 FG000989 Figure 41 13. Install set screws (31) and hex nut (32) into cam (27) and tighten it.
Page 656 14. Position cam (27) on cover (25), and insert cam shaft (29) using hammer. FG000986 Figure 43 15. Install set screw (30) in cam (27) and tighten it using torque wrench. FG000985 Figure 44 16. Check cam balance. FG001009 Figure 45 17.
Page 657: Installation
INSTALLATION Position pedal valve (1, Figure 47) on cabin ﬂoor plate and install four bolts and washers (2). FG003016 Figure 47 Install pedal brackets (3) and levers (4, Figure 48) on pedal valve and install four bolts and washers (2). Install rubber boots (1, Figure 48).
Page 658: Start-Up Procedures
START-UP PROCEDURES Start engine and set throttle at "LOW IDLE." Set safety lever on "UNLOCK" position. HAOB290L Figure 50 Slowly push and pull both travel lever about ﬁve times without a load to vent air from pilot lines. HAOB903L Figure 51 Travel Control Valve (with Damper) SP000070 Page 26...
Page 659 SP000191 SOLENOID VALVE ASSEMBLYSP000191 Solenoid Valve Assembly Edition 1 Solenoid Valve Assembly SP000191 Page 1...
Page 660 MEMO SP000191 Solenoid Valve Assembly Page 2...
Page 661 Table of Contents Solenoid Valve Assembly Safety Precautions..........5 Applicable Models..........5 Parts List............... 6 Functions of 5-Solenoid Valve Assembly Package ..............7 Functions of Solenoid Valve Assembly Package ..... 7 Assembly Diagram and Tools Required......9 Solenoid Valve Diagram ..........11 Check Points and Solutions for Problems .....
Page 662 MEMO SP000191 Solenoid Valve Assembly Page 4...
Page 663: Solenoid Valve Assembly
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up SP000191...
Page 664: Parts List
PARTS LIST Components used for the solenoid valve package are the same as in the parts list below. Figure 1 Reference Description Sizes Quantity Remarks Number Block Body 95x120x240 1-A1079-05-0 Solenoid valve TF-S34-00-VDL24VDC C1, C2, C3, C4, C5 Check Valve FD-DCP-0-A Pilot Shift Valve FD-PSS1-0005...
Page 665: 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 666 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 667: 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. Figure 2 Reference Torques Components Screw Sizes Tools Number (kg/cm) Solenoid valve UNF7/8 - 14" 200 ±...
Page 668 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 669: Solenoid Valve Diagram
Solenoid Valve Diagram Figure 3 SP000191 Solenoid Valve Assembly Page 11...
Page 670: 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 case valve assemble and the spool.
Page 671 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). SP000191 Solenoid Valve Assembly Page 13...
Page 672 Solenoid Valve Assembly SP000191 Page 14...
Page 673 SP000192 BREAKER EPPR VALVE (OPT)SP000192 Breaker EPPR Valve (Opt) Edition 1 Breaker EPPR Valve (Opt) SP000192 Page 1...
Page 674 MEMO SP000192 Breaker EPPR Valve (Opt) Page 2...
Page 675 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 ..............9 Assembly ...............
Page 676 MEMO SP000192 Breaker EPPR Valve (Opt) Page 4...
Page 677: Breaker Eppr Valve (Opt)
The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 5001 and Up DX340LC 5001 and Up DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up SP000192 Breaker EPPR Valve (Opt)
Page 678: 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 679: 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 680: 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 681: 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 682: 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 683 Assemble the spool, the spring, and the pin. Figure 10 • The spring and the pin should not be fell off. Figure 11 Assemble the solenoid correctly. Figure 12 SP000192 Breaker EPPR Valve (Opt) Page 11...
Page 684 • Take care not to damage O-rings of the solenoid. Figure 13 Breaker EPPR Valve (Opt) SP000192 Page 12...
Page 685 SP000209 FAN MOTOR (VANE TYPE)SP000209 Fan Motor (Vane Type) Edition 1 Fan Motor (Vane Type) SP000209 Page 1...
Page 686 MEMO SP000209 Fan Motor (Vane Type) Page 2...
Page 687 Table of Contents Fan Motor (Vane Type) Safety Precautions..........5 Applicable Models..........5 Parts list ..............6 Introduction and Description......... 7 General................7 Description ..............7 Applications ..............7 Operation................. 8 Operating Characteristics - Typical ....... 9 Performance Data ............9 Loads on Shaft ..............
Page 688 Priming ................19 Cold Starting ..............19 Changing Porting Position ..........19 Cartridge Replacement ..........20 End Cap Replacement ..........20 Shaft Replacement............20 Shaft Seal Replacement..........20 Seal Driver..............21 Couping Dimensions .......... 21 Taper Keyed Shafts ............21 Fan Motor (Vane Type) SP000209 Page 4...
Page 689: Fan Motor (Vane Type)
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up SP000209...
Page 690: Parts List
PARTS LIST Figure 1 Reference Reference Description Description Number Number End Cap (UNC) Retaining Ring Rotor Insert Assembly Retaining Ring Spring Vane Shaft Seal Pin-Vane Holdout Sq. Section seal Vane Dowel Pin Cam Ring 012 Sq. Section seal Port Plate Pressure Needle Bearing O-ring Screw...
Page 691: Introduction And Description
INTRODUCTION AND DESCRIPTION General This manual covers installation, operation, maintenance and overhaul instructions for the single vane type hydraulic motor. Description It has been designed especially for severe duty applications which require high pressure, up to 320 bar (4,600 PSI) and high operating speed (up to 6,000 rpm).
Page 692: Operation
Operation Operation of these rugged hydraulic motors is simple. The motor shaft is driven by the rotor. Vanes, closely ﬁtted into the rotor slots move radially to seal against the cam ring. The ring has two major and two minor radial sections joined by transitional sections called ramps.
Page 693: Operating Characteristics - Typical
OPERATING CHARACTERISTICS - TYPICAL Performance Data Cartridge Displac- Theoretical Real inlet ﬂow Real Real ement Power torque power Theoretical 1000 RPM 1000 RPM torque 1000 RPM 10 bar 140 bar 275 bar 275 bar (150 PSI) (2000 PSI) (4000PSI) (4000 PSI) ml/rev Nm/bar kW/bar...
Page 694: Loads On Shaft
Loads on Shaft Loads on Shaft • Max. axial load : Fa max. = 6000 N • Max. radial load : Fr max. = 5500 N Lifetime Under Load Figure 3 • Theoretical lifetime (hour) : L 16.666 (Hour) = N (RPM) Figure 4 Fan Motor (Vane Type)
Page 695: Mounting Flange And Coupling
MOUNTING FLANGE AND COUPLING Mounting Flange 2 bolt special mounting, designed to make the bearing to be as close as possible to the shaft load. Misalignment Axial or radial loads on shaft may be caused by misalignment of motor and drive axles. The mounting pad or adaptor into which the motor is installed must be concentric with the receptor shaft within 0.15 mm (0.006 inch) TIR.
Page 696: Shafts
Shafts Doosan supplies the motor keyed shaft motors with high strength heat-treated keys. Therefore, when installing or replacing these motors, the heat-treated key must be used in order to insure maximum life in the application. If the key is replaced, it must be a heat treated key between 27 and 34 R.C.
Page 697: Flange Connections
Flange Connections The motor has 4 bolt ﬂange connections, conformable to ISO/ DIS 6162, with metric or UNC threads. Flanged heads must be made of steel. Split ﬂange clamp valves must be made from a material with a minimum yield of 414 MPa (60,000 PSI) and a minimum elongation of 3%.
Page 698: Cleanliness And Seals
CLEANLINESS AND SEALS Fluid Cleanliness The ﬂuid must be cleaned before and during operation to maintain contamination level of NAS 1638 class 8 (or ISO 18/14) or better. Filters with 25 micron (or better, β 10 ≥ 100) nominal ratings may be adequate but do not guarantee the required cleanliness levels.
Page 699: Maintenance
MAINTENANCE General Internal parts of the motor are lubricated by the operating ﬂuid itself ; therefore, preventive maintenance is limited to keeping the ﬂuid in the system clean. The system ﬁlters should be replaced frequently. When possible, dirt should not be allowed to accumulate on the motor or around the shaft seal.
Page 700 With the same screws, remove the pressure plate (7). CAUTION! the cartridge and the pressure plate may go out from the housing together, sticked by oil. Figure 9 Remove the retaining ring (13) by using the tool. Figure 10 Remove the shaft (12) from the housing. Figure 11 Fan Motor (Vane Type) SP000209...
Page 701: Reassembly
Reassembly Use clean hydraulic ﬂuid to lubricate all the internal parts, including seals. Figure 12 Install the shaft in the housing. Install the remaining ring by using the tool. Figure 13 Install seal (16) on the pressure plate spigot (7). Install seal (8) in the housing (9).
Page 702 By using two 10-24 UNC-2B screws, install the pressure plate inside the housing and make sure it is completely inserted and seated on its two seals. Figure 15 Install the two dowel pins (17) and two 10-24 UNC-2B screws on the cam ring. By using the screws, insert the cartridge into the housing, dowel pins facing the corresponding hole on the pressure plate.
Page 703: Priming
Insert the four screws (20) and tighten them at 100 Nm (136 ft lb). Check that it is possible to rotate the shaft, and ﬁll the motor with oil before connecting the pipes. Figure 19 Priming It is important to purge the air off the circuit and the motor. Manually, ﬁll the motor housing with ﬂuid, and connect the motor to the circuit.
Page 704: Cartridge Replacement
Cartridge Replacement Disassemble the motor without removing the pressure plate (7). Replace the cartridge. Reassemble the motor. Nota : to change the cam ring only, or to reassemble an exploded cartridge, it is necessary to use a very speciﬁc tool to compress the springs under the vanes.
Page 705: Seal Driver
Seal Driver NOTE: Remove all burrs and break sharp edges : 0.13 / 0.25 R (0.010 / 0.005 R). Concave connecting radius between length 2 and shoulder. Grease length 2 installing shaft seal onto tool to prevent to the seal from being damaged. Material : XC42 or equivalent.
Page 706 2-Ø19 54.0 +0.9 Ø29 -0.9 M16~1.5 15° Ø19.7 MOUNTING TORQUE MIN. 80.0 N-m 90° SHAFT CODE1 "D" DATAIL SAE"BB"-J 744(with M16?j (SCALE 1/1) TAPER 125/1000 22.2 M18~1.5 DEEP 13.5max. 8-M10~P1.5 19 DEEP DRAIN PORT 38.1 2-Ø14 C.W. C.C.W. Ø4 +0.2 (34.7) -0.2 92.4...
Page 707 SP000208 GEAR PUMP (FAN COOLING DRIVE)SP000208 Gear Pump (Fan Cooling Drive) Edition 1 Gear Pump (Fan Cooling Drive) SP000208 Page 1...
Page 708 MEMO SP000208 Gear Pump (Fan Cooling Drive) Page 2...
Page 709 Table of Contents Gear Pump (Fan Cooling Drive) Safety Precautions..........5 Applicable Models..........5 Disassembling Single Gear Pump ......6 Reassembling Single Gear Pump......9 Disassembling Double Gear Pump(Opt) .... 12 Reassembling Double Gear Pump(Opt) ..... 15 Gear Pump (Fan Cooling Drive) SP000208 Page 3...
Page 710 MEMO SP000208 Gear Pump (Fan Cooling Drive) Page 4...
Page 711: Safety Precautions
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up SP000208...
Page 712: Disassembling Single Gear Pump
DISASSEMBLING SINGLE GEAR PUMP Clean the pump externally with care Figure 1 Loosen and remove the clamp bolts Figure 2 Coat the sharp edges of the drive shaft with adhesive tape and smear a clean grease on the shaft end extension to avoid any damaging lip of the shaft seal when removing the mounting ﬂange.
Page 713 Remove the mounting ﬂange taking care to keep the ﬂange as straight as possible during removal. If mounting ﬂange is stuck, tap around the edge with rubber mallet in order to break away from the body. NOTE: Ensure that while removing mounting ﬂange, shaft and other components remain position.
Page 714 Ease the drive gear up to facilitate removal the front plate. Figure 8 Remove driving gear, driven gear, keeping gears as straight as possible. And rear plate. Figure 9 Gear Pump (Fan Cooling Drive) SP000208 Page 8...
Page 715: Reassembling Single Gear Pump
REASSEMBLING SINGLE GEAR PUMP Clean all components externally with care Figure 10 Insert the shaft seal carefully and ﬁt it inside of mounting ﬂange with proper tool. Figure 11 Fit the snap ring in pre-arranged position with proper tool. Figure 12 SP000208 Gear Pump (Fan Cooling Drive) Page 9...
Page 716 Fit the o-ring on the body. Smear clean grease on the o-rings to avoid drifting away of o-ring from the body. Figure 13 Locate the seals on the groove pre-arranged on the pressure plates. Then, locate back-up ring on the groove pre-arranged on the seals.
Page 717 Insert the pressure plate in to body with attention to the direction. Figure 17 Locate mounting ﬂange in right position. Tap around mounting ﬂange with rubber mallet. Figure 18 10. Tighten the bolts with washer in a crisscross pattern to torque value of 140 Nm.
Page 718: Disassembling Double Gear Pump(Opt)
DISASSEMBLING DOUBLE GEAR PUMP(OPT) Clean the pump externally with care Figure 21 Loosen and remove the clamp bolts Figure 22 Coat the sharp edges of the drive shaft with adhesive tape and smear a clean grease on the shaft end extension to avoid any damaging lip of the shaft seal when removing the mounting ﬂange.
Page 719 Remove the mounting ﬂange taking care to keep the ﬂange as straight as possible during removal. If mounting ﬂange is stuck, tap around the edge with rubber mallet in order to break away from the body. NOTE: Ensure that while removing mounting ﬂange, shaft and other components remain position.
Page 720 Remove ﬁrst section, and through shaft. Figure 28 Remove all remaining components with same way of removal ﬁrst section. Figure 29 Gear Pump (Fan Cooling Drive) SP000208 Page 14...
Page 721: Reassembling Double Gear Pump(Opt)
REASSEMBLING DOUBLE GEAR PUMP(OPT) Clean all components externally with care Figure 30 Insert the shaft seal carefully and ﬁt it inside of mounting ﬂange with proper tool. Fit the snap ring in pre-arranged position with proper tool. Figure 31 Fit the o-ring on the pre-arranged groove of rear body. Smear clean grease on the o-rings to avoid drifting away of o-ring from the body.
Page 722 Locate the seals on the groove pre-arranged on the pressure plates. Then, locate back-up ring on the groove pre-arranged on the seals. Smear clean grease on the seals. (The front and rear pressure plates and seals and back-up rings are same) Figure 33 Insert the complete pressure plate in to body while keeping the plate straight.
Page 723 Locate front section on the rear section slightly and tap around the body with rubber mallet. Figure 37 Repeat same process from 5 to 7, after inserting through shaft. Figure 38 10. Locate mounting ﬂange while taking care not to give any damage on the shaft seal by edge of shaft.
Page 724 12. Check that the pump rotate freely when the drive shaft is turned by hand. If not a pressure plate seal may be pinched. Figure 41 Gear Pump (Fan Cooling Drive) SP000208 Page 18...
Page 725 SP000207 FAN COOLING FLOW IN-OUT CHANGE VALVE SP000207 Fan Cooling Flow In-Out Change Valve Edition 1 Fan Cooling Flow In-Out Change Valve SP000207 Page 1...
Page 726 MEMO SP000207 Fan Cooling Flow In-Out Change Valve Page 2...
Page 727 Table of Contents Fan Cooling Flow In-Out Change Valve Safety Precautions..........5 Applicable Models..........5 Cooling Fan a Change of Direction Valve ..... 6 Fan Cooling Flow In-Out Change Valve SP000207 Page 3...
Page 728 MEMO SP000207 Fan Cooling Flow In-Out Change Valve Page 4...
Page 729 Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up DX480LC 5001 and Up DX520LC 5001 and Up SP000207...
Page 730 COOLING FAN A CHANGE OF DIRECTION VALVE Figure 1 Reference Reference Description Description Number Number Relief Valve Seal Kit Seal Kit Check Valve : Make up Coil Check Valve Seal Kit O-ring Socket Bolt Solenoid Valve Body Fan Cooling Flow In-Out Change Valve SP000207 Page 6...
Page 731 SP000274 HYDRAULIC SCHEMATIC (DX420LC)SP000274 Hydraulic Schematic (DX420LC) Edition 1 Hydraulic Schematic (DX420LC) SP000274 Page 1...
Page 732 MEMO SP000274 Hydraulic Schematic (DX420LC) Page 2...
Page 733 Table of Contents Hydraulic Schematic (DX420LC) Safety Precautions..........5 Applicable Models..........5 General Description..........7 DX420LC .............. 8 Hydraulic Schematic (DX420LC) SP000274 Page 3...
Page 734 MEMO SP000274 Hydraulic Schematic (DX420LC) Page 4...
Page 735 Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up SP000274 Hydraulic Schematic (DX420LC) Page 5...
Page 736 Hydraulic Schematic (DX420LC) SP000274 Page 6...
Page 737 SENSOR (REAR) Opt. Pedal Hammer Select Operating 177u ENGINE SHUTTLE VALVE S1 from JOYSTICK(R) BOTTON Hammer Select from JOYSTICK(R) SWITCH from SELECT SWITCH to #34 P Shear Select Hammer Select Shear Select Figure 1 SP000274 Hydraulic Schematic (DX420LC) Page 7...
Page 738 #36 P 40k@24L from JOYSTICK(L) SWITCH Pcr=2.0k Pcr=2.0k 0.5k 0.05k ENGINE Opt. Pedal Hammer 1.5k 0.2k Operating Select 1.5k 1.5k DV11 280HP/2000rpm 177u 140kgm/1300rpm from SELECT SWITCH Hammer Select Shear Select Figure 2 Hydraulic Schematic (DX420LC) SP000274 Page 8...
Page 739 #35 A pa6 pb1 pa10 SWING BOOM BUCKET DOWN LEFT DUMP DUMP RIGHT CROWD CROWD LH-HI RH-HI (CLOSE) (OPEN) C/V pa7 #35 P1 from JOYSTICK(R) BOTTON from JOYSTICK(R) SWITCH Hammer Select Shear Select DX420LC Hydraulic Schematic (DX420LC) SP000274 Page 9...
Page 740 Hydraulic Schematic (DX420LC) SP000274 Page 10...
Page 741 Electrical System...
Page 743 SP000269 ELECTRICAL SYSTEMSP000269 Electrical System Edition 1 Electrical System SP000269 Page 1...
Page 744 MEMO SP000269 Electrical System Page 2...
Page 745 Table of Contents Electrical System Safety Precautions..........7 Applicable Models..........7 Introduction ............9 Electrical Supply System ........10 Engine Starting Circuit........12 Start Operation .............. 12 After Start ..............14 Engine Preheating System ......... 16 Engine Stop ............18 Charging System ..........
Page 746 Adjust Display..............36 Set Password ..............37 Special Menu ............38 Entering/Accessing and Exiting/Escaping Menus ..38 Special Menu Selections ..........39 Electronic Hydraulic Control System (e-EPOS).. 56 Control System Schematic ..........56 Power Mode Control ........... 58 Operation............... 60 Power Mode Control - Circuit Diagram ....
Page 747 Relay - Blower ............... 96 Relay - A/C ..............96 Duct Sensor..............96 Water Temp Sensor ............97 Internal Air Temp Sensor ..........97 Ambient Air Temperature Sensor ........97 Sun Sensor..............98 Control Panel..............98 Compressor..............105 Receiver Dryer ............105 Control of Cooling Fan........
Page 748 MEMO SP000269 Electrical System Page 6...
Page 749: Electrical System
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up SP000269 Electrical System Page 7...
Page 750 Electrical System SP000269 Page 8...
Page 751: 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 752: Electrical Supply System
ELECTRICAL SUPPLY SYSTEM MEMO The electric power circuit supplies electric current to each electric component. It consists of a battery, battery relay, starter switch, circuit breaker, fusible link and fuse box. The negative terminal of the battery is grounded to the vehicle body.
Page 753 0.5G 12V 150AH 12V 150AH R(I) B(B+) P(R) STARTER SWITCH CONNECTION START FG001476 Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM Reference Reference Description Description Number Number Battery Starter Switch Battery Relay Fuse Box Fusible Link Alternator Circuit Breaker Diode Electrical System SP000269 Page 11...
Page 754: 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 755 CN1-15 CN2-1 R(I) B(B+) P(R) STARTER SWITCH CONNECTION START FG004533 Figure 2 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 756: After Start
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 757 Operation of the Start Circuit (2) - Immediately After Start CN1-15 CN2-1 R(I) B(B+) P(R) STARTER SWITCH CONNECTION START FG004666 Figure 3 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START Reference Reference Description Description Number Number Battery Starter Relay Battery Relay Starter Fusible Link...
Page 758: 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 759 MEMO CN6-1,2 CN7-4,5,6 PREHEAT CN4-4,5,6 CN2-1 STARTER SWITCH CONNECTION 1-33,34,35 1-39 1-16 1-04 START FG001478 Figure 4 ENGINE PREHEAT CIRCUIT Reference Reference Description Description Number Number Battery Preheat Relay Battery Relay Air Heater Fusible Link Preheat Indicator Light Circuit Breaker Diode Starter Switch e-EPOS Controller...
Page 760: 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. NOTE: There is an individual injector solenoid (9) for each of the six cylinders.
Page 761 STARTER SWITCH CONNECTION START 0.5G 1-19 1-45 1-39 FG001473 Figure 6 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 SP000269 Page 19...
Page 762: 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 763: Monitoring System
MONITORING SYSTEM CHECK 02/05 [MO] 11:30 1700 E/G SPEED POWER AUTO FG000547 Figure 8 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...
Page 764: Instrument Panel
Instrument Panel CHECK 02/05 [MO] 11:30 1700 < CONNECTOR AND TERMINAL NO.> E/G SPEED AMP 040 28P POWER AUTO (CN7) (CN6) FG000548 Figure 9 Electrical System SP000269 Page 22...
Page 765 Gauges Warning Lights Mode Selector Switches Fuel Gauge Charge Warning Light 13. Power Mode Selector Switch and Indicator Engine Coolant Temperature Engine Oil Pressure Warning Gauge Light 14. Work Mode Selector Switch and Indicator Hydraulic Oil Temperature Coolant Temperature Gauge Warning Light 15.
Page 766: Monitoring System Schematic
Monitoring System Schematic CN6-1 CN6-3 ILL. CN6-2 CN6-12 CN6-11 CN6-9 CN6-10 WARNING LAMP CN2-1 L1 : CHARGE L2 : ENG OIL PRESS L3 : W/T OVER HEAT L4 : E/G WARNING L5 : PREHEAT L6 : WORK LAMP CN3-1 CN3-2 LCD DISPLAY PANEL WATER TEMPERATURE FUEL LEVEL...
Page 767 Reference Reference Description Description Number Number Instrument Panel Pilot Filter Switch Pilot Buzzer Return Filter Switch Light Switch Alternator Starter Switch e-EPOS Controller Front Pump Pressure Sensor Battery Rear Pump Pressure Sensor Battery Relay Hydraulic Oil Temperature Circuit Breaker Sensor Fusible Link Fuel Sensor Fuse Box...
Page 768: 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 FG000550 Blue 1/10 LCD (Red Zone) CN3-7 Blinking → over 5K ohms Fuel Level CN3-8 FULL → under 525 ohms 1/10 Full FG000552...
Page 769 Sensor Speciﬁcation Function Display Input Terminal Input Speciﬁcation N = 162 f / 60 ECU-CAN N = Engine speed (rpm) 1700 E/G SPEED Tachometer Communication f = Frequency of engine speed sensor (Hz) FG000049 28.0 BATTERY VOLT Voltmeter CN2-14 0 - 32 VDC FG000050 Main pump CN3-1...
Page 770: Warning And Indicator Lights
WARNING AND INDICATOR LIGHTS Indication of Warning Lights Input Description Symbol Operation Remarks Terminal It lights in case of no charge [voltage of Normally, it lights "R(I)" terminal is when starting engine Charge CN2 - 14 below 12 ±1V] or and is out after engine overcharge [voltage starts.
Page 771: Indication Of Multifunction Gauge And Letter Information
Input Description Symbol Operation Remarks Terminal It lights when work Work Light CN2 - 6 light turns "ON" (24V applied). HB4O2003 Indication of Multifunction Gauge and Letter Information Area Input Description Symbol Operation Remarks Terminal When hydraulic oil CN3-9 Hydraulic Oil temperature is above Temperature CN3-10...
Page 772 When pilot ﬁlter pressure is above Pilot Filter CN2-18 about 1 kg/cm∑ (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 773: 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 774: Graphic Information Area Display
GRAPHIC INFORMATION AREA DISPLAY Overview Many kinds of condition of machine are displayed on the letter information display department. The information display department is divided into two menus. One is main menu for user and the other is special menu for specialist. These menus can be moved from normal display mode by the combination of selector buttons.
Page 775: Main Menus For The Graphic Display Area
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 11): Move the cursor to up, left and previous screen.
Page 776: Main Menu
MAIN MENU When the "ESC" button is pressed for more than 3 seconds, the main menu screen is displayed. M A I N M E N U 1. Language Main menu offers sub-menus (language setting, time setting, or ﬁlter/oil information, brightness adjustment, password) to the 2.
Page 777: Set Clock
Set Clock M A I N M E N U It is used to adjust time of the digital clock. 1. Language Pressing the Enter Button ( , 3 on Figure 11) in the Main 2. Set Clock Menu after putting cursor on Set Clock brings Set Clock display. 3.
Page 778 Menu Display Order and Icon Explanation 1. Fuel Filter 2. Air Cleaner 3. Engine Oil Filter 4. Return Filter 5. Pilot Filter 6. Engine Oil 7. Pilot Filter 8. Coolant Water FG004977 Figure 19 Adjust Display M A I N M E N U Pressing the Enter Button ( , 3 on Figure 11) in the main 1.
Page 779 Set Password M A I N M E N U This menu is used to apply (lock), release, or change password. 1. Language Please refer to the Operation Manual for detailed information on 2. Set Clock Password Setting. 3. Filter / Oil Info 4.
Page 780 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 781 Special Menu Screen S P EC I A L M E N U NOTE: Displayed language on the special menu screen consists of Korean and English. 1. Machine Info If any language except for Korean is selected during 2. Failure Info language selection mode of main menu, only English will be displayed on special menu screen.
Page 782 Analog Inputs Description Analog Input Items Display Remark 1. Pump P/V Current in pump proportional valve. 2. Cooling Fan P/V Current in ﬂow control proportional valve. 3. Flow Control P/V Current in ﬂow control proportional valve. 4. Dial Indicating dial voltage. 5.
Page 783 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 784 Menu Select DIGITAL INPUT STATE DIGITAL INPUT STATE 1. Alternator 7. E/G Oil Press. SW 2. Travel Select SW 8. Air Cleaner Clogged 3. High Speed Sel. SW (M) 9. Return Filter Clogged 4. High Speed Sel. SW (A) 10. Pilot Filter Clogged 5.
Page 785 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." Lights up when the swing priority 3.
Page 786 Current failure information R E A LT I M E FA I L Current status of failure is displayed (Failure code, failure contents). CODE : V204-05 CODE : E011-04 When a number of failures are produced, failure information can be checked using "UP" ( , 1 on Relief Pressure Up S/V Figure 23) or "DOWN"...
Page 787 Input your password with one of No. 1 - 8 switches. DELETE FAIL LOG When "NO" (ESC, 4 on Figure 23) button is pressed, the screen will recover to previous menu without deletion. ENTER PASSWD : Yes ESC: No FG000568 Figure 36 Delete Completed screen will appear 3 seconds and the screen will move to Failure Info screen.
Page 788 Failure Information Code at Machine Side Correct Value Measuring Code Failure Component Remarks Points Active Passive CN7-4 It is a Gauge Panel Communication V201 R = 60 ±5 Ω composite Error CN7-5 resistance of CAN line. This value has to be CN4-4 measured by V202...
Page 789 Correct Value Measuring Code Failure Component Remarks Points Active Passive CN3-1 It has to be V220 Front Pump Press. Sensor V = 1V measured in CN3-2 engine stop CN3-3 state. V221 Rear Pump Press. Sensor V = 1V CN3-4 R = 2.45 ±0.25 kΩ...
Page 790 Failure Information Code at Engine Side Current Valve Measuring Code Failure Component Remarks Points Active Passive 2-36 R=186 ±5 Ω E011 Coolant temperature sensor (100°C 2-18 (212°F)) R=186 ±5 Ω 2-34 E012 Fuel temperature sensor (100°C 2-17 (212°F)) 2-29 R=186 ±5 Ω E013 Boost air temperature sensor (100°C...
Page 791 Current Valve Measuring Code Failure Component Remarks Points Active Passive 2-23 E043 E/G speed (Camshaft) 2-30 Synchronizing error between crank shaft E044 Engine speed sensor speed sensor and cam shaft speed sensor. Data storing E045 EEPROM error when engine stop. E046 Recovery When the...
Page 792 Current Valve Measuring Code Failure Component Remarks Points Active Passive Fuel metering Fuel HI pressure pump unit error of E083 (E/G: Current controlled high-pressure Highside power stage 1) pump. Power supply error System start-up test E091 shutoff path Engine controller error. Injector error Speed signal...
Page 793 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 794 Operating Hours Screen OPERATING HOURS Exiting Sub-menus: If escape button (ESC, 4 on Figure 23) is pressed for more than 1 second, this 1. Power : 00042 Hr information screen will be returned to previous 2. Trenching : 00003 Hr screen.
Page 795 Menu Selection of Operation Hour Information 2. Trenching Mode 3. Auto Idle 1. Power Mode 4. Travel Speed 1st, 2nd 6. Coolant Temperature Distribution 5. Hydraulic Oil Temperature Distribution FG000574 Figure 42 Example of Machine Operation Info Screen OPERATING HOURS OPERATING HOURS 1.
Page 796 Reset screen of operation hour OPERATING HOURS Exiting Sub-menus: If escape button (ESC, 4 on Figure 23) is pressed for more than 1 second, this information screen will be returned to previous All Operating screen. Hours will be NOTE: When "YES" ( , 3 on Figure 23) button is DELETED.
Page 797 Electrical System SP000269 Page 55...
Page 798 ELECTRONIC HYDRAULIC CONTROL SYSTEM (e-EPOS) Control System Schematic Work Mode Auto Idle Machine Info CHECK E/G speed order 02/05 [MO] 11:30 1700 E/G SPEED POWER AUTO 21 19 FG000795 Figure 49 Electrical System SP000269 Page 56...
Page 799 Reference Reference Description Description Number Number Instrument Panel Solenoid Valve (Swing Priority) 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...
Page 800 POWER MODE CONTROL POWER AUTO FG000796 Figure 50 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 Control Valve...
Page 801 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 802 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 803 FG000580 Figure 52 Reference Reference Description Description Number Number Engine Horsepower (hp) Pump Discharge Pressure (kg/ Engine Speed (rpm) Pump Discharge Volume (lpm) Electrical System SP000269 Page 61...
Page 804 Standard Mode Standard Mode is used for general work. When this mode is selected it will reduce noise and fuel consumption in comparison with Power Mode. The current to the E.P.P.R. valve is shut off and pump discharge volume is controlled by pump regulator.
Page 805 Electrical System SP000269 Page 63...
Page 806 POWER 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 1-35 1-34 1-33 CN1-10 P/V-(A) 1-53 1-52 CN1-21 VEHICLE 1-51 CONN (CONN.1) 1-03 1-09 CN3-15 +(5V) CW LOW 1-14 CN3-16 1-15 CN3-17 HIGH...
Page 807 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 SP000269 Page 65...
Page 808 WORK MODE CONTROL POWER AUTO FG000797 Figure 55 Reference Reference Description Description Number Number Instrument Panel (Trenching Aux Pump Mode Selector Switch) Control Valve e-EPOS Controller Solenoid Valve Engine Controller Engine Control Dial Main Pump Depending on the working condition, one of two work modes, "DIGGING"...
Page 809 Operation Digging Mode This mode is used for general digging work, loading work and ground leveling work requiring quick stops. The current to the solenoid valve for swing priority is shut off. Trenching Mode This mode is used for heavy duty ditch digging work or for loading work requiring big swing angles.
Page 810 WORK 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 (C5) CN1-13 CN1-8 CN1-9 AMP 070 18P AMP MIC 21P AMP 070 16P AMP 040 12P AMP 040 20P 9 8 7 18 17 21 20 19 18 17 16 15 14 13 12 11...
Page 811 ENGINE CONTROL SYSTEM (Drive Signal) (Command Signal) FG004980 Figure 58 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 812 ENGINE CONTROL DIAL 7th STEP 13th STEP 1st 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 59 Reference Description Number Knob Potentiometer (Variable Resistor) Electrical System SP000269...
Page 813 The engine control dial has a built in potentiometer. When the control knob is moved the output voltage (through "2 and 3" terminals) will vary from the 5 V supplied from the e-EPOS controller as shown in the graph. SP000269 Electrical System Page 71...
Page 814 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 1-35 1-34 1-33 1-53 1-52 VEHICLE 1-51 CONN CN2-15 (CONN.1) 1-03 1-09 CN3-15 +(5V) CW LOW 1-14 CN2-16 CN3-16 1-15 CN3-17 HIGH 1-01 1-07 1-12...
Page 815 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 SP000269 Page 73...
Page 816 AUTOMATIC DECELERATION CONTROL (AUTO IDLE CONTROL) POWER AUTO FG000798 Figure 61 Reference Reference Description Description Number Number Instrument Panel (Auto Idle Switch) Engine Control Dial e-EPOS Controller Pressure Switch Engine Controller Electrical System SP000269 Page 74...
Page 817 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 818 ENGINE OVERHEAT PROTECTION SYSTEM (Pump control signal) (E/G overheating signal) CHECK 02/05 [MO] 11:30 (E/G overheating signal) 1700 E/G SPEED POWER AUTO FG000802 Figure 62 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)
Page 819 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 820 POWER BOOST MODE Operation CHECK 02/05 [MO] 11:30 1700 E/G SPEED POWER AUTO FG000800 Figure 63 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 (Top of Right Aux Pump Work Lever) Control Valve...
Page 821 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 822 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 SHEAR BREAKER CN4-6 (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 823 Electrical System SP000269 Page 81...
Page 824 AUTOMATIC TRAVEL SPEED CONTROL FG000799 Figure 65 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 SP000269...
Page 825 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 826 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 16P AMP 040 12P AMP 040 20P AMP 070 18P AMP MIC 21P 6 5 4 15 14 11 10 9 19 18...
Page 827 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 67 Reference Reference Description Description Number Number Upper Digit Power Monitor (Stays "ON"...
Page 828 Normal Operation Display Readout Display Readout Mode Selection Operation Status Upper Digit Lower Digit Normal Operation Power Mode Power Mode HAOH340L Power Mode Normal Operation Standard Mode Standard Mode HAOH350L Normal Operation Digging Digging Mode HAOH370L Work Mode Normal Operation Trenching Trenching Mode HAOH380L...
Page 829 AIR CONDITIONER SYSTEM Outline FG000784 Figure 68 Solid-type heater and air conditioner are installed in the cover behind the driver's seat. Temperature of the driver's room is adjusted automatically to the temperature set by operator. SP000269 Electrical System Page 87...
Page 830 (Please refer to the Operation Manual for detailed whole automatic control. Vent mode selects the direction of discharged air. Outlets by vent modes Modes Outlets Internal and External Filters Internal and external air puriﬁcation ﬁlters are installed for the driver's room. Filters should be cleaned every 500 hours.
Page 831 Turn marked knobs (1, Figure 71) at the rear side of the cabin to open the cover. FG000441 Figure 71 Remove the ﬁlter attached to the cover and clean the contaminated ﬁlter using compressed air. Close the cover, replace the knobs, and secure the cover to the support with butterﬂy bolts.
Page 832 Air-Conditioning System Layout FG003919 Figure 73 Reference Reference Description Description Number Number Air Conditioner/heater Unit Liquid Hose (1) Condenser Liquid Hose (2) Compressor Ambient Temperature Sensor Receiver Dryer Sun Sensor Discharge Hose Control Panel Suction Hose Electrical System SP000269 Page 90...
Page 833 Air Conditioner/Heater Circuit Diagram 0.5RW FUSIBLE LINK LAMP SWITCH STARTER SWITCH BATTERY RELAY AIRCON UNIT BATT. A/C CONTROL PANEL 1.25LR CN11-2 LED 1~12 130C CN9-6 0.85LR CN10-8 CN9-11 0.5WR CN10-18 CN9-5 1.25LR 0.85BW 0.85LR RECEIVER DRIER BLOWER RELAY RELAY COMPRESSOR 168B CN8-10 CN10-16...
Page 834 Air Conditioner/Heater Unit Air Flow Diagram External Air Inlet Cold Box Internal Air Inlet Outlet Vent Rear Outlet Vent Front Outlet Foot Outlet Outlet External Air VENT COOL DOOR -INTAKE DOOR -MIX Internal Air WARM Heater Evaporator Core FOOT FG001359 Figure 75 Electrical System SP000269...
Page 835 Door Open by Vent Modes Mode Door Vent Bi-level Foot Def/foot Vent Foot Main Components Air Flow Actuator Blower Blower Duct Control - Internal/external Relay Motor Actuator Sensor Module Air Exchanger - Temp Relay Control Internal Internal Air Sensor Air Filter Actuator Water Temp Evaporator...
Page 836 FG001361 Figure 77 Actuator - Wind direction control Wind Direction Mode Output Terminal Voltage Vent 0.5 ±0.2V Bi-level 1.3 ±0.2V c(+): CN10-10 Foot 2.45 ±0.2V b(-): CN10-4 Foot/def 3.5 ±0.2V 4.5 ±0.2V Actuator - Temp control Set Temp Output Terminal Voltage Max cooling c(+): CN10-9...
Page 837 Actuator - Internal/external air exchange CN10-20 CN10-2 FG001055 Figure 78 Sel mode Output Terminal Output Internal Air Moving of exchange door P1(+), P2(-) by selecting external air External Moving of exchange door P1(-), P2(+) by selecting internal air Air Flow Control Module Air ﬂow is controlled through the control of voltage between GATE and SOURCE.
Page 838: Relay - Blower
Relay - Blower Power is supplied to the blower motor when the system is turned Speciﬁcations Rated voltage Rated current Figure 80 Relay - A/C Power is supplied to the magnetic clutch of the compressor. Speciﬁcations Rated voltage Rated current FG001058 Figure 81 Duct Sensor...
Page 839: Water Temp Sensor
Water Temp Sensor It senses the temperature of coolant water in the heater core. Temp (°C) Resistance (KΩ Ω Ω Ω ) 55.8 ±1.7 32.9 ±0.9 15.76 ±0.5 10.0 ±0.3 6.5 ±0.2 Figure 83 Internal Air Temp Sensor Built in the internal air ﬁlter, it senses the internal temperature. Temp (°C) Resistance (KΩ...
Page 840: Sun Sensor
Sun Sensor Built beside the socket of spare power, it senses the quantity of the sun radiation to optimize discharge temperature and air ﬂow as set by driver. 83.7 76.2 67.7 58.8 46.6 36.0 21.4 1.0 2.0 3.0 4.0 5.0 6.0 7.0 LUX(x10,000) FG001062 Figure 86...
Page 841 Terminal Terms Term No. Terms Term No. Terms Temperature control Water temperature (warm) sensor Sensor ground Duct sensor Temperature control Sun sensor Power (5V) Mix feedback Ambient air temperature sensor Power (KEY "ON") Internal air temperature sensor Back-up A/C output (LOW) Ground D.P.S CHECK Illumination...
Page 842 Categories Inputs System Operation Sensor Set temperature In case of sensor failure, following defaults are applied: compensatio Internal air temperature Internal air temperature sensor: 25°C, Ambient air sensor temperature sensor: 25°C, Duct sensor: -2°C Ambient air temperature Temperature control actuator: sensor - Set Temperature 17 - 24.5°C: Max cooling, Set Water temperature sensor...
Page 843 Categories Inputs System Operation Start condition (AND condition) (1) When wind direction mode is one of the following modes in the Auto or manual control mode - BI-LEVEL, FOOT or FOOT/DEF (2) The Water temperature sensor is stable and the water temperature <...
Page 844 Categories Inputs System Operation Starting Water temperature sensor Entry condition (AND condition) control of Ambient air temperature (1) Auto Mode heating (2) sensor (2) Ambient air temperature < 5°C and difference between Internal air temperature ambient and internal air temperature ??5°C sensor (3) Failure of water temperature sensor Auto mode...
Page 845 Self Diagnosis How to start self diagnosis Starter Switch ON Set temp to 25 C Set temp to 77 F Press the SEL switch more than 3 times in 5 secs while pressing the A/C switch Auto diagnosis starts after every graphic in LCD displays twice every 0.5 sec.
Page 846 Error codes Code Description Normal Internal Air Temp Sensor Short Internal Air Temp Sensor Open Ambient Air Temp Sensor Short Ambient Air Temp Sensor Open Duct Sensor Short Duct Sensor Open Sun Sensor Short Sun Sensor Open Water Temp Sensor Short Water Temp Sensor Open D.P.S OPEN Position Error of Wind Direction...
Page 847: Compressor
Volume of refrigerant by model Model Volume of refrigerant (g) kgf/cm DX300LC 800 ± 20 kgf/cm DX340LC 800 ± 20 DX420LC 800 ± 20 FG003921 DX480LC 800 ± 20 Figure 92 DX520LC 800 ± 20 SP000269 Electrical System Page 105...
Page 848: Control Of Cooling Fan
CONTROL OF COOLING FAN Control of Cooling Fan Speed The e-EPOS controller controls the speed of the cooling fan to the optimum rotation according to temperature by comparing temperatures of active oil detected by the active oil temperature sensor and of the engine coolant by the engine controller and controlling current of the cooling fan speed control valve.
Page 849: Cooling Fan Control Circuit
Cooling Fan Control Circuit BR B Figure 93 Reference Reference Description Description Number Number Start Switch Engine Controller Hydraulic Oil Temperature Coolant Temperature Sensor Sensor Cooling Fan Speed Control Valve e-EPOS Controller Work interrupt switch Battery Cooling Fan Reverse Rotation Battery Relay Switch Circuit Braker...
Page 850: 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 851: Wiper Operation
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 852 - Stopping the intermittent action Pressing three times the Intermittent switch in the switch panel (7) while the wiper is operating stops the action of the wiper motor. NOTE: The wiper system does not work when the wiper cutoff switch (9) is "ON." Electrical System SP000269 Page 110...
Page 853 Electrical System SP000269 Page 111...
Page 854: 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 SP000269 Page 112...
Page 855: Kind Of Light
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 856: 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 96 Reference Reference Description Description Number Number Battery Audio Control Panel Battery Relay Stereo Fuse Box...
Page 857 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 SP000269 Electrical System Page 115...
Page 858 Electrical System SP000269 Page 116...
Page 859 SP000275 ELECTRICAL SCHEMATIC (DX420LC)SP000275 Electrical Schematic (DX420LC) Edition 1 Electrical Schematic (DX420LC) SP000275 Page 1...
Page 860 MEMO SP000275 Electrical Schematic (DX420LC) Page 2...
Page 861 Table of Contents Electrical Schematic (DX420LC) Safety Precautions..........5 Applicable Models..........5 General Description..........7 DX420LC .............. 8 Electrical Schematic (DX420LC) SP000275 Page 3...
Page 862 MEMO SP000275 Electrical Schematic (DX420LC) Page 4...
Page 863: Electrical Schematic
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up SP000275 Electrical Schematic (DX420LC) Page 5...
Page 864 Electrical Schematic (DX420LC) SP000275 Page 6...
Page 865: General Description
0.85GB 2-PUMP SWITCH 153A 1-16 0.85W (AIR HEATER RELAY) 0.85W 0.85W 0.85W (549-00101/K1002406DXX) 180H 0.85BrW 180E 154B 1-04 0.85BG (AIR HEATER RELAY) 0.85BG 0.85BG 0.85BG DA3-3 0.85GB 0.85GB 0.85GB 0.85GB (CONN.2) (CONN.1) Figure 1 SP000275 Electrical Schematic (DX420LC) Page 7...
Page 866: Dx420Lc
HIGH 0.5GBr 0.5GBr 1-12 0.85RW 1-13 0.85RW 0.5Br 0.5Br 1-39 0.5Br (KEY SW) 0.85W 0.85W 153A 1-16 0.85W (AIR HEATER RELAY) 154B 0.85BG 0.85BG 1-04 0.85BG (AIR HEATER RELAY) 0.85GB (CONN.2) (CONN.1) Figure 2 Electrical Schematic (DX420LC) SP000275 Page 8...
Page 867 A/C CONTROL PANEL (420-00468 ) (543-00107 ) 0.5WR (ON JOYSTICK R.H) 0.5WR 0.85RY 179B 2-PUMP S/V 180A 180F 180C 0.5GBr 0.85BrW 0.85BrW 0.5WR 0.5B DIODE 8 0.5Br 0.85GB 2-PUMP SWITCH 0.85W (549-00101/K1002406DXX) 0.85BG DX420LC 0.85GB 0.85GB Electrical Schematic (DX420LC) SP000275 Page 9...
Page 868 Electrical Schematic (DX420LC) SP000275 Page 10...
Page 869 Attachments...
Page 871 SP000463 BOOM AND ARM SP000463 Boom and Arm Edition 1 Boom and Arm SP000463 Page 1...
Page 872 MEMO SP000463 Boom and Arm Page 2...
Page 873 Table of Contents Boom and Arm Safety Precautions..........5 Applicable Models..........5 Front Attachment Pin Speciﬁcations..... 6 Front Attachment - Removal and Installation..8 Arm Removal Procedure ..........8 Boom Removal Procedure ..........10 Installation ............11 Arm Installation Procedure ..........11 Boom Installation Procedure .........
Page 874 MEMO SP000463 Boom and Arm Page 4...
Page 875: Boom And Arm
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX420LC 5001 and Up SP000463 Boom and Arm Page 5...
Page 876: Front Attachment Pin Specifications
NOTE: Some mounting pins must be drilled and tapped for lubrication ﬁttings and piping, or may have other required speciﬁcations. Consult DOOSAN After Sales Service for information on wear tolerances and replacement limits for mounting pins. FG004069...
Page 877 Criteria Mark Measuring Part Tolerance Remedy Standard Standard Clearance Size Clearance Limit Hole 120 mm -0.10 +0.18 Boom Foot 0.13 ~ 0.33 (4.724") -0.15 +0.03 110 mm -0.10 +0.18 Boom Cylinder Head 0.13 ~ 0.33 (4.331") -0.15 +0.03 120 mm -0.10 +0.18 Boom Center...
Page 878: Front Attachment - Removal And Installation
FRONT ATTACHMENT - REMOVAL AND INSTALLATION DANGER! DOOSAN warns any user, that the removal of the counterweight from the machine, front attachment or any other part, may affect the stability of the machine. This could cause unexpected movement, resulting in death or serious injuries.
Page 879 Park the excavator away from obstructions and all trafﬁc on clear, ﬂat, level ground. Extend the arm cylinder and crowd the arm into the boom. Partially retract the boom cylinder so that the boom is stretched out in front of the excavator, as low to the ground as possible, with the arm crowded under the boom.
Page 880: Boom Removal Procedure
Remove retainers on the end of the mounting pin for the arm cylinder rod end. Use the assist crane to relieve the weight load and withdraw the pin. Lower the arm down to the blocking support for any continued disassembly procedures. Boom Removal Procedure NOTE: Boom removal may be simpliﬁed if the shell of the...
Page 881: Installation
Diagrams and Weights of Materials sections in the Operation and Maintenance Manual. Consult your dealer or DOOSAN After Sales Service for more information if you have any questions or require more information. Begin with the arm securely supported on blocking in front of the excavator.
Page 882 Boom and Arm SP000463 Page 12...
Page 883 SP000072 BUCKET SP000072 Bucket Edition 1 Bucket SP000072 Page 1...
Page 884 MEMO SP000072 Bucket Page 2...
Page 885 Table of Contents Bucket Safety Precautions..........5 Applicable Models..........5 Bucket Tooth Inspection and Replacement... 6 Bucket O-ring Replacement........7 Bucket Shimming Procedures ......9 New Bucket Installation ........... 9 Bucket Attachment, Removal and Reversal..11 Detaching the Bucket ............ 11 Attaching the Bucket............
Page 886 MEMO SP000072 Bucket Page 4...
Page 887: Safety Precautions
Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 5001 and Up DX340LC 5001 and Up DX420LC 5001 and Up SP000072 Bucket Page 5...
Page 888: Bucket Tooth Inspection And Replacement
BUCKET TOOTH INSPECTION AND REPLACEMENT There are several different types of attachment methods for replaceable bucket teeth. Some of the most common types are shown in the following drawings. Bucket teeth are usually replaced in sets but it may sometimes be necessary to replace individual teeth.
Page 889: Bucket O-Ring Replacement
BUCKET O-RING REPLACEMENT WARNING! Due to possibility of ﬂying metal objects, always wear safety helmet, protective gloves and eye protection when changing pins. Inspect the bucket O-rings on a routine basis. If worn or damaged, replacement is necessary. ARO1350L Figure 3 Roll the old O-ring (1, Figure 4) onto the boss (2) around the bucket pin (3).
Page 890 Roll the new O-ring (1, Figure 6) into the O-ring groove. ARO1392L Figure 6 Bucket SP000072 Page 8...
Page 891: Bucket Shimming Procedures
BUCKET SHIMMING PROCEDURES New Bucket Installation WARNING! When performing this adjustment, put the hydraulic cativation control lever in the LOCKED position and stop the engine. Improperly adjusted clearance could cause galing on the contact surfaces of the bucket and arm, resulting in excessive noise and damaged O-ring.
Page 892 Shimming Procedures for Installed Bucket The clearance of the bucket linkage on this machine can be adjusted by shimming. If the gap between the bucket and the arm becomes excessive, adjust bucket clearance to 1.0 mm. The thickness of the shims are 1.0 mm (0.04 inch) Position the machine on a level surface and lower the bucket to the ground.
Page 893: Bucket Attachment, Removal And Reversal
BUCKET ATTACHMENT, REMOVAL AND REVERSAL Detaching the Bucket Park the excavator away from obstructions on clear, ﬂat, level ground. Lower the bucket carefully to preassembled blocking on the ground. Brace the bucket so that there is no load weight on the pin connecting the bucket and arm.
Page 894: Reversing The Bucket
When the link pin has been installed, withdraw the temporary support rod from the bucket pin holes, lower and raise the arm and boom and install the bucket pin. WARNING! When making linkage alignments, never insert ﬁngers into pin holes. The attachment or bucket could shift position and cause a severe injury.

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