Doosan DX350LC Instructions Manual
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Doosan DX350LC Instructions Manual

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Table of Contents

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DX300LCA
Shop Manual
950106-00075E
Serial Number 5001 and Up
DOOSAN reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
950106-00075E Shop Manual
Copyright 2010 DOOSAN

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Summary of Contents for Doosan DX350LC

  • Page 1 950106-00075E 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. 950106-00075E...
  • Page 5 Table of Contents Safety Track Excavator Safety................. SP002025 Specifications Specification for DX300LCA ..............SP002026 General Maintenance General Maintenance Procedures ............SP000016 Standard Torques ................. SP000813 Upper Structure Cabin ....................SP001737 Counterweight..................SP001748 Fuel Tank....................SP002027 Fuel Transfer Pump (Opt)..............SP000021 Swing Bearing..................
  • Page 6 Remote Control Valve (Work Lever / Joystick) ........SP000069 Travel Control Valve (With Damper)............. SP001743 Solenoid Valve Assembly ..............SP001622 Breaker EPPR Valve (Opt) ..............SP000192 Hydraulic Schematic DX300LC/DX300LCA ......... SP001752 Electrical System Electrical System .................. SP002030 Electrical Schematic DX300/340/350LC/DX300LCA......SP002031 Attachments Boom and Arm..................
  • Page 7 Safety...
  • Page 9 SP002025 TRACK EXCAVATOR SAFETYSP002025 Track Excavator Safety Edition 1 Track Excavator Safety SP002025 Page 1...
  • Page 10 MEMO Track Excavator Safety SP002025 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 Excavator.... 6 General Safety Essentials ........9 Location of Safety Labels ........10 Summary of Safety Precautions for Lifting in Digging Mode .............
  • Page 12 MEMO Track Excavator Safety SP002025 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 DX300LCA 5001 and Up Track Excavator Safety SP002025 Page 5...

  • Page 14: To The Operator Of A Doosan Excavator

    TO THE OPERATOR OF A DOOSAN 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 sent. If this machine has been purchased in another...
  • Page 16 Safety precautions are described in SAFETY from page -10 on. DOOSAN cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions.

  • Page 17: 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 18: 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. SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING IN DIGGING MODE DANGER Unsafe use of the excavator while making rated lifts could...

  • Page 19: Unauthorized Modifications

    UNAUTHORIZED MODIFICATIONS Any modification made without authorization or written approval from DOOSAN can create a safety hazard, for which the machine owner will be held responsible. For safety's sake, replace all OEM parts with the correct authorized or genuine DOOSAN part. For example, not taking...
  • Page 20 Safety Features Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired immediately if damaged. Be sure that you understand the method of use of safety features such as safety lock lever and the seat belt, and use them properly.
  • Page 21 Clothing and Personal Protective Items Secure long hair, and avoid loose clothing and jewelry. These items have the tendency to catch on controls or protrude into parts and cause serious injury or death. Do not wear oily clothes. They are highly flammable. Full eye protection, a hard hat, safety shoes and gloves may be required at the work site.
  • Page 22 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 23 Mounting and Dismounting Before getting on or off the machine, if there is any oil, grease, or mud on the handrails, steps, or track shoes, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts. Never jump on or off the machine.
  • Page 24 Precautions When Handling Fluids at High Temperature Immediately after operations are stopped, the coolant, engine oil, and hydraulic oil are at highest temperatures and the radiator and hydraulic tank are still under pressure. Attempting to remove cap, drain the oil or coolant, or replace the filters may lead to serious burns.
  • Page 25 Injury from Work Equipment Do not enter or put your hand, arm or any other part of your body between movable parts, such as between the work equipment and cylinders, or between the machine and work equipment. If the control levers are operated, the clearance between the machine and the work equipment will change and this may lead to serious damage or personal injury.
  • Page 26 If any glass on the machine is broken, replace it with new glass immediately. Attachment Precautions Option kits are available through your dealer. Contact DOOSAN for information on available one-way (single-acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because...
  • Page 27 When carrying out disassembly or maintenance of accumulator, when disposing accumulator, the charged gas must be properly released. Contact your DOOSAN distributor. • Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil under pressure can penetrate the skin and cause serious injuries.

  • Page 28: Before Starting Engine

    BEFORE STARTING ENGINE Work Site Precautions Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. Check the terrain and condition of the ground at the work site, and determine the best and safest method of operation. Make sure the ground surface is as hard and horizontal as possible before carrying out operations.
  • Page 29 Avoid operating your machine to close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground collapses, the machine could fall or tip over resulting in serious injury or death. Remember that soil after heavy rain, blasting or after earthquakes, is weakened.
  • Page 30 Engine Starting Walk around your machine before getting in the operator's cabin. Look for evidence of leaking fluid, loose fasteners, misaligned assemblies or any other indications of possible equipment hazard. All equipment covers and machinery safety guards must be in place, to protect against injury while the machine is being operated.
  • Page 31 Before Operating Machine If checks are not carried out properly after starting the engine, it may result in a delay in discovering abnormalities in the machine, and this may lead to personal injury or damage to the machine. Carry out the checks in an open area where there are no obstructions.

  • Page 32: Machine Operation

    MACHINE OPERATION When Swinging or Changing Direction of Travel Before operating the machine or the work equipment, always observe the following precautions to prevent serious injury or death. • Start and operate the machine only while seated. • When changing travel direction of travel from forward to reverse or from reverse to forward, reduce speed early and stop the machine before changing travel HAOA190L...
  • Page 33 Travel Precautions TRAVEL POSTURE Never turn the starting switch to the "O" (OFF) position when traveling. It is dangerous if the engine stops while the machine is traveling. It will be impossible to operate the steering. Attachment control levers should not be operated while traveling.
  • Page 34 Traveling on Slopes Never jump onto a machine that is running away to stop it. There is a 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 35 Prohibited Operations Do not dig the work face under an overhang. This may cause the overhang to collapse and fall on top of the machine. FG000368 Figure 19 Do not carry out deep digging under the front of the machine. The ground under the machine may collapse and cause the machine to fall.
  • Page 36 Precautions for Operation Be careful not to mistakenly travel too close to the edge of a cliff. Use the machine only for its main purpose. Using it for other purposes will cause failures. To ensure a good view, always do the following: •...
  • Page 37 Protecting Cabin from Falling Object (Optional) In a work site where falling objects or flying objects are expected, be sure to install adequate protective devices for covering the cabin. When using a breaker, be sure to install the front window protection guard (Figure 24).
  • Page 38 Operations on Slopes When working on slopes. there is a danger that machine may lose its balance and turn over, when swinging, or when work equipment is operated. Always carry out these operations carefully. Do not swing the work equipment from the uphill side to the downhill side when the bucket is loaded.

  • Page 39: Maintenance

    OSHA certified lockout device and a length of chain or cable to keep the safety lever in the fully when performing inspection lowered, nonactive position. Warning tags, for controls are available from DOOSAN 190-00695A distributors. FG012195...
  • Page 40 Proper Tools Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools could cause personal injury. There is a danger that pieces from, chisels with crushed heads, or hammers, may get into your eyes and cause blindness. HDO1037L Figure 31 Use of Lighting...
  • Page 41 Burn Prevention When checking the radiator coolant level, shut down engine, let the engine and radiator cool down, then check the coolant recovery tank. If the coolant level in the coolant recovery tank is near the upper limit, there is enough coolant in the radiator. Loosen the radiator cap gradually to release the internal pressure before removing the radiator cap.
  • Page 42 Warning for Counterweight and Front Attachment Removal DANGER DOOSAN warns any user, that removal of the counterweight from the machine, front attachment or any other part, may affect the stability of the machine. This could cause unexpected movement, resulting in death or serious injuries.
  • Page 43 Precautions for Removal, Installation, and Storage of Attachments Before starting removal and installation of attachments, decide on the team leader. Do not allow anyone except the authorized workers close to the machine or attachment. Place attachments that have been removed from the machine in a safe place so they do not fall.
  • Page 44 Prevention of Crushing and Cutting You should always have at least two people working together if the engine must be run during service. One person needs to remain in the operator's seat, ready to work the controls or stop the machine and shut off the engine. Unless you are instructed otherwise, never attempt adjustments while the machine is moving or while the engine is running.
  • Page 45 If necessary depending on the type of failure, please contact your DOOSAN distributor for repairs. Precautions with High-pressure Lines, Tubes and Hoses When inspecting or replacing high-pressure piping or hoses, check to verify that pressure has been released from the circuit.
  • Page 46 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 47: 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 48 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 49: Towing

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

  • Page 50: 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 51 Specifications...
  • Page 53 SP002026 SPECIFICATION FOR DX300LCASP002026 Specification for DX300LCA Edition 1 Specification for DX300LCA SP002026 Page 1...
  • Page 54 MEMO Specification for DX300LCA SP002026 Page 2...
  • Page 55 Performance Tests ..........20 Excavator Performance Standards..... 21 Test Conditions ............. 21 Travel Speed and Travel Motor Balance (Steering Deviation) Tests ............21 Swing Speed and Deceleration Force Test ....23 Cylinder Performance Tests .......... 25 Specification for DX300LCA SP002026 Page 3...
  • Page 56 MEMO Specification for DX300LCA SP002026 Page 4...

  • Page 57: 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 DX300LCA 5001 and Up Specification for DX300LCA SP002026 Page 5...
  • Page 58 Specification for DX300LCA SP002026 Page 6...

  • Page 59: 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.) Specification for DX300LCA SP002026 Page 7...

  • Page 60: Component Locations

    COMPONENT LOCATIONS 11 12 FG000671 Figure 1 Specification for DX300LCA SP002026 Page 8...
  • Page 61 Air Cleaner Lower Roller Swing Bearing Center Joint Seat Upper Roller Cabin Sprocket Boom Cylinder Travel Motor Work Lever (Joystick) Controls Track Link and Shoe Arm Cylinder Suction Filter Boom Return Filter Travel Lever Pumps SP002026 Specification for DX300LCA Page 9...

  • Page 62: General Dimensions

    3,475 mm (11' 5") 2,960 mm (9' 9") 1,500 mm (4' 11") 1,460 mm (4' 9") 2,600 mm (8' 6") 3,200 mm (10' 6") 600 mm (23.62 in) 500 mm (19.69 in) 3,065 mm (10' 1") Specification for DX300LCA SP002026 Page 10...
  • Page 63 Specification for DX300LCA SP002026 Page 11...

  • Page 64: 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. FG001449 Figure 2 Specification for DX300LCA SP002026 Page 12...
  • Page 65 (9' 7") 625 mm 1,995 mm - 305 mm Min. Digging Reach (2' 1") (6' 7") (- 1' 0") 4,055 mm 4,060 mm 4,060 mm Min. Swing Radius (13' 4") (13' 4") (13' 4") Specification for DX300LCA SP002026 Page 13...

  • Page 66: General Specifications

    (6.1 psi) Optional 850 mm (33.5") shoe - 0.41 kg/cm (5.8 psi) Transport Dimensions Overall Shipping Length 10,620 mm (34' 10") (standard boom and arm) Overall Shipping Width 3,200 mm (10' 6") (standard shoes) Specification for DX300LCA SP002026 Page 14...
  • Page 67 Track Shipping Length 4,940 mm (16' 2") Transport Trailer Capacity 30 tons (33 short tons), minimum load capacity Transport Loading Ramp Allowable 15° angle CAUTION: Refer to Transport Maximum Procedure for Safe Slope Shipping Instructions. Specification for DX300LCA SP002026 Page 15...

  • Page 68: Engine Performance Curves (Per Din 6270 Standard)

    ENGINE PERFORMANCE CURVES (PER DIN 6270 STANDARD) 1000 1500 2000 REVOLUTION (rpm) FG015470 Figure 3 Specification for DX300LCA SP002026 Page 16...
  • Page 69 Performance Standard KS R1004 200 ps @ 1,900 rpm Power (197 hp @ 1,900 rpm) 86 kg•m @ 1,300 rpm Max. Torque (620 ft lb @ 1,300 rpm) 165 g/ps•h Fuel Consumption (Rated) (5.90 oz/hp•h) Specification for DX300LCA SP002026 Page 17...

  • Page 70: 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 DX300LCA SP002026 Page 18...
  • Page 71 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 Specification for DX300LCA SP002026 Page 19...

  • Page 72: Performance Tests

    14.3 ± 1.0 Travel Speed 20 m (66 ft) 25.5 ± 1.5 24.2 ± 1.5 High mm (in) 150 (6) 150 (6) Travel Deviation 20 m (66 ft) mm (in) 150 (6) 150 (6) Specification for DX300LCA SP002026 Page 20...

  • Page 73: 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. Specification for DX300LCA SP002026 Page 21...
  • Page 74 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 DX300LCA SP002026 Page 22...

  • Page 75: Swing Speed And Deceleration Force Test

    3 full 360° rotations. The time required for 3 revolutions should be between 15.5 and 17.5 seconds in Standard Mode, 15.5 and 17.5 seconds in Power Mode. Specification for DX300LCA SP002026 Page 23...
  • Page 76 Maximum distance should be less than 1200 mm (47-1/4"), in both Power Mode and Standard Mode. Reference Description Number Start Swing 90° Swing FG000659 Swing Force Figure 7 Swing Stop Specification for DX300LCA SP002026 Page 24...

  • Page 77: Cylinder Performance Tests

    Operation Standard Mode Power Mode High Speed 21.8 - 23.8 sec 20.2 - 23.2 sec Low Speed 37.8 - 40.8 sec 35.3 - 39.3 sec Specification for DX300LCA SP002026 Page 25...
  • Page 78 Specification for DX300LCA SP002026 Page 26...
  • Page 79 General Maintenance...
  • Page 81 SP000016 GENERAL MAINTENANCE PROCEDURES SP000016 General Maintenance Procedures Edition 1 General Maintenance Procedures SP000016 Page 1...
  • Page 82 MEMO SP000016 General Maintenance Procedures Page 2...
  • Page 83 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 84 MEMO SP000016 General Maintenance Procedures Page 4...

  • Page 85: Safety Precautions

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

  • Page 86: 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 87: 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 88 When starting the engine (particularly after long layoff or storage intervals), make sure that all hydraulic controls and operating 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.

  • Page 89: 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 90: Hydraulic System Cleanliness And Oil Leaks

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

  • Page 91: 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 92: 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 93: Bearing Inspection

    Curling under of any seal lip will seriously impair its efficiency. Apply a thin coat of Loctite #120 to outer diameter, of metal casing, on oil seals to assure an oil tight fit into retainer. Use extreme care not to get Loctite on lips of oil seals.
  • Page 94 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 95 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 96 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 97 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 98 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 99 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 100 General Maintenance Procedures SP000016 Page 20...
  • Page 101 SP000813 STANDARD TORQUESSP000813 Standard Torques Edition 1 Standard Torques SP000813 Page 1...
  • Page 102 MEMO Standard Torques SP000813 Page 2...
  • Page 103 Table of Contents Standard Torques Safety Precautions ..........5 Applicable Models ..........5 Torque Values for Standard Metric Fasteners..6 Torque Values for Standard U.S. Fasteners ..7 Type 8 Phosphate Coated Hardware ....9 Torque Values for Hose Clamps ......10 Torque Values for Split Flanges ......
  • Page 104 MEMO Standard Torques SP000813 Page 4...

  • Page 105: Safety Precautions

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

  • Page 106: 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 107: 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 108 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 109: 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 110: 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 111: 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 112: Torque Wrench Extension Tools

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

  • Page 113: Other Uses For Torque Wrench Extension Tools

    NOTE: The formula assumes that there is no added deflection or "give" in the joint between the extension torque wrench. Readings also inaccurate: • If the extension itself absorbs some of the tightening force and starts to bend or bow out. •...

  • Page 114: Tightening Torque Specifications (Metric)

    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 115 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 116 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 117 Upper Structure...
  • Page 119 SP001737 CABIN SP001737 Cabin Edition 1 Cabin SP001737 Page 1...
  • Page 120 MEMO Cabin SP001737 Page 2...
  • Page 121 Table of Contents Cabin Safety Precautions ..........5 Applicable Models ..........5 Removal ............... 6 Installation ............10 Cabin SP001737 Page 3...
  • Page 122 MEMO Cabin SP001737 Page 4...

  • Page 123: Cabin

    APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327 and Up...

  • Page 124: 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 125 12. Remove floor mat (1, Figure 2). 13. Remove seat (2, Figure 2). NOTE: Be careful not to damage seat covering. 14. Remove cup holder (3, Figure 2). Remove front cover (4, Figure 2) and side covers (5 and 6, Figure 2).
  • Page 126 20. Remove air ducts (1, 2, 3 and 4, Figure 5) from cabin rear panel. 21. Remove across bar (5, Figure 5) between left and right side of cabin. Figure 5 22. Remove air ducts (1, 2, 3, 4 and 5, Figure 6) right side of cabin step by step from the front duct.
  • Page 127 27. Using a suitable lifting device, attach slings to four lift points on top of cab (Figure 8). NOTE: Cabin weights approximately 315 kg (700 lb). 28. Lift cab from 25 ~ 50 mm (1" ~ 2") above deck height. Check that electrical...

  • Page 128: Installation

    INSTALLATION Using a suitable lifting device, attach slings to four lift points on top of cab (Figure 9). NOTE: Cabin weights approximately 315 kg (700 lb). Lower cab into position on cab floor. Figure 9 Install four mounting nuts from four corners of cabin floor (1, Figure 10).
  • Page 129 Install across bar (5, Figure 12) between left and right side of cabin. 10. Install air ducts (1, 2, 3 and 4, Figure 12) from cabin rear panel. Figure 12 11. Install electric box (4, Figure 13). 12. Install cassette bracket (2, Figure 13) and connet antenna and speaker wire.
  • Page 130 16. Install front cover (4, Figure 15), and side covers (5 and 6, Figure 15), when install cover (4, Figure 15) connect hour meter connector. 17. Install seat (2, Figure 15). NOTE: Be careful not to damage seat covering. 18. Install floor mat (1, Figure 15). 19.
  • Page 131 SP001748 COUNTERWEIGHT SP001748 Counterweight Edition 1 Counterweight SP001748 Page 1...
  • Page 132 MEMO Counterweight SP001748 Page 2...
  • Page 133 Table of Contents Counterweight Safety Precautions ..........5 Applicable Models ..........5 General..............6 Warning for Counterweight and Front Attachment Removal6 Removal ............... 8 Installation ............9 Counterweight SP001748 Page 3...
  • Page 134 MEMO Counterweight SP001748 Page 4...

  • Page 135: 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 7440 and Up DX300LCA 5001 and Up Counterweight SP001748 Page 5...

  • Page 136: 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 137 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 138: Removal

    REMOVAL Park on firm and level ground. Lower front attachment (bucket) to the ground. Shut down engine. Set safety lever on "RELEASED" position. Turn starter switch to "I" (ON) position. WARNING when performing inspection WARNING 190-00695A FG014348 If engine must be run while performing maintenance, Figure 3 use extreme care.

  • Page 139: Installation

    Figure 5 Model Bolt Torque DX300LC 250 kg•m (1,807 ft lb) DX300LCA Remove lifting device and lifting eyes from counterweight lifting holes (5, Figure 5). Install engine compartment cover. Connect negative (-) battery cable to battery. Counterweight SP001748...
  • Page 140 Counterweight SP001748 Page 10...
  • Page 141 SP002027 FUEL TANK SP002027 Fuel Tank Edition 1 Fuel Tank SP002027 Page 1...
  • Page 142 MEMO Fuel Tank SP002027 Page 2...
  • Page 143 Table of Contents Fuel Tank Safety Precautions ..........5 Applicable Models ..........5 General Description ..........6 Parts List ................. 6 Specifications ..............7 Removal ............... 8 Installation ............12 Start-up Procedures ........... 15 Fuel Tank SP002027 Page 3...
  • Page 144 MEMO Fuel Tank SP002027 Page 4...

  • Page 145: 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 DX300LCA 5001 and Up Fuel Tank SP002027 Page 5...

  • Page 146: General Description

    GENERAL DESCRIPTION WARNING Engine fuel is highly flammable and potentially explosive. To prevent possible injury and/or damage to equipment, extinguish or move to a safe distance all potential fire hazards. Parts List FG000470 Figure 1 Fuel Tank SP002027 Page 6...

  • Page 147: Specifications

    Reference Reference Description Description Number Number Fuel Tank Fuel Strainer O-ring Cover Level Gauge Bolt Spacer Spring Washer Bolt Drain Valve Clip Bolt Fuel Sender Shim Bolt Shim Spring Washer Specifications Fuel tank capacity is 500 liters (132 U.S. gal). SP002027 Fuel Tank Page 7...

  • Page 148: Removal

    REMOVAL Look at fuel level display (Figure 2) on instrument panel in operator's cabin to see what it displays. The display is divided into ten separated segments, each representing 10 percent of total fuel supply. Also, look at level gauge on side of tank to estimate volume of fuel left in tank.
  • Page 149 12. Clean area around fuel tank fill cap (11, Figure 5). Open fuel cap. FG003871 Figure 5 13. Place a large enough container under fuel tank to collect remaining fuel. Open drain valve (6, Figure 6) at bottom of tank and drain. NOTE: Fuel tank capacity is 500 liters (132 U.S.
  • Page 150 16. If equipped, remove components from fuel filler pump port (22, Figure 8) on side of fuel tank (1). FG003874 Figure 8 17. Remove five bolts (23, Figure 9) and cover (24) from fuel tank. FG003875 Figure 9 18. Remove six bolts (25 and 26, Figure 10) and stay (27) from fuel tank and frame.
  • Page 151 19. Tag and disconnect wires leading to fuel sender (16, Figure 11) on side of fuel tank (1). FG003877 Figure 11 20. Remove four bolts (35 and 36, Figure 12) and cover (37) from fuel tank and support. FG003878 Figure 12 21.

  • Page 152: Installation

    INSTALLATION Install two 12 mm eyebolts in threaded holes (38 and 39, Figure 14). Using a suitable lifting device, sling eyebolts. Set fuel tank (1, Figure 14) into position. Install six bolts (7) and spacers (13) finger tight, to secure tank to frame. NOTE: The clear level gauge on the side of the tank is easily damaged.
  • Page 153 Install four bolts (33, Figure 17) and battery cover (34) on frame. Install two bolts (31) and bracket (32) on fuel tank. Install four bolts (28 and 29) and fuel tank cover (30) on fuel tank. Install six bolts (25 and 26) and stay (27) on fuel tank and frame.
  • Page 154 10. Connect as tagged, fuel supply line (21, Figure 20) and fuel return line (19) to fuel tank (1). 11. Install clamp (20, Figure 20) to hold fuel return line (19) to tank (1). FG003873 Figure 20 12. Make sure fuel tank drain valve (6, Figure 21) on bottom of tank is closed.

  • Page 155: Start-Up Procedures

    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. FG015484 Figure 22 Loosen plug (1, Figure 23) on top of fuel filter head. Pump hand operated primer pump (2, Figure 23) by the fuel injection pump.
  • Page 156 Fuel Tank SP002027 Page 16...
  • Page 157 SP000021 FUEL TRANSFER PUMP (OPT)SP000021 Fuel Transfer Pump (Opt) Edition 1 Fuel Transfer Pump (Opt) SP000021 Page 1...
  • Page 158 MEMO Fuel Transfer Pump (Opt) SP000021 Page 2...
  • Page 159 Table of Contents Fuel Transfer Pump (Opt) Safety Precautions ..........5 Applicable Models ..........5 General Description ..........6 Theory of Operation ............6 Troubleshooting ............ 7 Replacement of Rotor and Vane ......7 Replacement of Rear Cover ......... 8 Replacement of Armature........
  • Page 160 MEMO Fuel Transfer Pump (Opt) SP000021 Page 4...

  • Page 161: Safety Precautions

    APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327 and Up...

  • Page 162: General Description

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

  • Page 163: Troubleshooting

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

  • Page 164: Replacement Of Rear Cover

    Insert vane, with the circled edge of vane facing in the counterclockwise direction. (Detail A) Insert a new O-ring during reassembly of pump cover. FG003883 Figure 6 REPLACEMENT OF REAR COVER Brush assembly and a thermal limiter are installed in the rear cover.
  • Page 165 SP001856 SWING BEARING SP001856 Swing Bearing Edition 1 Swing Bearing SP001856 Page 1...
  • Page 166 MEMO Swing Bearing SP001856 Page 2...
  • Page 167 Table of Contents Swing Bearing Safety Precautions ..........5 Applicable Models ..........5 Swing Bearing Maintenance ......... 6 Operating Recommendation ........... 6 Measuring Swing Bearing Axial Play....... 6 Measuring Bearing Lateral Play ........6 Swing Bearing Basic Operation........7 Disassembly ..............7 Assembly .................
  • Page 168 MEMO Swing Bearing SP001856 Page 4...

  • Page 169: Safety Precautions

    APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327 and Up...

  • Page 170: 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 171: 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 172 Lift outer ring and check that inner ring can move freely. See Figure 5, if not, replace seal (7, Figure 6). Figure 5 Turn inner ring and use magnet bar (C, Figure 6) to remove steel balls (5). Figure 6 Turn inner ring and use wire (D, Figure 7) to remove retainers (6).

  • Page 173: Assembly

    Assembly Clean (degrease) the seal groove for the outer and inner seals (7). Apply instant glue to seal (7). Install both seals respectively into position. Figure 8 Hoist the outer race by crane horizontally and match it with the inner race coaxially. Rotating the outer race, insert balls (5), support (6) into the plug (4) hole one by one with a round bar.
  • Page 174 Swing Bearing SP001856 Page 10...
  • Page 175 SP002028 SWING REDUCTION GEARSP002028 Swing Reduction Gear Edition 1 Swing Reduction Gear SP002028 Page 1...
  • Page 176 MEMO Swing Reduction Gear SP002028 Page 2...
  • Page 177 Table of Contents Swing Reduction Gear Safety Precautions ..........5 Applicable Models ..........5 General Description ..........7 Theory of Operation ............7 Parts List ................. 8 Specifications ..............9 Troubleshooting, Testing and Adjustment ..10 Removal ............. 11 Disassembly ............12 Cleaning and Inspection (Wear Limits and Tolerances)......
  • Page 178 MEMO Swing Reduction Gear SP002028 Page 4...

  • Page 179: 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 DX300LCA 5001 and Up Swing Reduction Gear SP002028 Page 5...
  • Page 180 Swing Reduction Gear SP002028 Page 6...

  • Page 181: General Description

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

  • Page 182: Parts List

    Parts List FG000852 Figure 1 Swing Reduction Gear SP002028 Page 8...

  • Page 183: Specifications

    Reference Reference Description Description Number Number Shaft Lock Ring Gear Case Spherical Roller Bearing No. 2 Carrier Spherical Roller Bearing No. 2 Sun Gear Oil Seal No. 2 Planetary Gear Spring Pin No. 2 Thrust Plate Plug No. 2 Shaft Plug No.

  • Page 184: 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 increases and disengagement, check release pressure Internal damage to gearbox Replace broken gears, drive train drive train assemblies Overload Reduce load weight...

  • Page 185: Removal

    REMOVAL Park on firm and level ground. Lower front attachment (bucket) to ground. Shut down engine. Set safety lever on "RELEASED" position. Turn starter switch to "I" (ON) position. WARNING when performing inspection WARNING 190-00695A FG014348 Figure 2 engine must running while performing...

  • Page 186: Disassembly

    DISASSEMBLY IMPORTANT Select a clean place. Spread a rubber mat or cloth on top of the overhaul workbench to prevent parts from being damaged. Remove bolts and motor from swing reduction case. CAUTION The motor should be separated without damage or any foreign substance.
  • Page 187 Figure 7 Figure 8 Remove No. 1 sun gear from No. 1 carrier. CAUTION Care should be taken not to damage teeth of No. 1 sun gear. Figure 9 SP002028 Swing Reduction Gear Page 13...
  • Page 188 Figure 10 Remove No. 1 carrier. Figure 11 Figure 12 Swing Reduction Gear SP002028 Page 14...
  • Page 189 Remove washer and No. 2 sun gear. CAUTION Care should be taken not to damage teeth of No. 2 sun gear. Figure 13 Figure 14 Install eye bolts in No. 2 carrier and remove it from ring gear. CAUTION Care should be taken not to damage teeth of No. 2 carrier and ring gear.
  • Page 190 Figure 16 Install eye bolts in ring gear and remove it. CAUTION Care should be taken not to damage mounting surfaces of ring gear and case. Carefully remove all gasket material from mounting surfaces. Figure 17 Figure 18 Swing Reduction Gear SP002028 Page 16...
  • Page 191 Use a rollover machine to turn assembly over, loosen lock wire, bolts and cover. Figure 19 Figure 20 Figure 21 Swing Reduction Gear SP002028 Page 17...
  • Page 192 Figure 22 10. Remove pinion gear. Figure 23 11. Using a gear puller to remove collar. Figure 24 Swing Reduction Gear SP002028 Page 18...
  • Page 193 12. Using snap ring pliers, remove lock ring and disassemble plate. Figure 25 Figure 26 13. Use a rollover machine to turn case over and place a jig on drive shaft. Use a press to remove drive shaft from case. CAUTION Care should be taken not to have drive shaft drop to floor when it is pressed out of case.
  • Page 194 Figure 28 14. Remove bearing from case. Figure 29 15. Put drive shaft in press, and remove bearing and spacer. Figure 30 Swing Reduction Gear SP002028 Page 20...

  • Page 195: Cleaning And Inspection (Wear Limits And Tolerances)

    Figure 31 CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section. SP002028 Swing Reduction Gear Page 21...

  • Page 196: Reassembly

    REASSEMBLY Shaft and S/R Bearing Heat-fit To cleaning shaft, remove any remnants of anticorrosion liquid applied on shaft and remove all of foreign substances using an air gun. Insert spacer on cleaned shaft as shown in figure below and heat bearing on a special heater. Stop heating when bearing temperature is between 90°...
  • Page 197 Align No. 1shaft with hole and press it into place. FG000878 Figure 33 FG000879 Figure 34 Make sure that shaft is fully pressed into position. FG000880 Figure 35 Install remaining three No. 1 shafts into carrier in same manner. FG000881 Figure 36 Swing Reduction Gear SP002028...
  • Page 198 Turn over carrier. Install a No. 1 thrust washer onto each of the four shafts. FG000882 Figure 37 FG000883 Figure 38 Install four No. 1 planetary gears. FG000884 Figure 39 Position a No. 3 thrust washer on each gear, as shown in Figure 40.
  • Page 199 Install retaining rings on No. 1 shafts. Make sure that retaining rings are fully seated in grooves. Make sure that gears properly rotate. FG000886 Figure 41 FG000887 Figure 42 Assembly of No. 2 Carrier Put No. 2 carrier on assembly jig as shown in Figure 43. NOTE: Lifting eye hole should be facing up.
  • Page 200 Turn over gear assembly and insert it into No. 2 carrier. Align bushing hole with carrier holes. NOTE: Thrust washer must be on bottom side of gear. FG000890 Figure 45 FG000891 Figure 46 Align spring pin hole in No. 2 shaft with spring pin hole of No.
  • Page 201 Install three remaining No. 2 gears in same manner. FG000894 Figure 49 After all four shafts are installed, align spring pin with carrier hole and drive it into position using a hammer. FG000895 Figure 50 FG000896 Figure 51 Using a hammer and punch, calking spring pin into position.

  • Page 202: Assembly Of Main Case

    FG000898 Figure 53 Repeat procedure for other three spring pins. Make sure that gears properly rotate. FG000899 Figure 54 Assembly of Main Case Cleaning Casing and Other Parts Steam clean case and other parts, to remove any foreign substances. • Cleaning fluid: PK6540 (alkali) •...
  • Page 203 FG000901 Figure 56 FG000902 Figure 57 FG000903 Figure 58 Remove bearing insertion jig and assemble plate with its step part so it is facing down, as shown in Figure 59. FG000904 Figure 59 SP002028 Swing Reduction Gear Page 29...
  • Page 204 FG000905 Figure 60 Install lock ring in groove of gear case. NOTE: Make sure lock ring is inserted completely into groove. FG000906 Figure 61 FG000907 Figure 62 Insert collar on shaft, making sure it is properly seated. Install pinion gear and special jig on shaft, and press collar and pinion gear into place on shaft and case.
  • Page 205 FG000909 Figure 64 Install lock plate and drilled head bolts on end of shaft. NOTE: Coat bolts with Loctite #262. NOTE: Torque bolts to 2,700 kg•cm (195 ft lb). FG000910 Figure 65 FG000911 Figure 66 FG000912 Figure 67 SP002028 Swing Reduction Gear Page 31...
  • Page 206 FG000913 Figure 68 Use lock wire to hold drilled head bolts in final position. FG000914 Figure 69 FG000915 Figure 70 FG000916 Figure 71 Swing Reduction Gear SP002028 Page 32...
  • Page 207 FG000917 Figure 72 Assembly of Seal and Bearing Postion case so that pinion gear is pointing down. FG000918 Figure 73 FG000919 Figure 74 Make sure that there is no foreign substance left on seal assembly, apply grease to and around lip of oil seal (TC5001300) as in Figure 75 and Loctite #609 to its external part.
  • Page 208 CAUTION Make sure that there is no foreign substances on lip area. Use care not to damage seal when inserting it. Chack for proper installation after pressing seal into position. FG000921 Figure 76 FG000922 Figure 77 FG000923 Figure 78 FG000924 Figure 79 Swing Reduction Gear SP002028...
  • Page 209 FG000925 Figure 80 FG000926 Figure 81 FG000927 Figure 82 Using seal installation jig, position bearing on end of shaft, with bearing trade mark on inner race facing up. Press bearing firmly into place, making sure it is properly seated. FG000928 Figure 83 SP002028 Swing Reduction Gear...
  • Page 210 FG000929 Figure 84 FG000930 Figure 85 FG000931 Figure 86 Rotate pinion by hand and check if it turns properly. FG000932 Figure 87 Swing Reduction Gear SP002028 Page 36...
  • Page 211 Insstall plugs into PT1/2 and PT1/8 drain ports. FG000933 Figure 88 FG000934 Figure 89 FG000935 Figure 90 Assembly of Ring Gear Insertion of lock pin. Insert four lock pins in four reamed holes of case flange. Tap them into place, by gently hitting them with a soft-face hammer.
  • Page 212 FG000937 Figure 92 Apply liquid gasket (Three Bond #1104) evenly to ring gear assembly of casing. FG000938 Figure 93 Lift ring gear with hoist, wipe its mating surface clean with Aim at holes. cloth, match and align holes after checking its assembling direction, and press assembled parts firmly by tightening special bolts (M16x160) on which no Loctite has been applied.
  • Page 213 Assembly of Carrier. Using a suitable lifting device, lower No. 2 carrier assembly into ring gear, making sure that planetary gears are engaged. Continue to lower carrier and engaging it onto splines of pinion shaft. Make sure that carrier is resting on bearing.
  • Page 214 FG000945 Figure 100 Position No. 1 carrier assembly into ring gear making sure it engages No. 2 sun gear. FG000946 Figure 101 FG000947 Figure 102 Install No. 1 sun gear in middle of No. 1 carrier . FG000948 Figure 103 Swing Reduction Gear SP002028 Page 40...
  • Page 215 Remove press-in bolts that were installed to hold ring gear in position. Apply liquid gasket on ring gear. FG000949 Figure 104 FG000950 Figure 105 FG000951 Figure 106 Align mounting holes and postion case cover on ring gear. Penetrating hole of the ring gear (Should be matched.) Coat socket head bolts with Loctite and install.
  • Page 216 FG000953 Figure 108 FG000954 Figure 109 FG000955 Figure 110 FG000956 Figure 111 Swing Reduction Gear SP002028 Page 42...
  • Page 217 FG000957 Figure 112 FG000958 Figure 113 SP002028 Swing Reduction Gear Page 43...

  • Page 218: Assembly Of Motor

    Assembly of Motor Add Gear Oil Fill case with 7.0 liters (1.8 U.S. gal.) of gear oil (EP80W/ 90). FG000968 Figure 114 Install level pipe in plug hole. FG000970 Figure 115 Assembly of Motor Apply liquid gasket to cover assembly. FG000983 Figure 116 Swing Reduction Gear...
  • Page 219 Lift motor with hoist. Install retaining ring on shaft spline. Align mounting holes and intall motor on case cover. NOTE: Gear oil fill plug should point towards fill tube. Gear Oil Inlet PT3/8 FG001350 Figure 117 Should be placed on a straight line.
  • Page 220 Tighten bolts to specified torque. Mark them with paint marker. FG000975 Figure 121 FG000976 Figure 122 FG000977 Figure 123 Supply of Grease Install grease fitting in grease inlet and add grease through grease until it starts to be discharged from the opposite hole.
  • Page 221 FG000979 Figure 125 Remove grease fitting and install a plastic plug in hole to prvent contamination. A grease hose will be connected during installtion on machine. FG000980 Figure 126 FG000981 Figure 127 SP002028 Swing Reduction Gear Page 47...

  • Page 222: Installation

    FG000982 Figure 128 INSTALLATION Coat pinion gear with grease. Refer to operation manual for specifications. Make sure two alignment pins (6, Figure 129) are installed in flange of swing reduction gearbox (5). Using a suitable lifting device, sling swing motor (1, Figure 129) and position swing motor and reduction gearbox (5) as an assembly on unit.

  • Page 223: Start-Up Procedures

    START-UP PROCEDURES IMPORTANT If air is not vented from system, it will cause damage to swing motor and bearings. Disconnect drain hose and fill swing motor case with hydraulic oil. Connect drain hose. ARO1689P Start engine and set throttle at "LOW IDLE" and swing Figure 130 upper structure slowly two full revolutions to left and right.
  • Page 224 Swing Reduction Gear SP002028 Page 50...
  • Page 225 Lower Structure and Chassis...
  • Page 227 SP001741 TRACK ASSEMBLY SP001741 Track Assembly Edition 1 Track Assembly SP001741 Page 1...
  • Page 228 MEMO Track Assembly SP001741 Page 2...
  • Page 229 Table of Contents Track Assembly Safety Precautions ..........5 Applicable Models ..........5 General Description ..........6 Track Tension ............7 Cleaning and Inspection (Wear Limits and Tolerances)....... 9 Track Shoe ..............10 Lower Roller ..............12 Upper Roller ..............13 Front Idler ..............
  • Page 230 MEMO Track Assembly SP001741 Page 4...

  • Page 231: Safety Precautions

    APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up Track Assembly SP001741...

  • Page 232: 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 Assembly SP001741 Page 6...

  • Page 233: Track Tension

    TRACK TENSION WARNING Safely measuring track tension requires two people. One person must be in the operator's seat, running the controls to keep one side frame in the air, while the other person makes dimensional checks. Take all necessary precautions to make sure the machine won't move or shift position during service.
  • Page 234 "E" on below table for operation over gravel, rocky terrain, or over sand or snow. Distance "A" Terrain Type DX300LC / DX300LCA DX340LC / DX350LC 320 - 340 mm 330 - 360 mm Normal "B"...

  • Page 235: 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 236: Track Shoe

    Track Shoe FG003910 Figure 4 Track Assembly SP001741 Page 10...
  • Page 237 Limit for Use Recommended Limit for Check Item Standard Dimension (Repair - P or Maintenance Replace - R) 216 mm Link Pitch (8.504") Bushing Outside 66.5 mm 62.5 mm 59 mm [R] Diameter (2.618") (2.461") (2.323") 116 mm 108 mm 103 mm [P] Link Height (4.567")

  • Page 238: Lower Roller

    Lower Roller FG000508 Figure 5 Limit for Use Recommended Limit for Check Item Standard Dimension (Repair - P or Maintenance Replace - R) Outside Diameter of 212 mm flange (8.346") Outside Diameter of 178 mm 166 mm 164 mm [P] Tread (7.008") (6.535")

  • Page 239: Upper Roller

    Upper Roller FG000509 Figure 6 Limit for Use Recommended Limit for Check Item Standard Dimension (Repair - P or Maintenance Replace - R) Outside Diameter of 175 mm flange (6.890") Outside Diameter of 142 mm 135 mm 130 mm [P] Tread (5.591") (5.315")

  • Page 240: 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 630 mm flange (24.803") Outside Diameter of 580 mm 572 mm 568 mm [P] Tread (22.835") (22.520")

  • Page 241: 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 242: 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 243 Track Assembly SP001741 Page 17...

  • Page 244: Front Idler Roller

    FRONT IDLER ROLLER Parts List FG003913 Figure 14 Reference Reference Description Description Number Number Idler Assembly Idler Floating Seal Bearing O-ring Shaft Plug Bushing Track Assembly SP001741 Page 18...

  • Page 245: Front Idler Roller Disassembly

    Front Idler Roller Disassembly Remove plug (9, Figure 15) from idler assembly (1), and drain into a suitable container. FG003914 Figure 15 Separate the pin (6, Figure 16) from the bearing (3). FG003915 Figure 16 Use a press to remove the bearing from the axle (4). Separate the O-ring (8, Figure 17) from the axle.
  • Page 246 Use a press to separate the axle (4, Figure 19), O-ring (8) and bearing (3). FG001484 Figure 19 Remove bushing (5, Figure 20) with the press and special tool (10, ST-1909). FG001485 Figure 20 Track Assembly SP001741 Page 20...

  • Page 247: Front Idler Roller Reassembly

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

  • Page 248: Lower Roller

    LOWER ROLLER Parts List FG000483 Figure 24 Track Assembly SP001741 Page 22...

  • Page 249: 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 250: Lower Roller Reassembly

    Separate the collar (2, Figure 27) from the axle, using press. FG001490 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 251: Lower Roller Installation

    Apply grease to the O-rings (7, Figure 29) and insert into axle. Align collar (2, Figure 30) and axle (3) pin holes and pin (5) the collar. FG001492 Figure 30 Insert floating seals (6, Figure 31) into the roller (1) and collar (2).

  • Page 252: Upper Roller

    UPPER ROLLER Parts List Track Frame FG001141 Figure 34 Track Assembly SP001741 Page 26...

  • Page 253: Upper Roller Removal

    Reference Reference Description Description Number Number Roller Plug Shaft Cover Thrust Ring Washer Bushing Bolt Bushing Blot Floating Seal Spring Washer O-ring Spring Washer O-ring Upper Roller Removal Relieve track tension. This will allow track to be raised so that links clear top of roller. Position a bottle jack on top of track frame and apply pressure to track shoe.
  • Page 254 Remove the bolts (13, Figure 37) and cover (10). Detach bolts (12) and washer (11). FG001495 Figure 37 Separate the roller (1, Figure 38) from the axle (2). FG001497 Figure 38 Separate the floating seal (6, Figure 39) from the roller. Separate the O-ring (8) and thrust ring (3) from the axle.

  • Page 255: Upper Roller Reassembly

    Upper Roller Reassembly Degrease, clean and dry all parts before reassembly. Insert bushing (4 and 5, Figure 41) into the roller (1). FG003917 Figure 41 Insert floating seal (6, Figure 42) into the roller (1) and bushing. NOTE: Apply clean engine oil to the joint side of the floating seal.

  • Page 256: Track Spring And Track Adjusting Cylinder

    TRACK SPRING AND TRACK ADJUSTING CYLINDER Parts List 9 11 FG003918 Figure 44 Reference Reference Description Description Number Number Cylinder Lock Plate Piston Rod Bolt Yoke Spring Pin Spacer Spring Washer Shaft Packing Spring Backup Ring Lock Nut Dust Seal Track Assembly SP001741 Page 30...
  • Page 257 Engine and Drive Train...
  • Page 259 SP002029 DRIVE COUPLING (MAIN PUMP)SP002029 Drive Coupling (Main Pump) Edition 1 Drive Coupling (Main Pump) SP002029 Page 1...
  • Page 260 MEMO Drive Coupling (Main Pump) SP002029 Page 2...
  • Page 261 Table of Contents Drive Coupling (Main Pump) Safety Precautions ..........5 Applicable Models ..........5 Drive Coupling ............6 Special Tools ............7 Drive Coupling Installation ........8 Installation Procedure............ 10 Drive Coupling (Main Pump) SP002029 Page 3...
  • Page 262 MEMO Drive Coupling (Main Pump) SP002029 Page 4...

  • Page 263: 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 DX300LCA 5001 and Up Drive Coupling (Main Pump) SP002029 Page 5...

  • Page 264: Drive Coupling

    DRIVE COUPLING When installing the main pump on the engine, it is very important to properly adjust clearance between the face of the coupling hub and end of pump drive shaft ("Measurement H" shown in the following procedure) to a specific value. Figure 1 thru Figure 2, show typical drive coupling installations.

  • Page 265: Special Tools

    HAAA8350 Figure 4 Dimensional Details for Figure 4 Dimension Measurement Models 6 ±0.1 mm DX300LC, DX300LCA, S300LC-V (0.2362 ±0.0039 in) 7 ±0.1 mm (0.2756 ±0.0039 in) 20.0 mm (0.787 in) 7.0 mm (0.275 in) 18.0 mm (0.708 in) Radius 22.0 mm (0.866 in) Radius 30.0 mm (1.181 in) Radius...

  • Page 266: Drive Coupling Installation

    DRIVE COUPLING INSTALLATION Whenever the drive coupling for main pump is installed, the following mounting dimensions and installation procedures must be observed. NOTE: If these procedures are not followed, noise will occur and/or the service life of drive coupling or main pump will be reduced.
  • Page 267 "Measurement H" Number "Ta" "Tb" DX300LC 5.5 - 6.5 mm 44 - 49 kg•m 20 - 22 kg•m DX300LCA 414-00040A (0.216 - 0.256 in) (318 - 354 ft lb) (145 - 159 ft lb) S300LC-V S340LC-V 6.5 - 7.5 mm 44 - 49 kg•m...

  • Page 268: Installation Procedure

    Installation Procedure NOTE: Refer to Figure 5 while using following procedure. Install spring pin (1) and attach insert (2) with bolt (3) to engine flywheel (4). NOTE: Tighten bolts to value "Ta" in the tables. Install two spring pins (5) and attach insert (6) to hub (7) bolts (8).
  • Page 269 Hydraulics...
  • Page 271 SP001751 HYDRAULIC SYSTEM TROUBLESHOOTING, TESTING AND ADJUSTMENTSP001751 Hydraulic System Troubleshooting, Testing and Adjustment Edition 1 Hydraulic System Troubleshooting, Testing and Adjustment SP001751 Page 1...
  • Page 272 MEMO Hydraulic System Troubleshooting, Testing and Adjustment SP001751 Page 2...
  • Page 273 Table of Contents Hydraulic System Troubleshooting, Testing and Adjustment Safety Precautions ..........5 Applicable Models ..........5 Hydraulic System - General Notes ....... 6 Hydraulic Schematic..........7 General Notes ..............7 Operation of Working Components ...... 9 Boom Operating Circuit ........... 9 Boom Up Circuit ..............

  • Page 274: Hydraulic System Troubleshooting, Testing And Adjustment

    Checks and Adjustments..........18 Pump Input Power Control ......... 20 Pump Regulator Adjustment ......... 20 Flow Meter and Flow Meter Kit Installation and Testing ..............23 Swing System Troubleshooting ......25 Precautions/Initial Checks ..........25 Swing Relief Valve Checking and Adjustment ....26 Troubleshooting –...

  • Page 275: 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 7440 and Up DX300LCA 5001 and Up Hydraulic System Troubleshooting, Testing and Adjustment SP001751 Page 5...

  • Page 276: Hydraulic System - General Notes

    HYDRAULIC SYSTEM - GENERAL NOTES Center Joint Travel Motor Travel Motor FG001322 Figure 1 hydraulic system several improvements over conventional hydraulic systems - including cross-sensing total horsepower control - to maximize output efficiency. The system features an electronically controlled output optimization system, which allows the operator to choose between two, distinctly different power modes: high-output/rapid cycling maximum speed power mode, and a standard power...
  • Page 277 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 278 • 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 279: 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 280: Arm Operating Circuit

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

  • Page 281: 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 282: Right Swing Operating Circuit

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

  • Page 283: Forward Travel Circuit

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

  • Page 284: 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 285 NOTE: System specification performance tests of individual activator function are determined by flow rate through the component or circuit, not the control pressure or system pressure available to the actuator. Poor flow through the individual circuit may indicate that the component is worn beyond tolerance limits, while all other hydraulic functions are adequate.

  • Page 286: 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 287: 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 288: 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 289 Main Pressure and Pilot Pressure and Power Mode Operation Tolerance Tolerance 20 - 40 bar 30 bar +10 bar Power Mode Neutral, No Operation (290 - 580 psi) (435 psi +145 psi) 330 bar +5 bar 30 bar +10 bar Power Mode Cylinder Stall (4,785 psi +75 psi)

  • Page 290: 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 291 FG000654 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 two different adjustments, along with the Negacon, negative control, adjustment screw (3, directly below 1 and 2). Each one of the adjustment procedures could affect the setting of the others.
  • Page 292 Start the engine and turn the engine speed dial to maximum. When normal operating temperature is reached, loosen the largest diameter lock nut around the adjustment screw (2) for the outer regulator spring. Tightening the screw shifts the P/Q (Pressure/Flow) control curve to the right, and increases compensating control pressure.

  • Page 293: Flow Meter And Flow Meter Kit Installation And Testing

    The After Sales Service department of the nearest local DOOSAN dealer can assist you with these tests or, if you prefer carrying out your own testing, they should be able to help in putting together a hose and fitting kit (or the required dimensions and specifications for hoses and fittings) to allow you to install a flow meter downstream from the main pump assembly.
  • Page 294 • Unloaded maximum engine speed baseline test (all controls in neutral). • Front pump test – operate "travel right" lever. Record values at all specified pressures. • Rear pump test – operate "travel left" lever. Record values at all specified pressures. Record the values for each of the three tests (neutral, travel right and travel left) at the following pump pressure levels, with travel speed control set at "high speed."...

  • Page 295: Swing System Troubleshooting

    SWING SYSTEM TROUBLESHOOTING Precautions/Initial Checks Stop work. Release all weight or any type of load safely before proceeding. Avoid risking injury or adding to damage. Shut down engine and disengage control functions until initial tests are ready to be made. WARNING Prevent possible injury and/or loss of operating control.

  • Page 296: Swing Relief Valve Checking And Adjustment

    Swing Relief Valve Checking and Adjustment Make a check of operating pressures through the swing relief valve if: • The swing motor fails to turn. • Swings in one direction only. • Swings but continues to coast. • There is drifting on a slope. Check operation by connecting: Two 600 bar (8,700 psi) pressure gauges to the inlet and outlet measuring ports on top of the swing motor.
  • Page 297 If pressure tested at the motor makeup valve falls below recommended minimum level, and consequent problems with cavitation, stalling and surging are observed, check the restriction valve. If pressure adjustment to the valve has been restored but if problems with cavitation continues, disassemble the upper swing motor housing and clean or replace assembly components as required.

  • Page 298: 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 299: 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 300 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 301: Troubleshooting - Control Valve

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

  • Page 302: Troubleshooting - Travel Control Valve

    Problem Possible Cause Remedy Irregular or uneven Poppet seat damaged or pilot Clean/replace. pressure. piston sticking to main poppet. Loose lock nut and adjusting screw. Readjust. Components worn out, past wear Replace. limits. TROUBLESHOOTING – TRAVEL CONTROL VALVE Problem Possible Cause Remedy Secondary pressure does Low primary pressure.

  • Page 303: Troubleshooting - Joystick Control Valve

    TROUBLESHOOTING – JOYSTICK CONTROL VALVE Problem Possible Cause Remedy Secondary pressure does Low primary pressure. Check primary pressure. not increase. Broken spring. Replace spring. Spool sticking. Clean, repair or replace. Excess spool to casing clearance. Replace spool casing. Worn or loose handle subassembly. Repair or replace handle subassembly.
  • Page 304 Hydraulic System Troubleshooting, Testing and Adjustment SP001751 Page 34...
  • Page 305 SP000028 ACCUMULATOR SP000028 Accumulator Edition 1 Accumulator SP000028 Page 1...
  • Page 306 MEMO Accumulator SP000028 Page 2...
  • Page 307 Table of Contents Accumulator Safety Precautions ..........5 Applicable Models ..........5 General Description ..........6 Specifications ..............8 Accumulator SP000028 Page 3...
  • Page 308 MEMO Accumulator SP000028 Page 4...

  • Page 309: Safety Precautions

    APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327 and Up...

  • Page 310: 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 311 When hydraulic fluid is pushed out the lower valve opening by the pressure of the gas charge on the other side of the diaphragm - and there is no counterpressure from system oil - the valve button on the bottom of the diaphragm eventually seals off the lower oil passage.

  • Page 312: Specifications

    Volume 320 cc 10 kg/cm DX300LC S/N 7440 and Up Pilot (140 psi) (19.53 in 320 cc 10 kg/cm DX300LCA S/N 5001 and Up Pilot (140 psi) (19.53 in 320 cc 10 kg/cm DX340LC S/N 5980 and Up Pilot (140 psi) (19.53 in...
  • Page 313 SP001620 CENTER JOINT (SWIVEL)SP001620 Center Joint (Swivel) Edition 1 Center Joint (Swivel) SP001620 Page 1...
  • Page 314 MEMO Center Joint (Swivel) SP001620 Page 2...
  • Page 315 Table of Contents Center Joint (Swivel) Safety Precautions ..........5 Applicable Models ..........5 General Description ..........7 Parts List ................. 8 Troubleshooting, Testing and Adjustment .... 9 Inspection ................ 9 Testing................9 Disassembly ............10 Reassembly ............13 Center Joint (Swivel) SP001620 Page 3...
  • Page 316 MEMO Center Joint (Swivel) SP001620 Page 4...

  • Page 317: Safety Precautions

    The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX225LC 5433 and Up DX225LCA 5167 and Up DX300LC 7440 and Up DX300LCA 5001 and Up Center Joint (Swivel) SP001620 Page 5...

  • Page 318: 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) SP001620 Page 6...

  • Page 319: Parts List

    Parts List Figure 1 Reference Reference Description Description Number Number O-Ring (1AP105) Shaft O-Ring (1BP90) Cover Retaining Ring Spacer PT-Plug (PT1/4) Shim HEX-Bolt (M12) Shim Spring Washer Wear Ring O-Ring (1AG100) Sliper Seal Center Joint (Swivel) SP001620 Page 7...

  • Page 320: Troubleshooting, Testing And Adjustment

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

  • Page 321: Disassembly

    DISASSEMBLY IMPORTANT Do not unbolt the center joint from the lower car body until an adequate number of piping block-off plates are available, for disconnected piping lines. Be sure that system pressure has been vented - including the hydraulic accumulator and tank reserve pressure - before disassembly is started.
  • Page 322 CAUTION Care should be taken not to make a flaw on the surface of the Shaft when disassembling the Hub of the Shaft assembly. Disassemble the hub from the shaft assembly. It can be disassembled easily by fixing the Shaft assembly, tightening at least 2-10mm eye bolts on the Hub, and lifting it with a hoist slowly.
  • Page 323 Remove the PT plugs sealing the shaft * PT 1/4 : 6mm wrench FG013237 Figure 7 10. Remove foreign substance at every pieces disassembled and wash them out. 11. Replace disassembled O-rings and slipper seals with new ones, for they cannot be reused. 12.

  • Page 324: Reassembly

    REASSEMBLY CAUTION Apply a very light film of white grease or petroleum jelly to the lower rim of the stem and inner surface of the center swivel body. Apply slow, even-handed pressure, using both hands, to slowly push the stem into the body. Seals may be damaged if the stem is pushed in too quickly.
  • Page 325 CAUTION Applying active oil to the surface of the shaft enables the assembly without any damage to the sliper seal. Fix the position of the shaft and press the hub carefully into shaft with both being parallel each other. Use a plastic (or urbber) hammer to tap the hub until it is inserted completely.
  • Page 326 Center Joint (Swivel) SP001620 Page 14...
  • Page 327 SP000030 CYLINDERS SP000030 Cylinders Edition 1 Cylinders SP000030 Page 1...
  • Page 328 MEMO Cylinders SP000030 Page 2...
  • Page 329 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 ...............
  • Page 330 MEMO Cylinders SP000030 Page 4...

  • Page 331: Safety Precautions

    APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327 and Up...

  • Page 332: 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 333 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(D >...

  • Page 334: 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 335 Reference Reference Description Description Number Number Tube Assembly O-ring Bushing Backup Ring Rod Assembly Piston Nut Bushing Set Screw Rod Cover Socket Head Bolt DD-Bushing Pipe Band Assembly Retaining Ring Hex Socket Bolt Buffer Seal Check Valve U-Packing Spring Backup Ring Spring Support Dust Wiper Hex Socket Plug...

  • Page 336: 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 337 BOOM (5.59 in) (4.02 in) (0.47 in) (0.20 in) DX300LC / 147.0 mm 107.0 mm 12.0 mm 5.0 mm S/ARM DX300LCA (5.79 in) (4.21 in) (0.47 in) (0.20 in) 140.0 mm 98.0 mm 12.0 mm 5.0 mm BUCKET S/BUCKET (5.52 in) (3.86 in)

  • Page 338: 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 339 BOOM (4.33 in) (0.51 in) (2.99 in) (5.51 in) DX300LC / 120.0 mm 13.0 mm 85.0 mm 150.0 mm S/ARM DX300LCA (4.72 in) (0.513 in) (3.35 in) (5.91 in) 110.0 mm 13.0 mm 76.0 mm 140.0 mm BUCKET S/BUCKET (4.33 in) (0.51 in)

  • Page 340: 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 341 BOOM (3.54 in) (4.13 in) (1.58 in) (0.28 in) DX300LC / 90.0 mm 105.0 mm 40.0 mm 6.5 mm S/ARM DX300LCA (3.54 in) (4.13 in) (1.58 in) (0.26 in) 90.0 mm 105.0 mm 40.0 mm 7.0 mm BUCKET S/BUCKET (3.54 in) (4.13 in)

  • Page 342: 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 343 BOOM (3.74 in) (4.29 in) (0.24 in) (2.28 in) DX300LC / 105.0 mm 121.0 mm 6.0 mm 7.0 mm S/ARM DX300LCA (4.13 in) (4.76 in) (0.24 in) (2.28 in) 90.0 mm 104.0 mm 6.0 mm 7.0 mm BUCKET S/BUCKET (3.54 in) (4.10 in)

  • Page 344: Slipper Seal Jig

    Slipper Seal Jig (B+40) ARS4770L Figure 10 Cylinders SP000030 Page 18...
  • Page 345 øA +0.1 +0.1 140.0 mm 28.5 mm BOOM (5.51 in) (1.12 in) DX300LC / 150.0 mm 28.5 mm S/ARM DX300LCA (5.91 in) (1.12 in) 140.0 mm 28.5 mm BUCKET S/BUCKET (5.51 in) (1.12 in) 150.0 mm 28.5 mm BOOM OPT BOOM (5.91 in)

  • Page 346: Slipper Seal Straightening Jig

    Slipper Seal Straightening Jig ∅ ARS4780L Figure 11 Cylinders SP000030 Page 20...
  • Page 347 +0.2 MODEL CYLINDER MODEL (CYLINDER) øA +0.1 140.0 mm BOOM (5.51 in) DX300LC / 150.0 mm S/ARM DX300LCA (5.91 in) 140.0 mm BUCKET S/BUCKET (5.51 in) 150.0 mm BOOM OPT BOOM (5.91 in) DX340LC / 170.0 mm OPT ARM DX350LC (6.69 in)

  • Page 348: 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 349 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 350 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 351 12. Use a dull, rounded tip tool to pry off O-ring (11) and backup ring (12). HAOF37OL Figure 23 13. Find a screwdriver with an appropriate width tip to facilitate removal of slipper seal (19), wear ring (18) and slide ring (17) from piston (16).
  • Page 352 16. Disassemble retaining ring (3) and dust wiper (2). Separate retaining ring (8) and rod bushing (6). Figure 27 17. Force out pin bushing (1) from body of cylinder. Figure 28 Cylinders SP000030 Page 26...

  • Page 353: 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 354 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 355 Use specially fabricate or factory sourced tool to tighten piston nut (22). Figure 35 Assemble wear ring (18), slide ring (17) and set screw (23) 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 356 Cylinders SP000030 Page 30...
  • Page 357 SP000031 SWING MOTOR SP000031 Swing Motor Edition 1 Swing Motor SP000031 Page 1...
  • Page 358 MEMO Swing Motor SP000031 Page 2...
  • Page 359 Table of Contents Swing Motor Safety Precautions ..........5 Applicable Models ..........5 General Description ..........6 Theory of Operation ............6 Makeup Check Valve ............9 Operation of Time Delay Valve ........9 Operation of Swing Reactionless Valve ......9 Parts List ...............
  • Page 360 MEMO Swing Motor SP000031 Page 4...

  • Page 361: 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 7740 and Up DX300LCA 5001 and Up Swing Motor SP000031 Page 5...

  • Page 362: General Description

    GENERAL DESCRIPTION Theory of Operation Structure The hydraulic motor consists of the following five parts: • Rotary part generating rotary power. • Relief valve. • Parking brake. • Makeup check valve. • Time delay valve. • Swing reactionless valve. Circuit Diagram FG001323 Figure 1 Swing Motor...
  • Page 363 Generation of Rotary Power High-pressure oil from hydraulic pump flows into the cylinder (9) through the valve casing (1) and the valve plate (22). The motor is designed to only let high-pressure oil to flow into one side with relationship to Y-Y axis (the centerline of top and bottom dead centers of piston (13)).
  • Page 364 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 365: 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 366: Parts List

    Parts List 28 30 9 : 9A ~ 9D FG000762 Figure 8 Swing Motor SP000031 Page 10...
  • Page 367 Reference Reference Description Description Number Number Body Socket Bolt (M20x2.5) Oil Seal Poppet Roller Bearing Spring Snap Ring Plug Shaft O-ring Parallel Pin Reductionless Valve Assembly Stop Ring Plug Shoe Plate O-ring Rotary Kit O-ring Cylinder Block Kit Back up Ring Cylinder Block Relief Valve Assembly Valve Plate...

  • Page 368: Specifications

    Specifications Items Units 260 l/min Oil Flow (69 gpm) Set Pressure of Relief V/V 275 kg/cm (Cracking) (3,900 psi) 194.5 cc/rev Motor Displacement (11.87 in³/rev) 85.1 kg•m Motor Output Torque (620 ft lb) Motor Speed 1280 rpm 88.2 kg•m Brake Torque (640 ft lb) Spool Cracking 8 kg/cm²...

  • Page 369: Tools And Materials

    TOOLS AND MATERIALS Tools Tools B Length Tools to Be Used Hex L Wrench 5 mm Plug (37), hex socket head bolt (36) 6 mm Plugs (40, 41, and 47) 14 mm Hex socket head bolt (27) Socket Wrench Plug (39), relief valve assembly (33) 36 mm Spanner Retaining Ring Pliers (For Orifice...

  • Page 370: 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 371 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 372: 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 373 Remove rear cover from body (1) by removing hex socket head bolt (23) of its assembly with impact. FG000685 Figure 12 FG000686 Figure 13 Remove brake piston assembly from body (1) using jig. FG000687 Figure 14 FG000688 Figure 15 Swing Motor SP000031 Page 17...
  • Page 374 Remove cylinder block assembly, friction plate (14), and plate (15) from body (1). NOTE: Pay attention to order of plates and friction plates. FG000689 Figure 16 FG000690 Figure 17 Remove O-ring (38) from body (1). FG000691 Figure 18 Remove shoe plate (8) from body (1) using jig. FG000692 Figure 19 Swing Motor...
  • Page 375 Remove retaining ring (4) from body (1) using retaining ring pliers. Turn body over, and separate shaft assembly using steel bar. FG000693 Figure 20 FG000694 Figure 21 FG000695 Figure 22 Separate piston assembly (13) from cylinder block assembly. FG000696 Figure 23 Swing Motor SP000031 Page 19...
  • Page 376 FG000697 Figure 24 10. Remove friction plate (12), plate (15), ball guide (11), and spring (10) from cylinder block. FG000698 Figure 25 FG000699 Figure 26 FG000700 Figure 27 Swing Motor SP000031 Page 20...
  • Page 377 11. Separate valve plate (22) from rear cover (19). FG000701 Figure 28 FG000703 Figure 29 12. Remove O-ring (17) from rear cover (19). FG000704 Figure 30 FG000705 Figure 31 Swing Motor SP000031 Page 21...
  • Page 378 13. Remove two relief valve assemblies (33) from rear cover (19). FG000706 Figure 32 FG000707 Figure 33 14. Remove check valve assemblies from rear cover (19) with L wrench, and disassemble it in order of plug (26), spring (23), and poppet (24). FG000708 Figure 34 FG000709...

  • Page 379: Cleaning And Inspection (Wear Limits And Tolerances)

    15. Remove plug (29) from rear cover (19) with L wrench and disassemble it in order of backup ring (50), O-ring (49), O- ring (48), spring, and anti-inversion valve assembly (28). FG000710 Figure 36 FG000711 Figure 37 FG000712 Figure 38 16.

  • Page 380: Reassembly

    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. Each connecting parts should be tightened according to its assigned torque. Only use a plastic soft-faced hammer. Assembly Put roll bearing (3) and bushing (39) on a heater and apply heat to their inner race (inlet temperature: 290°C for 2...
  • Page 381 Assemble heated roll bearing (3) and bushing (39). Use retaining ring pliers to assemble install retaining ring (7). FG000716 Figure 42 FG000717 Figure 43 Put body (1) on assembly jig and secure it so it cannot move. FG000718 Figure 44 Assemble oil seal (2) in body (1) using bar hammer.
  • Page 382 FG000720 Figure 46 Install shaft in body (1) using bar hammer. FG000717 Figure 47 FG000721 Figure 48 Secure shaft with retaining ring (4) using retaining ring pliers. FG000722 Figure 49 Swing Motor SP000031 Page 26...

  • Page 383: Assembly Of Cylinder Block Assembly Subassembly

    FG000723 Figure 50 Coat shoe plate (8) with grease, and assemble it into body. FG000724 Figure 51 FG000725 Figure 52 Assembly of Cylinder Block Assembly Subassembly Insert nine sets of springs (1 thru 9) in cylinder block (9). FG000726 Figure 53 SP000031 Swing Motor Page 27...
  • Page 384 FG000727 Figure 54 Insert ball guide (1-B-11) in cylinder block (9). FG000728 Figure 55 FG000729 Figure 56 10. Assemble friction plate (14) and plate (15) into cylinder block (9) FG000759 Figure 57 Swing Motor SP000031 Page 28...
  • Page 385 FG000730 Figure 58 11. Insert piston assembly (1-C-13) in set plate (1-B-12) and assemble it into cylinder block (9). NOTE: Coat piston with clean hydraulic oil. FG000731 Figure 59 FG000696 Figure 60 FG000732 Figure 61 SP000031 Swing Motor Page 29...
  • Page 386 12. Assemble cylinder block into body (1). FG000733 Figure 62 13. Insert O-ring (38) in body (1). FG000734 Figure 63 14. Assemble O-ring (17) into brake piston (16). FG000704 Figure 64 FG000687 Figure 65 Swing Motor SP000031 Page 30...

  • Page 387: Assembly Of Rear Cover Assembly Subassembly

    15. Insert brake piston assembly in body and secure it using jig. FG000735 Figure 66 16. Insert eighteen springs (18) into brake piston (16). FG000736 Figure 67 FG000737 Figure 68 Assembly of Rear Cover Assembly Subassembly Insert pins (6 and 21) in rear cover (19) with bar hammer and assemble needle bearing (20) using jig.
  • Page 388 FG000739 Figure 70 FG000740 Figure 71 Assemble O-ring (17) into rear cover (19). FG000741 Figure 72 Assemble check valve. Install O-ring (27) using jig. FG000742 Figure 73 Swing Motor SP000031 Page 32...
  • Page 389 FG000743 Figure 74 Insert poppet (24), spring (25), and plug (26) in rear cover (19). Tighten plug with L wrench. (Left and right symmetrically.) FG000708 Figure 75 FG000744 Figure 76 Assemble anti-inversion valve. Assemble body, spring seat, spring, poppet, poppet seat, stopper, and spring. Then assemble O-ring (31), backup ring (32), and O-ring (30).
  • Page 390 FG000711 Figure 78 FG000710 Figure 79 Assemble anti-inversion valve set. Assemble anti-inversion valve set and plug assembly (29) into rear cover (19) and tighten them with L wrench. FG000746 Figure 80 Assemble plug assembly (36) into rear cover (19) with L wrench.
  • Page 391 FG000748 Figure 82 Assemble two relief valve assemblies into rear cover (19) with torque wrench. (Left and right symmetrically.) FG000706 Figure 83 FG000749 Figure 84 Coat valve plate (1-A-22) with grease and attach it to rear cover (19). FG000701 Figure 85 SP000031 Swing Motor Page 35...
  • Page 392 FG000750 Figure 86 10. Position rear cover assembly on body (1) and tighten hex socket head bolt (23). FG000751 Figure 87 FG000752 Figure 88 11. Install time delay valve assembly onto rear cover (19) with hex socket head bolts (35). FG000682 Figure 89 Swing Motor...

  • Page 393: Air Pressure Test

    FG000753 Figure 90 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 91 Oil Leakage Check Wash motor with Color Check No.1, spray No.3, and check for any oil leakage.
  • Page 394 FG000756 Figure 93 FG000757 Figure 94 Swing Motor SP000031 Page 38...
  • Page 395 SP000032 TRAVEL MOTOR SP000032 Travel Motor Edition 1 Travel Motor SP000032 Page 1...
  • Page 396 MEMO Travel Motor SP000032 Page 2...
  • Page 397 Table of Contents Travel Motor Safety Precautions ..........5 Applicable Models ..........5 General Description ..........7 Structure ................7 Operation Basics ............. 8 Parts List ............... 14 Specifications ..............16 Connection Torque ............16 Special Tools and Materials ....... 17 Troubleshooting, Testing and Adjustment ..
  • Page 398 MEMO Travel Motor SP000032 Page 4...

  • Page 399: 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 7440 and Up DX300LCA 5001 and Up Travel Motor SP000032 Page 5...
  • Page 400 Travel Motor SP000032 Page 6...

  • Page 401: General Description

    GENERAL DESCRIPTION Structure The hydraulic motor consists of five parts: • Rotary part generating rotary power. • Cross-over relief valve. • Negative brake. • Counterbalance valve. • Tilting switching part. Counter balance valve part Relief valve part Swash tilting part Negative brake part Rotary part Hydraulic motor part...

  • Page 402: Operation Basics

    Operation Basics Generation of Rotary Power High-pressure oil from hydraulic pump flows into cylinder (111) through valve casing (303) and valve plate (131). The high- pressure oil is designed to flow only to one side in relationship to Y-Y, the connection line of top and bottom dead centers of piston (121).
  • Page 403 Operation of Relief Valve The relief valve performs two functions: It maintains uniform pressure when the hydraulic motor starts and bypasses surplus oil at the inlet of the motor to the outlet in relationship with acceleration of the inertia weight. Device is forced to stop by the generation of brake pressure at the discharge side when the inertia weight stops.
  • Page 404 Operation of Negative Brake Pressurized oil entering through counterbalance spool in valve casing (303), forces brake piston (702) to release the brake. When hydraulic oil pressure, is not present, the brake is spring applied by ten springs (705). Brake force is generated by frictional force between separator plate (741) (which is fixed by pin pressed into shaft casing) and friction plate (742) (which is connected to shaft casing, brake piston (702) and spline of cylinder block (111)).
  • Page 405 Counterbalance Valve The port Av is connected to hydraulic pump. Port Bv is connected to hydraulic oil tank. The oil supplied from the hydraulic pump tries to turn the hydraulic motor by opening the check valve poppet, allowing oil to flow from; Av → Cv → C' → L →...
  • Page 406 Operation of Swash Plate Control Capacity of traveling motor varies with the change of swash plate (201) tilting angle. The tilt angle is controlled by tilting valve. NOTE: The smaller the tilt angle is, the faster the motor will rotate, while creating less torque. NOTE: The larger the tilt angle is, the slower the motor will rotate, while creating more torque.
  • Page 407 External pilot pressure: Pi ≥ 20 kg/cm (284 psi) (Small tilt angle) If pilot pressure acts on tilting valve, the force acting to spool (531) is greater than the swash spring (533). This forces the swash spool (531) to move to the left. High- pressure oil flows through port Sa and Sb of tilting valve and passages, and acts on swash piston (502) until swash piston (501) is stopped by stopper (514).

  • Page 408: Parts List

    Parts List FG003961 Figure 8 Travel Motor SP000032 Page 14...
  • Page 409 Reference Reference Description Description Number Number Shaft O-ring Roller Bearing O-ring Needle Bearing Oil Seal Spacer - Bearing Swash Piston Retaining Ring Swash Piston Cylinder Block Stopper (Left) Spring Cylinder O-ring Spacer Swash Rod Piston and Shoe Assembly Lock Screw Bushing and Push Plate Assembly Hex Nut Valve Plate...

  • Page 410: Specifications

    Specifications Items Specification 260 l/min Input Flow (69 gpm) Set Pressure of Relief V/V 330 kg/cm (Cracking) (4,700 psi) 173/101 cc/rev Motor Displacement (10.56 - 6.16 in 90.9/53.1 kg•m Motor Output Torque (657 - 384 ft lb) Theoretical Output Speed 1503/2574 rpm 40 kg•m Theoretical Brake Torque...
  • Page 411 SPECIAL TOOLS AND MATERIALS Tools B Length Tools to Be Used Hex L wrench 4 mm Plug (461), orifice screws (545 and 546) 8 mm Hex socket head bolt (367), lock screw (506), plug (571) 10 mm Hex socket head bolt (368) 46 mm Relief Valve (350) Socket wrench spanner...

  • Page 412: 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 413 Problem Possible Cause Remedy Number of rotation is below specification. Insufficient rotation. Lack of incoming oil. Check hydraulic circuits up to motor. Too high oil temperature. Decrease oil temperature. Too much leakage. Replace or repair faulty parts. Each way worn or broken that tilting Replace or repair faulty parts.

  • Page 414: 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 415 FG001099 Figure 12 Rotate disassembly/reassembly jig 90°, so hydraulic motor shaft is pointing up. Remove lock ring (435) using retaining ring pliers. FG001100 Figure 13 Remove hex socket head bolts (401 and 402) holding valve casing. FG001101 Figure 14 Remove valve casing subassembly and valve plate (131). NOTE: If valve plate is excessively worn, replace it with new one.
  • Page 416 FG001103 Figure 16 Remove brake spring (705) and brake piston by connecting two M16 bolts to piston (702) and pulling them upwards. NOTE: There are ten brake springs. FG001104 Figure 17 FG001105 Figure 18 FG001106 Figure 19 Travel Motor SP000032 Page 22...
  • Page 417 Rotate disassembly/reassembly jig 90° so motor is horizontal. Remove cylinder and piston subassembly. Figure 20 Disassemble stopper L (503) and swash plate piston (502). NOTE: Swash plate piston: M5 bolt used. FG001108 Figure 21 Remove swash plate (201). FG001109 Figure 22 10.
  • Page 418 11. Disassemble swash plate piston (501) and stopper (S) (514). FG001111 Figure 24 12. Rotate disassembly/reassembly jig 90° so drive shaft (101) points up. Tap bottom of shaft using hammer to separate it from shaft casing. NOTE: Take care not to damage roller bearing (102). FG001112 Figure 25 Disassembly of Valve Casing...
  • Page 419 FG001114 Figure 28 Remove hex socket head bolts (367 and 368), remove caps (365 and 366), and disassemble counterbalance valve (361). NOTE: Pay attention to direction of left and right sides of plunger when disassembling counterbalance valve. NOTE: If spool or spring is damaged, replace it with a new one.

  • Page 420: Disassembly Of Cylinder Subassembly

    FG001119 Figure 32 FG001120 Figure 33 Disassembly of Cylinder Subassembly Remove push plate (122) and piston (121). FG001121 Figure 34 Travel Motor SP000032 Page 26...
  • Page 421 Remove friction plate (742) and separation plate (741). FG001122 Figure 35 Remove bush plate (122), spacer (116), and spring (114). FG001123 Figure 36 FG001124 Figure 37 FG001125 Figure 38 Travel Motor SP000032 Page 27...

  • Page 422: Cleaning And Inspection

    CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section. Maintenance Standard Change parts with standard of the following table. If parts have damages of external appearance, change without the following table.
  • Page 423 Recommend Standard Parts name and inspection item ed value of Remedy dimension replacement When disassembling, O-ring/Oil seal replace as a rule. If there are crushing parts, Kinds of bolt replace. there signs Piston ring sticking deforming, replace. Clearance between piston and cylinder bore: D-d Figure 39 Thickness of shoe: t Figure 40...
  • Page 424 Height difference of spherical bush and pressure plate: H-h Figure 42 Parts Inspection and Inspection Standard of Reduction Gear This reduction gear has few parts and designing life of each part is about the same. And so a state of single part can be supplied, but when changing there are many parts to change simultaneously for structure and function.
  • Page 425 Inspection item Standard Standard of replacement Remark Carrier Clearance between 0.3 - 0.7 assembly cluster gear thrust washer Smoothing turn and noise of cluster gear Floating Seal Damage of sliding surface seal O-ring Damage Thrust bearing Below 4.7 Below 5.2 Below 5.7 Gear oil Refer...

  • Page 426: Reassembly

    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. Each connecting parts should be tightened according to its assigned torque. Only use a plastic soft-faced hammer. Reassembly of Drive Shaft Subassembly Assemble bearing spacer (106) into drive shaft and insert cylindrical roller bearing (102) by heating it.

  • Page 427: Assembly Of Valve Casing Subassembly

    Assemble ring stop (107) using retaining ring pliers. NOTE: Pay attention to direction of ring stop (its round part faces bearing). FG001129 Figure 46 Assembly of Valve Casing Subassembly Connect 5 plugs (461) to valve casing (303) according to a specified torque.
  • Page 428 Assemble in proper order, sheet (541), ball (543), stopper (542), and O-ring (568). NOTE: Pay attention to assembly order and direction of sheet and stopper. NOTE: Connection torque: 370 kg•cm (27 ft lb). FG001133 Figure 50 FG001134 Figure 51 Assemble HP plug (567) to which O-ring (568) is attached. NOTE: Five places.
  • Page 429 Insert counterbalance spool (361) and damper check (364) in valve casing. FG001118 Figure 54 FG001117 Figure 55 FG001120 Figure 56 FG001119 Figure 57 Travel Motor SP000032 Page 35...
  • Page 430 Connect caps R (366) and L (365) with hex socket head bolts (367 and 368). NOTE: Take care not to change connection points of Caps R and L. NOTE: Connection torque: M12: 1,000 kg•cm (72 ft lb) -- (368) M10: 670 kg•cm (48 ft lb) -- (367) FG001136 Figure 58 Insert automatic switching spool (531), spring (533), and...

  • Page 431: Assembly Of Cylinder Subassembly

    11. Install O-ring (472) on valve casing. FG001139 Figure 62 12. Connect drain plug (464) with O-ring (485). NOTE: Connection torque: 1,100 kg•cm (80 ft lb). FG001140 Figure 63 Assembly of Cylinder Subassembly Assemble cylinder spring (114), spacer (116), and bush plate (112) into cylinder (111).
  • Page 432 FG001149 Figure 66 Assemble friction plate (742) and separation plate (741) into cylinder. FG001150 Figure 67 Insert piston shoe (121) in push plate (122) and assemble it into cylinder. FG001151 Figure 68 FG001152 Figure 69 Travel Motor SP000032 Page 38...

  • Page 433: Assembly Of Motor Body

    Insert oil seal (491) in shaft casing (272) using jig. Make sure it is properly seated. FG001153 Figure 70 Assembly of Motor Body Connect 5 plugs (461) to shaft casing (303) according to a specified torque. NOTE: Wrap sealing tape around plug, or spread Loctite before starting assembly.
  • Page 434 FG001157 Figure 74 Assemble drive shaft subassemblies. FG001158 Figure 75 Use M12 bolts when assembling swash plates (201). NOTE: Pay attention to insertion direction of swash plate supports. FG001159 Figure 76 Assemble swash plate supports (201) into swash plates. NOTE: Apply grease to slideway of swash plate.
  • Page 435 Assemble stopper L (503) where tilting piston (502) and O- ring (504) are inserted. FG001161 Figure 78 FG001162 Figure 79 Rotate disassembly/reassembly jig 90° to change shaft direction from vertical to horizontal. NOTE: Take care that swash plate does not fall apart from its support.
  • Page 436 Rotate disassembly/reassembly jig 90° to change shaft direction from horizontal to vertical. FG001165 Figure 82 10. Install piston rings 252 (707) and 278 (708) onto brake piston (702). FG001166 Figure 83 11. Install brake piston into shaft casing. NOTE: Pay attention to direction of assembling brake piston.
  • Page 437 13. Install orifice screw (545 and 546) according to a specified torqued and insert O-ring (509). NOTE: Qty and size: 2 (546) with ø0.8 1 (545) with ø1.5 NOTE: Connection torque: 70 kg•cm (5 ft lb). FG001169 Figure 86 14. Insert valve plate (131) in valve casing and connect it to shaft casing with a hex socket head bolt (401 and 402).
  • Page 438 Travel Motor SP000032 Page 44...
  • Page 439 SP000068 AXIAL PISTON PUMPSP000068 Axial Piston Pump Edition 1 Axial Piston Pump SP000068 Page 1...
  • Page 440 MEMO Axial Piston Pump SP000068 Page 2...
  • Page 441 Table of Contents Axial Piston Pump Safety Precautions ..........5 Applicable Models ..........5 Axial Piston Pump ..........6 General Description............6 Model Number Designation........6 Theory of Operation ........... 7 Parts List ..............8 Torques ..............10 Special Tools and Materials .......... 11 Tools.................
  • Page 442 Maximum Flow Is Not Available ....... 37 Adjustment of Maximum and Minimum Flows..37 Preparation for Disassembly ......... 39 Regulator Disassembly ..........40 Regulator Reassembly ..........43 Axial Piston Pump SP000068 Page 4...

  • Page 443: 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 7440 and Up DX300LCA 5001 and Up Axial Piston Pump SP000068 Page 5...

  • Page 444: Axial Piston Pump

    AXIAL PISTON PUMP General Description Model Number Designation K 5 V 1 4 0 D T - 1 C 9 R - 9 N 0 1 Regulator type: For more details, see the instruction manual for the regulator. Shaft rotation viewed from shaft end.

  • Page 445: Theory Of Operation

    Theory of Operation Construction This pump assembly consists of two pumps connected by a spline inside 1st gear (116). The two pumps can be driven simultaneously as the rotation of the prime mover (engine) is transferred by the drive shaft (F) (111) on the front side. The suction and discharge ports are integrated at the connecting part of the two pumps;...

  • Page 446: Parts List

    Valve Block Group The valve block group consists of valve block (312), valve plate (313) and valve plate pin (885). The valve plate has two melon-shaped ports, that are mated to the valve block. These feed and collect oil to and from the cylinder block. The oil changed over by the valve plate is connected to an external pipeline by way of valve block.
  • Page 447 Reference Reference Description Description Number Number Gear Pump Plug Drive Shaft (F) Tilting Pin Drive Shaft (R) Servo Piston 1st Gear Stopper (L) Roller Bearing Stopper (S) Needle Bearing Feed Back Pin Bearing Spacer O-ring Cylinder Block O-ring Piston O-ring Shoe O-ring Set Plate...

  • Page 448: Torques

    Torques Part Name Size Tightening Tool Name (B) Torque (kg•cm) Hex socket head bolt Allen wrench (Material: SCM 435) 1000 1600 2400 3400 4400 PT plug (Material: PT 1/16 S45C) PT 1/8 PT 1/4 Wind a seal tape 1 PT 3/8 2 turns round the plug.

  • Page 449: Tools

    Special Tools and Materials Tools The tools necessary to disassemble / reassemble the K3V pump are shown in the following list. The sizes of the bolts and plugs depend on the pump type. Necessary Tool (Marked with O) Tool Name and Size Part Name Pump Type PT Plug...
  • Page 450 Necessary Tool (O) Tool Name and Size Part Name Pump Type Hex headed VP plug (PF Name K5V80 K5V140 Hex nut bolt thread) Double ring VP-1/4 spanner, Socket wrench, Double (single) open VP-1/2 end spanner. VP-3/4 VP-1 VP-1 VP-1 Adjustable angle Medium size, 1 set wrench Screwdriver...

  • Page 451: Troubleshooting, Testing And Adjustment

    Troubleshooting, Testing and Adjustment General Cautions This section describes the countermeasures to be taken if any abnormality is detected during the operation of the Kawasaki swash plate type axial piston pump. The general cautions are as follows: Consider the condition before starting work. Judge the nature of the abnormality, before starting work.
  • Page 452 If the failure is a problem in control, do not unnecessarily overhaul the pump, but measure pressures at various areas to investigate the abnormal position. Overload of Prime Mover Possible Cause Remedy Remark Is the speed pressure higher than their Set them as specified.

  • Page 453: Disassembly

    Disassembly For disassembling the pump, read this section thoroughly and disassemble it in the following sequence. The figures in parentheses after part names show the items in Figure 22 construction of pump. This maintenance manual describes disassembling procedures for both the single pump and tandem type double- pump.
  • Page 454 Place pump horizontally on workbench with its regulator- fitting surface down, and separate pump casing (271) from valve block (312). IMPORTANT Before laying this surface down, spread rubber mat on workbench to prevent this surface from being damaged. HDM3017L Figure 6 Pull cylinder (141) out of pump casing (271) straight over drive shaft (111).
  • Page 455 10. Remove shoe plate (211) and swash plate (212) from pump casing (271). HDM3021L Figure 10 11. Lightly tapping shaft ends of drive shafts (111 and 113) with plastic hammer, remove drive shafts from swash plate supports. Figure 11 12. Remove valve plates (313 and 314) from valve block (312). IMPORTANT These may be removed in work 6.

  • Page 456: 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. Worn Part Replacement Criteria When a part exceeds any of the following criteria, replace or readjust it. However, when a part is damaged seriously in appearance, replace it without fail.

  • Page 457: Correction Criteria For Cylinder, Valve Plate And

    Clearance between Piston & Cylinder Free Height of Cylinder Spring : L Bore : D-d Play between Piston & Shoe : Combined Height of Set Plate & FG001294 Thickness of Shoe : t Spherical Bush : H-h Figure 13 Correction Criteria for Cylinder, Valve Plate and Swash Plate (Shoe Plate) Surface roughness necessary to be Surface roughness for valve...

  • Page 458: Reassembly

    Reassembly For reassembling reverse the disassembling procedures, paying attention to the following items. • not fail to repair parts damaged during disassembling, and prepare replacement parts in advance. • Clean each part fully with cleaning oil and dry it with compressed air.
  • Page 459 On swash plate support (251), secure drive shaft (111), set bearing (123), bearing spacer (127) and retaining ring (824). IMPORTANT Do not tap drive shaft with hammer. Assemble them into support, lightly tapping outer race of bearing with plastic hammer. Fully seat them, using steel bar.
  • Page 460 Position valve block (312) in pump casing (271) and tighten hex socket head bolts (401). IMPORTANT Assemble the rear pump side first, to make the procedure easier. Do not mistake direction of valve block. Clockwise rotation (viewed from input shaft side) - Install block with regulator up and with delivery flange left, viewed from front side.
  • Page 461 710 774 153 156 FG000609 Figure 22 Axial Piston Pump SP000068 Page 23...

  • Page 462: Start-Up Procedures

    Start-up Procedures Oil filling and Air Venting Applied Item Caution Type Oil filling. Fill the pump casing with oil. Inside the pump there are high- All types. speed sliding and moving parts, such as bearings, pistons/ shoes, retainer, etc. If not filled with oil, these parts may suffer some serious problems, such as seizures damage.

  • Page 463: Regulator For Axial Piston Pump

    REGULATOR FOR AXIAL PISTON PUMP General Description Model Number Designation K R 3 S - 9 N 0 1 Regulator Design Series Number Kind of flow control O : Without flow control N : Negative flow control P : Positive flow control M : Manual flow control E : electric flow control C : Negative flow control...

  • Page 464: Parts List

    Parts List Figure 24 Axial Piston Pump SP000068 Page 26...

  • Page 465: Outline

    Reference Reference Description Description Number Number Hex Socket Head Screw Spool Hex Socket Head Screw Spring Seat Hex Socket Head Screw Return Spring Hex Socket Head Screw Set Spring Plug Block Cover Tilting Pin O-ring Feedback Pin O-ring Casing O-ring Feedback Lever O-ring Lever (1)
  • Page 466 Horsepower Control Code Control Type Control Curve Function and Features According to the rise of delivery pressure Constant of a pump, the tilting angle of the pump is horsepower control automatically controlled and torque control is achieved. According to the rise of delivery pressure of a pump, the tilting angle of the pump is automatically controlled and torque control Companion...

  • Page 467: Specifications

    Code Control Type Control Curve Function and Features Negative flow Negative flow control can be carried out by control using the pilot pressure. Two-stage max. Two-stage max. flow control can be flow control obtained supplying external pilot pressure. (only in negative flow control) One flow control and one horsepower control pump can be combined for use.
  • Page 468 Regulator Function Diagram Figure 25 Negative Flow Control By changing the pilot pressure Pi, the pump tilting angle (delivery flow) is regulated arbitrarily, as shown in Figure 26. This regulator is a negative flow control in which the delivery flow Q decreases as the pilot pressure Pi rises. With this mechanism, when the pilot pressure corresponding to the flow required for the work is commanded, the pump discharges the required flow only, so it does not consume unnecessary power.
  • Page 469 The groove (A) in the pilot piston is attached with pin (875) that is fixed to lever 2 (613). Therefore, when the pilot piston moves, lever 2 rotates around the fulcrum of point B (fixed by the fulcrum plug (614) and pin (875).
  • Page 470 Adjustment of flow control characteristic The flow control characteristic can be adjusted with the adjusting screw. Adjust it by loosening the hex nut (801) and by tightening (or loosening) the hex socket head screw (924). Tightening the screw shifts the control chart to the right as shown in the Figure 27.
  • Page 471 As the spool moves, the delivery pressure P1 is admitted to the large-diameter section of the servo piston via Port C liter, causes the servo piston move to the right, reduces the pump delivery flow rate, and prevents the prime mover from being overloaded. The movement of the servo piston is transmitted to the feedback lever via point D.
  • Page 472 Adjustment of outer springs Adjust it by loosening the hex nut (630) and by tightening (or loosening) the adjusting screw C (628). Tightening the screw shifts the control chart to the right and increases the input horsepower as shown in the Figure 29.
  • Page 473 Tightening Torque Part Name Size Tightening Torque Tool Name Hex socket head bolt 70 kg•cm B = 4 (Material: SCM 435) 120 kg•cm 300 kg•cm M 10 580 kg•cm M 12 1,000 kg•cm M 14 1,600 kg•cm M 16 2,400 kg•cm Allen wrench M 18 3,400 kg•cm...
  • Page 474 Special Tools and Materials Tools Name Description 4,5,6 (Dimension B mm) Allen Wrench Socket Wrench, Double-ended (Single- ended) Wrench Adjustable Wrench Small size (max. 36 mm) Screwdriver Plastic Hammer Torque Wrench Pliers 2 sets for retaining ring Steel Bar 4 mm or less in dia., L=100 mm Pincers Bolt M4, L = about 50 mm...
  • Page 475 Maximum Flow Is Not Available Check that the pilot pressure Pi is normal. The pilot piston (643) is stuck: • Disassemble and clean the regulator. The spool (652) is stuck: • Disassemble and clean the regulator. The piston QMC stopper (647) and piston (648) are stuck with each other: •...
  • Page 476 Adjustment of Minimum Flow Adjust it by loosening the hex nut (909) and by tightening (or loosening) the hex socket head set screw (953). Similarly to the adjustment of the maximum flow, other characteristics are not chanced. However, remember that, if tightened too much, the required horsepower during the maximum delivery pressure (or during relieving) may increase.
  • Page 477 Preparation for Disassembly Since the regulator consists of small precision finished parts, disassembly and assembly are rather complicated. For this reason, replacement of a regulator assembly is recommended, unless there is a special reason, but in case disassembly is necessary for an unavoidable reason, read through this manual to the end before starting disassembly.
  • Page 478 Regulator Disassembly Choose a place for disassembly. CAUTION Choose a clean place. Spread rubber mat or cloth, on top of workbench to prevent parts from being damaged. Remove dust, rust, etc. from surfaces of regulator with cleaning oil. Remove hex socket head screws (412,413) and regulator main body from pump main body.
  • Page 479 Remove hex socket head screws (436, 438) and pilot cover (641). After removing pilot cover, remove set spring (655) from pilot section. Figure 37 Remove retaining ring (814), spring seat (653), return spring (654) and sleeve (651). IMPORTANT Sleeve (651) is attached with retaining ring (836). When removing retaining ring (814), return spring (654) may pop out.
  • Page 480 10. Remove lever (2) (613). Do not draw out pin (875). IMPORTANT Work will be promoted by using pincers. Figure 41 11. Draw out pin (874) and remove feedback lever (611). Figure 42 IMPORTANT Push out pin (874) (4 mm (0.16 in) in dia.) from above with slender steel bar so that it may not interfere with lever (1) (612).
  • Page 481 Regulator Reassembly For assembly, reverse disassembly procedures, but pay attention to the following. • Always repair parts that were scored at disassembly. Get replacement parts ready beforehand. • Mixing of foreign material will cause malfunction. Therefore, wash parts well with cleaning oil, let them dry with jet air and handle them in clean place.
  • Page 482 Press fit pin in lever (2) (613) into groove of pilot piston. Then attach lever (2). Figure 46 Install fulcrum plug (614) so that pin pressed into fulcrum plug (614) can be inserted into pin hole of lever (2). Then attach locking ring (858).
  • Page 483 12. Insert spring seat (644), pilot spring (646) and adjusting ring (Q) (645) into pilot hole. 13. Install spring seat (624), inner spring (626) and outer spring (625) into compensating hole. IMPORTANT When fitting spring seat, do not mistake direction of spring seat.
  • Page 484 Axial Piston Pump SP000068 Page 46...
  • Page 485 SP000033 GEAR PUMP SP000033 Gear Pump Edition 1 Gear Pump SP000033 Page 1...
  • Page 486 MEMO Gear Pump SP000033 Page 2...
  • Page 487 Table of Contents Gear Pump Safety Precautions ..........5 Applicable Models ..........5 Single Gear Pump ..........6 Disassembly ..............6 Reassembly..............8 Double Gear Pump ..........12 Disassembly ..............12 Reassembly..............14 Gear Pump SP000033 Page 3...
  • Page 488 MEMO Gear Pump SP000033 Page 4...

  • Page 489: Gear Pump

    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 7440 and Up DX300LCA 5001 and Up Gear Pump SP000033 Page 5...

  • Page 490: Single Gear Pump

    SINGLE GEAR PUMP Disassembly Clean exterior of pump. FG001072 Figure 1 Remove clamp bolts. FG001074 Figure 2 Cover sharp edges of drive shaft with adhesive tape and coat shaft end extension with clean grease, to avoid any damage to lip of shaft seal when removing mounting flange.
  • Page 491 Remove mounting flange taking care to keep flange as straight as possible during removal. If mounting flange is stuck, tap around edge with rubber mallet in order to break it away from body. NOTE: Make sure that while removing mounting flange, shaft and other components remain in position.

  • Page 492: Reassembly

    Remove driving gear and driven gear, keeping gears as straight as possible. FG001077 Figure 8 Remove rear plate and end cover. FG001078 Figure 9 Reassembly Clean all components with care. FG001078 Figure 10 Using a suitable driver, install shaft seal in mounting flange.
  • Page 493 Install retaining ring in groove. FG000840 Figure 12 Install O-ring on both sides of rear section of body. NOTE: Coat O-rings with grease to hold O-rings in body. FG001079 Figure 13 Install rear section body on rear cover. FG001080 Figure 14 Install seals in pressure plate(s) groove.
  • Page 494 Insert pressure plate assembly into body while keeping it straight. NOTE: Seal side should face to rear cover, opposite side of gears. NOTE: Pay attention to installation direction of seal. FG001081 Figure 16 Install drive gear and driven gear. FG001082 Figure 17 Insert pressure plate into body in proper direction.
  • Page 495 11. Tighten bolts with washer in a crisscross pattern to a torque value of 45 Nm. FG001085 Figure 20 12. Check that pump rotates freely when drive shaft is turned by hand. If not a pressure plate seal may be pinched. FG000851 Figure 21 Gear Pump...

  • Page 496: Double Gear Pump

    DOUBLE GEAR PUMP Disassembly Clean exterior of pump. FG000830 Figure 22 Remove clamp bolts. FG000831 Figure 23 Cover sharp edges of drive shaft with adhesive tape, and coat shaft end extension with clean grease, to avoid any damage to lip of shaft seal when removing mounting flange.
  • Page 497 Remove mounting flange taking care to keep flange as straight as possible during removal. If mounting flange is stuck, tap around edge with rubber mallet in order to break it away from body. NOTE: Make sure that while removing mounting flange, shaft and other components remain in position.

  • Page 498: Reassembly

    Remove intermediate cover and through shaft. FG000837 Figure 29 Remove all remaining components in same manner as first section. FG000838 Figure 30 Reassembly Clean all components with care. FG000838 Figure 31 Using a suitable driver, install shaft seal in mounting flange.
  • Page 499 Install retaining ring in groove. FG000840 Figure 33 Install O-ring on both sides of rear section of body. NOTE: Coat O-rings with grease to hold O-rings in body. FG000841 Figure 34 Install rear section body on rear cover. FG000842 Figure 35 Install seals in pressure plate(s) groove.
  • Page 500 Insert pressure plate assembly into body while keeping plate straight. NOTE: Seal side should face to rear cover, opposite side of gears. NOTE: Pay attention to direction of seal. FG000844 Figure 37 Install drive gear and driven gear. FG000845 Figure 38 Insert pressure plate into body in proper direction.
  • Page 501 11. Install remaining section using preceding procedure. FG000848 Figure 41 12. Locate mounting flange in right position. FG000849 Figure 42 13. Tighten bolts with washer in a crisscross pattern to a torque value of 45 Nm. FG000850 Figure 43 14. Check that pump rotates freely when drive shaft is turned by hand.
  • Page 502 Gear Pump SP000033 Page 18...
  • Page 503 SP000034 MAIN CONTROL VALVESP000034 Main Control Valve Edition 1 Main Control Valve SP000034 Page 1...
  • Page 504 MEMO Main Control Valve SP000034 Page 2...
  • Page 505 Table of Contents Main Control Valve Safety Precautions ..........5 Applicable Models ..........5 General Description ..........6 Theory of Operation ............6 Parts List ............... 38 Specifications ..............43 Troubleshooting, Testing and Adjustment ..44 Troubleshooting............. 44 Adjustment of Valves............. 45 Disassembly ............
  • Page 506 MEMO Main Control Valve SP000034 Page 4...
  • Page 507 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 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up Main Control Valve SP000034 Page 5...
  • Page 508 GENERAL DESCRIPTION Theory of Operation When All Spools are in Neutral Neutral Passage The oil supplied from the port (P1) enters into the tank passage (Ta) through the orifice (Lc 1) of negative relief from the neutral passage (L1) and returns to ports (T1, T2 and T3). The oil supplied from the port (P2) passes the tank passage (Ta) through orifice (Rc 1) of negative relief from the neutral passage (R1) and returns to port (T1, T2 and T3).
  • Page 509 Negative Control Negative Control Relief Valve (L) Relief Valve (R) ARM 1 ARM 2 [Section 5] [Section 9] BOOM 2 BOOM 1 [Section 4] [Section 8] SWING BUCKET [Section 3] [Section 7] TRAVEL OPTION [Section 6] [Section 2] STRAIGHT TRAVEL TRAVEL [Section 1] [Section ST]...
  • Page 510 ARM 1 [Section 5] BOOM 2 [Section 4] SWING [Section 3] OPTION [Section 2] TRAVEL [Section 1] SECTION "L-L" FG001296 "Z" Detail Figure 2 Main Control Valve SP000034 Page 8...
  • Page 511 ARM 2 [Section 9] BOOM 1 [Section 8] BUCKET [Section 7] TRAVEL [Section 6] STRAIGHT TRAVEL [Section ST] SECTION "R-R" FG001297 Figure 3 Main Control Valve SP000034 Page 9...
  • Page 512 Signal Passage Oil supplied to port (PP) flows through orifice (Lc3) to port (PT) and simultaneously flows through land (Lc4), passage (5), and land (Rc3) into tank passage (Ta). The same oil supplied to port (PP), then flows through orifice (Lc5) into port (PA), and it also flows through passages (L4, 7 and R4) to bucket spool land (Rc4) and then flows into drain passage (DR).
  • Page 513 Main Control Valve SP000034 Page 11...
  • Page 514 Single Operation Travel Spool Shift When shifting travel spool by increasing pressure of travel (Section 1) pilot port (Pb1 (Pa1)), oil supplied to port (P1) flows through neutral passage (L1) to spool and flows to port (B1 (A1)). Return oil flows through port (A1 (B1)), to spool and returns to tank passage (Ta).
  • Page 515 Switched Position OPTION [Section 2] Neutral Position Switched Position TRAVEL [Section 6] Neutral Position TRAVEL [Section 1] Switched Position STRAIGHT TRAVEL [Section ST] FG001299 Figure 5 Main Control Valve SP000034 Page 13...
  • Page 516 Swing Spool Shift When shifting swing spool by increasing pressure of swing (Section 3) pilot port (Pb3 (Pa3)), neutral port (L1) is closed. Oil supplied to port (P1) flows through parallel passage (L3), load check valve (S3-2), passage (S3-1) and spool, it then flows to port (B3 (A3)).
  • Page 517 Switched Position SWING [Section 3] Neutral Position BUCKET [Section 7] FG001300 Figure 6 Main Control Valve SP000034 Page 15...
  • Page 518 Regeneration When bucket spool is shifted by increasing pressure of bucket (Section 7) pilot port (Pb7), neutral passage (R1) is closed. Oil supplied to port (P2) flows through parallel passage (R3), load check valve (S7-2), passage (S7-1), spool and into port (A7). Oil flows through port (B7) and one portion of the oil returns through spool to tank passage (Ta), and the other portion of oil flows through inside of spool, and pushes up...
  • Page 519 Boom Spool Shift Neutral This valve also works with anti drift valves that are installed on the bottom side of each boom cylinder. When in neutral, poppet (AD1) is closed by port (A8) pressure that is sent through passage (AD2), spool (AD3) to spring chamber (AD4).
  • Page 520 Boom up (2-pump confluence) When boom 1 spool is shifted by increasing pressure of boom 1 (Section 8) pilot port (Pa8), neutral passage (R1) is closed. Oil supplied to port (P2) flows through parallel passage (R3) and load check valve (S8-2) to spool and flows into port (A8).
  • Page 521 (Boom down (regeneration) When boom 1 (Section 8) spool is shifted by increasing pressure of boom 1 pilot port (Pb8), neutral passage (R1) is closed. Oil supplied to port (P2) flows through parallel passage (R3) and load check valve (S8-2) to spool and flows into port (B8).
  • Page 522 Arm Spool Shift Neutral This valve also works with an anti drift valve that is installed on rod side of the arm cylinder. When in neutral, poppet (AD1) is closed by port (A5) pressure that is sent through passage (AD2), spool (AD3) and to spring chamber (AD4).
  • Page 523 Arm in 2-pump confluence When arm 1 spool is shifted by increasing pressure of arm 1 (Section 5) pilot port (Pb5), oil supplied to port (P1) flows through neutral passage (L1), load check valve (S5-2), passage (S5-1) and spool into port (B5). When arm 2 spool is shifted by increasing pressure of arm 2 (Section 9) pilot port (pb9), oil supplied to port (P2) flows through neutral passage (R1), load check...
  • Page 524 Variable regeneration When crowding arm, after return oil from port (A5) flows through notch (a), one portion of the oil returns through fixed orifice (d), passage (e) and variable orifice (f) and to tank passage (Ta). The other portion of the oil flows through fixed orifice (b), regeneration check (c), and fixed orifice (i) in arm 1 spool, and joins in bridge passage (S5-1).
  • Page 525 Arm out (2-pump confluence) When arm 1 spool is shifted by increasing pressure of arm 1 (Section 5) pilot port (Pa5), oil supplied to port (P1) flows through neutral passage (L1), load check valve (S5-2), passage (S5-1) and spool and into port (A5). Oil supplied to port (P2) flows through neutral passage (R1), load check valve (S9-2), passage (S9-1), spool and passage (8) and joins at port (A5).
  • Page 526 Parallel Orifice for Arm The orifice, that is installed in parallel passage for arm 1, controls arm speed when operating in a combined operation. Oil supplied from parallel passage (L3) of arm 1 (Section 5) pushes open poppet (S5-3). It then flows through orifice (Lc8) of variable orifice spool, and then is connected to passage (L5).
  • Page 527 Relief Valve Main relief valve Oil supplied to port (P1) flows through poppet (LP). Oil supplied to port (P2) flows through poppet (RP) and passage (3). They join at the main relief valve. The highest pressure of pump (P1 and P2) is controlled by reaction of main relief valve.
  • Page 528 Compound Operation Travel Compound Operation In the event of operating another function when the traveling left or right (when advancing, backing, or pivot turning) or operating for travel operation during the operation other than traveling, the oil supplied from the port (PP) is cut off from the tank passage (Ta) in the signal land part of the section other than the travel shifted from the land (Lc4), (Lc7), (Rc3), and (Rc5), and the pressure of the signal passage is increased to the relief set...
  • Page 529 TRAVEL [Section 1] TRAVEL [Section 1] STRAIGHT TRAVEL [Section ST] FG001310 Figure 17 Main Control Valve SP000034 Page 27...
  • Page 530 Bucket Compound Operation A priority control valve is installed in bucket (Section 7). This valve controls oil flow entering into bucket when operating during a combined operation with travel, boom 1, and arm 2 sections, on P2 side. If pressure at port (Pi) is increased when operating bucket, piston (S7-6), piston (S7-5) and plug (S7-4) are pressed, and poppet assembly (S7-2) is seated on valve housing.
  • Page 531 Switched Position SWING [Section 3] Neutral Position BUCKET [Section 7] FG001311 Figure 18 Main Control Valve SP000034 Page 29...
  • Page 532 Swing Compound Operation The valve's swing Section (Section 3) is equipped with the control valve that adjusts the flux that flows into the swing when combined operating with the Section (travel, boom 2, arm 1) of If port (Pi) is pressurized when operating swing function, piston (S3-6) is pushed to have the poppet assembly (S3-2) to be pressed under the seat part of the valve housing through the piston (S3-5) and plug (S3-4).
  • Page 533 Switched Position SWING [Section 3] Neutral Position BUCKET [Section 7] FG001312 Figure 19 Main Control Valve SP000034 Page 31...
  • Page 534 Antidrift Valve The antidrift valve is installed on the cylinder port on the arm load (boom bore) for the natural antidrift of the arm (boom) cylinder. (For typical example, arm (A5) is shown.) Neutral condition (maintaining port (A5)) The holding pressure of port (A5) is sent through passages (a, b, and c), and into spring chamber (d) of poppet (1).
  • Page 535 Main Relief Valve The main relief valve is between neutral oil passage (HP, "LP" Figure 23) and low-pressure oil passage (LP). Pressurized oil flows into neutral oil passage (HP) through orifice in the main poppet (C) to fill internal cavity (D). Due to the difference in areas between (A and B), on which hydraulic "HP"...
  • Page 536 Overload Relief Valve "LP" Operation The overload relief valve is between cylinder port (HP) and low-pressure oil passage (LP). Pressurized oil at cylinder "HP" port (HP), flows through an orifice in piston (C), to fill internal cavity (G). Due to the difference in area between (A and B) on which the hydraulic pressure acts, main poppet (D) seats on sleeve (K).
  • Page 537 Absorption Operation An anti void unit is installed in cylinder port (HP) to prevent "LP" the development of cavitation. If pressure at cylinder port (HP) becomes lower than that of oil passage (LP), sleeve (K) moves so that oil is supplied from the low-pressure oil passage (LP) to cylinder port (HP) to eliminate cavitation.
  • Page 538 Low-pressure Relief Valve Signal pressure Poppet Oil supplied from pump port (P1 (P2)) flows through neutral passage (L1 (R1)), low-pressure relief valve passage (L2 (R2)), and orifice (Lc1 (Rc1)) to tank passage (Ta). Lc1 [Rc1] Now, pressure generated at passage (L2 (R2)) by orifice (Lc1 (Rc1)) moves to low-pressure relief signal port (Ps1 (Ps2)).
  • Page 539 Main Control Valve SP000034 Page 37...

  • Page 540: Parts List

    Parts List VIEW A FG003962 Figure 34 Main Control Valve SP000034 Page 38...
  • Page 541 Reference Reference Description Description Number Number Poppet Plug Assembly Spring Socket Bolt (M10 x40L) Spacer Socket Bolt (M16 x130L) Plug Assembly Washer Plug O-ring O-ring Main Relief Valve Plug Assembly Overload Relief Valve Plug Assembly Plug Assembly Main Control Valve SP000034 Page 39...
  • Page 542 ARM 1 BOOM 2 SWING OPTION TRAVEL ARM 2 BOOM 1 BUCKET TRAVEL STRAIGHT TRAVEL VIEW A SECTION B FG003963 Figure 35 Main Control Valve SP000034 Page 40...
  • Page 543 Reference Reference Description Description Number Number Housing Valve Swing Spool Assembly Arm Spool Assembly 2 Option Spool Assembly Boom Spool Assembly 1 Plug Bucket Spool Assembly O-ring Travel Spool Assembly Orifice Plug T/S Spool Assembly O-ring O-ring O-ring Foot Relief Valve Plug Assembly Housing Valve Socket Bolt (M10x28L)
  • Page 544 VIEW A FG003964 Figure 36 Main Control Valve SP000034 Page 42...

  • Page 545: Specifications

    Reference Reference Description Description Number Number O-ring SP Valve Spring Spool Poppet Spring Seat Poppet Spring Flange End Spool Spacer O-ring O-ring Arm Regen Assembly Backup-ring Plug Anti-drift Valve Assembly O-ring Socket Bolt (M10x55L) Spring Socket Bolt (M10x40L) Spool Socket Bolt (M10x70L) O-ring Socket Bolt (M6x20L) Backup Ring...

  • Page 546: Troubleshooting, Testing And Adjustment

    TROUBLESHOOTING, TESTING AND ADJUSTMENT Troubleshooting Overall Control Valve Problem Possible Cause Remedy Spool does not move. Oil temperature is abnormally Remove part with resistance of oil increased. leakage within pipeline. Pollution of operation oil. Replace operation oil and wash circuit at same time.

  • Page 547: Adjustment Of Valves

    Relief Valve Problem Possible Cause Remedy Press does not increase. Main poppet, sleeve or pilot poppet Replace relief valve. are stuck open and valve seat part has dust. Unstable relief pressure. The seat part of pilot poppet has groove. Piston or main poppet gets stuck. Abnormal relief pressure.
  • Page 548 Loosen lock nut (4) and turn adjusting plug (6) clockwise to raise relief pressure of preceding step. Turn adjusting plug (6) counterclockwise to lower relief pressure. One turn varies pressure by approximately 28.4 MPa [9,290 kg/cm (4,120 psi)]. Tighten lock nut (4) after pressure has been adjusted. Low-pressure adjustment (second stage) Loosen lock nut (7) and turn adjusting plug (8) counterclockwise to lower relief pressure at state of...

  • Page 549: Disassembly

    DISASSEMBLY Caution in Disassembly Shut down engine when pressure of actuator is not indicated. It is dangerous to disassemble control valve while it is under pressure. High-pressure oil can squirt out or components can spring out. When partially disassembling control valve that is on machine, be careful to follow the following caution.
  • Page 550 Disassembly of Main Spool Part Remove socket head bolt (74, two places per each section, width across flats: 8 mm) and cap (8, ten places). Remove plug assembly (72, width across flats: 8 mm) and plug (91, width across flats: 22 mm) according to necessity.
  • Page 551 Disassembly of Arm 1 Para-turn Spool Part Remove socket head bolt (78, width across flats: 5 mm) and cap (18). Remove O-ring (23) from cap (18). Remove spool (19) from valve housing under subassembly conditions. Disassembly of spool. CAUTION Work with spool gripped in vise with wood (see Figure 37), so as not to scratch outside diameter of spool.
  • Page 552 Disassembly of Load Check Valve Part CAUTION Removing a plug, when pressure is not fully released, or bucket is not lowered to ground, is very dangerous. A part in the valve may spring out and drop the bucket at the same time.
  • Page 553 Disassembly of Antidrift Valve Part NOTE: The part including the assembly is shown (assembly number-part number). CAUTION Removing antidrift valve seat, when pressure is not fully released, or bucket is not lowered to ground, is very dangerous. A part in the valve may spring out and drop the bucket at the same time.
  • Page 554 Disassembly of Relief Valve CAUTION Removing relief valve, when pressure is not fully released, or bucket is not lowered to ground, is very dangerous. A part in the valve may spring out and drop the bucket at the same time. Always lower bucket to ground and fully release pressure before disassembling.
  • Page 555 Disassembly of Valve Housing Bolt CAUTION Do not disassemble combined bolt (77) if it is unnecessary. If it is necessary to disassemble it, work by placing it horizontally on a work bench. Prepare spare O-ring (65 and 66). Remove socket head bolt (77, eight places, width across flats: 14 mm) and washer (81, eight places).
  • Page 556 Disassembly of Main Relief Valve "O-ring" P/N: 95111-01100 Width across flat 27 Width across flat 30 (Plug) (Hex. Nut) Width across "O-ring" P/N: 95111-01400 Width across flat 36 flat 27 (Hex. Nut) (Plug) JIS O-ring Type Piston "O-ring" P/N: 21001-00098 Width across flat 32 (Plug) FG001317...
  • Page 557 Disassembly of Overload Relief Valve Poppet Spring "O-ring" P/N: 95113-01000 "O-ring" P/N: 21001-00098 Width across flat 31.75 Width across flat 17 Width across flat 6 (Cap) (Lock Nut) (Adjuster) FG001318 Figure 39 This relief valve should be replaced as an assembly. When replacing it, remove cap (1, width across flats: 32 mm) and O-ring (2).
  • Page 558 Instruction of Disassembly and Assembly of Low-pressure Relief Valve "O-ring" P/N: 95113-02100 "O-ring" P/N: 21001-00213 FG001321 Figure 40 This unit has press fit portion (D) and it should be replaced as a complete assembly. Main Control Valve SP000034 Page 56...

  • Page 559: 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. Cleaning Clean all parts thoroughly using a suitable cleaning fluid and dry them with moisture free compressed air. Put them on a clean paper or a vinyl for inspection.

  • Page 560: Reassembly

    REASSEMBLY Caution on Assembly Caution on Handling O-ring Do not use O-ring which has any defect or scratches from handling. Apply grease or hydraulic oil to installation portion of O-ring grooves and O-ring to ease installation. Do not stretch O-ring beyond permanent set. When installing O-ring, be careful not to twist it.

  • Page 561: Sequence Of Subassembly

    Sequence of Subassembly CAUTION Check number of each part, installation position and tools needed before reassembling. Spool Assembly (Main Spool) Apply Loctite to threaded portion of spool (2-6 and 14-17) and install spring seat, spring and spool end. After gripping spool in vise with wood (that is used when disassembling it), tighten spool end.
  • Page 562 Antidrift Valve Assembly Install O-ring (67-9 and 67-10) and backup ring (67-11 and 67-12) in groove of sleeve (67-6). CAUTION Be careful of installation position of O-ring and backup ring. If they are reversed, the O-ring will be damaged and drift speed of actuator can be increased.
  • Page 563 Assembly of Relief Valve Install main relief valve (68). Tightening torque: Tightening torque: 7.95 - 8.97 kg•m (58 - 65 ft lb). Install overload relief valve (69, six places) in each section. Tightening torque: 7.95 - 8.97 kg•m (58 - 65 ft lb). Install spring seat (67-16) on small diameter of poppet.
  • Page 564 Insert backup ring (103), O-ring (104), spring (98) and poppet assembly (100) in sleeve (99), and install it to body (96). Install O-ring (36) in valve housing and fasten body using socket head bolt (101). Tightening torque: 5.91 - 6.53 kg•m (43 - 47 ft lb) Insert poppet (32) and spring (33) in arm 1 para turn part (Section C-C).
  • Page 565 Assembly of Arm 1 Para-turn Spool Install spool subassembly (19) into valve housing. CAUTION After inserting spool, check to see if it slides easily. Install O-ring (23) on cap (18) and fasten it in place with socket head bolt (78). Tightening torque: 0.90 - 1.10 kg•m (6.49 - 7.97 ft lb).
  • Page 566 Assembly of Other Plugs Install O-ring on plug assembly (60) and install. Tightening torque: 11 - 12 kg•m (76 - 83 ft lb) Install O-ring (62) on plug assembly (61) and install. Tightening torque: 4 - 4.5 kg•m (29 - 32 ft lb) Tighten orifice plug (63).

  • Page 567: Maintenance Of Relief Valves

    Maintenance of Relief Valves Reassembly of Main Relief Valve "O-ring" P/N: 95111-01100 Width across flat 27 Width across flat 30 (Plug) (Hex. Nut) Width across "O-ring" P/N: 95111-01400 Width across flat 36 flat 27 (Hex. Nut) (Plug) JIS O-ring Type Piston "O-ring"...
  • Page 568 Reassembly of Overload Relief Valve (69, Total of 6 Places) Poppet Spring "O-ring" P/N: 95113-01000 "O-ring" P/N: 21001-00098 Width across flat 31.75 Width across flat 17 Width across flat 6 (Cap) (Lock Nut) (Adjuster) FG001318 Figure 42 Check if there is dirt and paint chips around cap (1). Replace O-ring with new one.
  • Page 569 Reassembly of Low-pressure Relief Valve (70, Total of 2 Places) "O-ring" P/N: 95113-02100 "O-ring" P/N: 21001-00213 FG001321 Figure 43 Check if there is dirt and paint chips around plug (1). Replace O-ring (3) with new one. Install new O-ring (4) on sleeve (2).

  • Page 570: Installation

    INSTALLATION Be careful not to apply stress on control valve when attaching piping and hoses. Unnecessary stress may cause spools to bind and the control valve from functioning properly. 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.
  • Page 571 SP000069 REMOTE CONTROL VALVE (WORK LEVER / JOYSTICK) SP000069 Remote Control Valve (Work Lever / Joystick) Edition 1 Remote Control Valve (Work Lever / Joystick) SP000069 Page 1...
  • Page 572 MEMO Remote Control Valve (Work Lever / Joystick) SP000069 Page 2...
  • Page 573 Table of Contents Remote Control Valve (Work Lever / Joystick) Safety Precautions ..........5 Applicable Models ..........5 General Description ..........7 Theory of Operation ............7 Parts List ................. 8 Specifications ..............10 Torques ................. 10 Tools and Materials ..........10 Disassembly ............
  • Page 574 MEMO Remote Control Valve (Work Lever / Joystick) SP000069 Page 4...

  • Page 575: Safety Precautions

    The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up Remote Control Valve (Work Lever / Joystick)
  • Page 576 Remote Control Valve (Work Lever / Joystick) SP000069 Page 6...

  • Page 577: General Description

    GENERAL DESCRIPTION Theory of Operation Structure The remote control valve contains four push rods, spring holders, spools and return springs, which are in the valve casing. The valve works as a pressure reduction valve. The housing has six ports, which include input port P, tank port T, and four secondary pressure ports.

  • Page 578: Parts List

    Parts List 37 : 24 ~ 28 Figure 1 FG003938 Remote Control Valve (Work Lever / Joystick) SP000069 Page 8...
  • Page 579 Reference Reference Description Description Number Number Case Joint Assembly Plug Swash Plate Bushing Spool Shim Handle Assembly (L) Handle Assembly (R) Spring Spring Seat Handle Bar Stopper Spring Pin Spring Bellows Stopper Bushing Spring Connector Assembly Push Rod Switch Assembly Spring Spool Kit 1, 3 Spring Seat...

  • Page 580: Specifications

    Specifications Performance (19.6) Operating Torque (20) Operating Torque 15.9 3 15.4 3 5.5 2 5.5 2 Secondary Pressure Secondary Pressure (6.2) FG003944 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...

  • Page 581: 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 Remote Control Valve (Work Lever / Joystick) SP000069 Page 11...
  • Page 582 Remove plate (19) from case (1). FG000808 Figure 7 Remove plug kit assembly, stopper (10), and spring (11) from case (1). FG000809 Figure 8 FG000810 Figure 9 FG000811 Figure 10 Remote Control Valve (Work Lever / Joystick) SP000069 Page 12...
  • Page 583 Remove four spool kit assemblies from case (1). FG000812 Figure 11 FG000813 Figure 12 The bushing (3) and plug cannot be removed from case (1). FG000814 Figure 13 FG000815 Figure 14 Remote Control Valve (Work Lever / Joystick) SP000069 Page 13...
  • Page 584 FG000816 Figure 15 FG000817 Figure 16 Remote Control Valve (Work Lever / Joystick) SP000069 Page 14...

  • Page 585: Cleaning And Inspection

    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 17 FG000817 Figure 18 Install bushing (3) into case (1) using jig. FG000814 Figure 19 Remote Control Valve (Work Lever / Joystick)
  • Page 586 FG000816 Figure 20 FG000818 Figure 21 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 22 FG000812...
  • Page 587 Install spring (9) into case (1). FG000820 Figure 24 Install spool kit assembly into case (1). (The same way is used for four parts.) FG000821 Figure 25 Assemble plug kit insert rod seal (18), O-ring (17), and push rod (2) into plug (16) in proper order. FG000822 Figure 26 FG000810...
  • Page 588 Assemble four springs (11) and stoppers (10) and insert assembled set in case (1) to form a plug kit assembly. NOTE: Pay attention to measurement specifications of stoppers (1 and 3, 2 and 4). FG000809 Figure 28 FG000811 Figure 29 FG000823 Figure 30 Install plate (19) into case (1).
  • Page 589 Install joint assembly (21) into case (1). FG000807 Figure 32 10. Install wash plate (22) and hex nut (23) into case (1). FG000806 Figure 33 11. Insert bar and tighten it with a spanner to check balance of joint assembly. FG000824 Figure 34 12.
  • Page 590 13. Install lever assembly into case (1). FG000805 Figure 36 14. Put lead wire in bushing (29), tie it, and arrange boot. FG000826 Figure 37 FG000827 Figure 38 15. Install lead wire terminal into connector terminal pressing them together. FG001097 Figure 39 Remote Control Valve (Work Lever / Joystick) SP000069...
  • Page 591 16. Assemble connector assembly (30), and connect it to lead wire terminal, and properly route wiring. FG000828 Figure 40 FG000829 Figure 41 Remote Control Valve (Work Lever / Joystick) SP000069 Page 21...

  • Page 592: Start-Up Procedures

    START-UP PROCEDURES Start engine and set throttle at "LOW IDLE." Set safety lever on "UNLOCK" position. HAOB290L Figure 42 Slowly cycle boom, arm, bucket cylinders and swing motor about five times without a load to vent air from pilot lines. Do this for five minutes.
  • Page 593 SP001743 TRAVEL CONTROL VALVE (WITH DAMPER) SP001743 Travel Control Valve (With Damper) Edition 1 Travel Control Valve (With Damper) SP001743 Page 1...
  • Page 594 MEMO Travel Control Valve (With Damper) SP001743 Page 2...
  • Page 595 Table of Contents Track Assembly Safety Precautions ..........5 Applicable Models ..........5 General Description ..........6 Track Tension ............7 Cleaning and Inspection (Wear Limits and Tolerances)....... 9 Track Shoe ..............10 Lower Roller ..............12 Upper Roller ..............13 Front Idler ..............
  • Page 596 MEMO Travel Control Valve (With Damper) SP001743 Page 4...
  • Page 597 APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327 and Up...
  • Page 598 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 599 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 600 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 601 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 602 Travel Control Valve (With Damper) SP001743 Page 10...
  • Page 603 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 604 Parts List 25,26 14,15 FG003925 Figure 5 Travel Control Valve (With Damper) SP001743 Page 12...
  • Page 605 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 606 REMOVAL Park on firm and level ground. Lower front attachment (bucket) to ground. Shut down engine. Set safety lever on "RELEASED" position. Turn starter switch to "I" (ON) position. WARNING when performing inspection WARNING 190-00695A FG014348 engine must running while performing Figure 6 maintenance, always use extreme caution.
  • Page 607 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 Travel Control Valve (With Damper)
  • Page 608 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) SP001743 Page 16...
  • Page 609 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 Travel Control Valve (With Damper) SP001743 Page 17...
  • Page 610 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 611 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 Travel Control Valve (With Damper)
  • Page 612 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 613 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 SP001743 Travel Control Valve (With Damper) Page 21...
  • Page 614 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 615 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 616 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 617 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 618 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) SP001743 Page 26...
  • Page 619 SP001622 SOLENOID VALVE ASSEMBLYSP001622 Solenoid Valve Assembly Edition 1 Solenoid Valve Assembly SP001622 Page 1...
  • Page 620 MEMO Solenoid Valve Assembly SP001622 Page 2...
  • Page 621 Table of Contents Solenoid Valve Assembly Safety Precautions ..........5 Applicable Models ..........5 5-Solenoid Valve ..........6 Parts List ................. 6 Functions of 5-Solenoid Valve Assembly ......7 Assembly Diagram and Tools Required ......10 Cautions During Disassembly and Reassembly ... 11 Solenoid Valve Diagram ..........
  • Page 622 MEMO Solenoid Valve Assembly SP001622 Page 4...

  • Page 623: Safety Precautions

    APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX420LC 5327 and Up DX480LC 5221 and Up...

  • Page 624: 5-Solenoid Valve

    5-SOLENOID VALVE Parts List Figure 1, shows components used in the 5-solenoid valve. FG013248 Figure 1 Reference Description Sizes Quantity Remarks Number Block Body 79x82x272.5 1-A0098-07-0 Solenoid Valve QF-S3A-0421 C1, C2, C3, C4, C5 Coil VDL24VDC C1, C2, C3, C4, C5 Check Valve FD-DCP-0-A Plug...

  • Page 625: Functions Of 5-Solenoid Valve Assembly

    Functions of 5-Solenoid Valve Assembly The solenoid valve assembly controls the following functions. Pilot Cut-off Breaker Pressure Supply High/Low Travel Speed Main Pressure (Power Boost) Increase Breaker/Shear Mode Selection Functions and Operations of Solenoid Valves Reference Function Operations Remarks Number Provides pressurized oil coming from the pilot pump Pilot Cut-off for the pilot pressure supply solenoid valve to operate...
  • Page 626 Breaker Pressure Supply Solenoid (C2) Pressing the breaker switch on the joystick operates the breaker solenoid valve (C2). This supplies pilot pressure to the option valve in the main control valve. The pilot pressure shifts the option valve spool, which then allows pressurized oil from the main pump to flow to the breaker system for operation.
  • Page 627 Breaker/Shear Mode Selection Solenoid (C5) The breaker/shear switch activates the solenoid valve when the front option attachment is changed from shear to breaker. When the switch is set to breaker, pilot pressure is supplied to shear valve shifting the spool inside. with the pressurized oil from the main pump supplied to breaker.

  • Page 628: Assembly Diagram And Tools Required

    Assembly Diagram and Tools Required Figure shows assembly torques recommended components in the solenoid valve. Designated tools and torques should be used. FG013248 Figure 2 Reference Description Sizes Torques (kg•cm) Tools Number 200 ± 25 kg•cm Solenoid Valve UNF7/8 - 14" Hex torque wrench/1,"...

  • Page 629: Cautions During Disassembly And Reassembly

    Cautions During Disassembly and Reassembly Choose a work area for disassembly. NOTE: Choose a clean work area. Use a rubber mat or other protective covering on the workbench area to prevent damage or scratching of any precision machined components. For disassembly and reassembly, use torques and tools listed in tables.

  • Page 630: Solenoid Valve Diagram

    Solenoid Valve Diagram Figure 3 Solenoid Valve Assembly SP001622 Page 12...

  • Page 631: Check Points And Solutions For Problems

    Check Points and Solutions for Problems Symptoms Causes How to Check Solutions Foreign sub- Disassemble the solenoid valve and check if Remove contami- stance, dirt and there is any contamination such as a foreign sub- nant, wash, and dust in solenoid stance and sludge between the case and the assemble compo- valve.

  • Page 632: 2-Solenoid Valve

    2-SOLENOID VALVE Parts List Figure 4, shows components used in the 2-solenoid valve. FG013249 Figure 4 Reference Description Size Quantity Remarks Number Block Body 57x73x105 1-A1097-07-0 Solenoid Valve QF-S3A-0421 C1, C2 Solenoid Valve Assembly SP001622 Page 14...

  • Page 633: Assembly Diagram And Tools Required

    Assembly Diagram and Tools Required The assembly torque of each part in the solenoid valve described in the table below. Observe the specified torque values using the right tool. FG013249 Figure 5 Reference Torques Description Sizes Tools Number (kg•cm) 200 ±25 kg•cm Solenoid Valve UNF7/8-14"...

  • Page 634: Cautions During Disassembly And Reassembly

    Cautions During Disassembly and Reassembly Choose a work area for disassembly. NOTE: Choose a clean work area. Use a rubber mat or other protective covering on the workbench area to prevent damage or scratching of any precision machined components. For disassembly and reassembly, use torques and tools listed in tables.

  • Page 635: Solenoid Valve Diagram

    Solenoid Valve Diagram Coil Nut Coil Cap Housing Tube & Retainer Case FG007535 Figure 6 Troubleshooting Guide Symptoms Causes How to Check Solutions Foreign substance, Disassemble the solenoid valve and check if there is Remove con- dirt and dust in sole- any contamination such as a foreign substance and taminant, wash, noid valve.
  • Page 636 Solenoid Valve Assembly SP001622 Page 18...
  • Page 637 SP000192 BREAKER EPPR VALVE (OPT)SP000192 Breaker EPPR Valve (Opt) Edition 1 Breaker EPPR Valve (Opt) SP000192 Page 1...
  • Page 638 MEMO Breaker EPPR Valve (Opt) SP000192 Page 2...
  • Page 639 Table of Contents Breaker EPPR Valve (Opt) Safety Precautions ..........5 Applicable Models ..........5 Structure ............... 6 Numbers and Names of Parts ......... 6 Functions and Operation ........7 Cautions for Operation ......... 7 Maintenance Instructions........8 Maintenance ..............8 Disassembly ..............
  • Page 640 MEMO Breaker EPPR Valve (Opt) SP000192 Page 4...

  • Page 641: Breaker Eppr Valve (Opt)

    APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327 and Up...

  • Page 642: Structure

    STRUCTURE Numbers and Names of Parts Figure 7 Reference Reference Description Description Number Number Solenoid Valve casing Spring Sleeve O-ring Spool O-ring Breaker EPPR Valve (Opt) SP000192 Page 6...

  • Page 643: 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 644: 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 645: 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 646: 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 647 Assemble the spool, the spring, and the pin. FG003695 Figure 13 • The spring and the pin should not be fell off. FG003696 Figure 14 Breaker EPPR Valve (Opt) SP000192 Page 11...
  • Page 648 Assemble the solenoid correctly. 426-00266 PART No.: SERIAL No.: FG003697 Figure 15 • Take care not to damage O-rings of the solenoid. FG003698 Figure 16 Breaker EPPR Valve (Opt) SP000192 Page 12...
  • Page 649 SP001752 HYDRAULIC SCHEMATIC DX300LC/DX300LCA SP001752 Hydraulic Schematic DX300LC/ DX300LCA Edition 1 Hydraulic Schematic DX300LC/DX300LCA SP001752 Page 1...
  • Page 650 MEMO Hydraulic Schematic DX300LC/DX300LCA SP001752 Page 2...
  • Page 651 Table of Contents Hydraulic Schematic DX300LC/DX300LCA Safety Precautions ..........5 Applicable Models ..........5 DX300LC/DX300LCA ........... 7 Hydraulic Schematic DX300LC/DX300LCA SP001752 Page 3...
  • Page 652 MEMO Hydraulic Schematic DX300LC/DX300LCA SP001752 Page 4...
  • Page 653 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 7440 and Up DX300LCA 5001 and Up Hydraulic Schematic DX300LC/DX300LCA SP001752 Page 5...
  • Page 654 Hydraulic Schematic DX300LC/DX300LCA SP001752 Page 6...
  • Page 655 PRESS. SWITCH ON #30 500k 500k (FRONT) SENSOR SENSOR (REAR) 1.5k+0.2k LH-HI RH-HI (OPEN) (CLOSE) 177u ENGINE from JOYSTICK(R) BOTTON Hammer Select from JOYSTICK(R) SWITCH to #34 P Shear Select FG014415 Figure 1 Hydraulic Schematic DX300LC/DX300LCA SP001752...
  • Page 657 Electrical System...
  • Page 659 SP002030 ELECTRICAL SYSTEMSP002030 Electrical System Edition 1 Electrical System SP002030 Page 1...
  • Page 660 MEMO Electrical System SP002030 Page 2...
  • Page 661 Table of Contents Electrical System Safety Precautions ..........6 Applicable Models ..........6 Introduction ............7 Electrical Supply System ........8 Engine Starting Circuit ........10 Engine Preheating System ......... 14 Engine Stop ............16 Charging System ..........18 Monitoring System ..........19 Operation ............
  • Page 662 Self-diagnostic Function ........75 Air Conditioner System ........77 Troubleshooting ..........97 Weight of R134a Gas Used In Machines ... 99 Refrigerant System Repairs ......100 Wiper System ........... 108 Lighting System ..........110 Overload Warning Device......... 112 Audio Controller ..........113 Electrical System SP002030 Page 4...
  • Page 663 MEMO Electrical System SP002030 Page 5...

  • Page 664: 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 DX300LCA 5001 and Up Electrical System SP002030 Page 6...

  • Page 665: 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 666: Electrical Supply System

    ELECTRICAL SUPPLY SYSTEM The electric power circuit supplies electric current to each electric component. It consists of a battery, battery relay, starter switch, circuit breaker, fusible link and fuse box. The negative terminal of the battery is grounded to the vehicle body.
  • Page 667 0.5G 12V 100AH 12V 100AH R(I) P(R) B(B+) STARTER SWITCH CONNECTION 0.5 uF I(L) REG. TRIO DIODE START FIELD FG007233 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...

  • Page 668: 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 669 CN1-15 CN2-1 R(I) P(R) B(B+) STARTER SWITCH CONNECTION 0.5 uF I(L) REG. TRIO DIODE START FIELD FG007234 Figure 3 STARTER CIRCUIT (1) - WHILE STARTING Reference Reference Description Description Number Number Battery Starter Relay Battery Relay Starter Fusible Link Alternator Circuit Breaker Diode Starter Switch...
  • Page 670 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 671 Operation of the Start Circuit (2) - Immediately After Start CN1-15 CN2-1 R(I) P(R) B(B+) 0.5 uF STARTER SWITCH CONNECTION I(L) REG. TRIO DIODE FIELD START FG007237 Figure 4 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START Reference Reference Description Description Number...

  • Page 672: 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 673 CN6-1,2 CN7-4,5,6 PREHEAT CN4-4,5,6 CN2-1 STARTER SWITCH CONNECTION 1-34,35 1-40 1-13 1-07 START FG007137 Figure 5 ENGINE PREHEAT CIRCUIT Reference Reference Description Description Number Number Battery Preheat Relay Battery Relay Air Heater Fusible Link Preheat Indicator Light Circuit Breaker Diode Starter Switch e-EPOS Controller Fuse Box...

  • Page 674: 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 675 STARTER SWITCH CONNECTION START 0.5G 1-29 1-87 1-40 FG007138 Figure 7 ENGINE STOP CIRCUIT Reference Reference Description Description Number Number Battery Fuse Box Battery Relay Diode Fusible Link Engine Controller Circuit Breaker Injector Solenoid Starter Switch Emergency Stop Switch Electrical System SP002030 Page 17...

  • Page 676: 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 677: Monitoring System

    MONITORING SYSTEM CHECK CHECK CHECK CHECK 02/05 [MO] 11:30 1700 E/G SPEED POWER AUTO FG015509 Figure 9 Reference Reference Description Description Number Number Instrument Panel Pnmp Discharge Pressure Sensor Battery Engine Coolant Temperature Engine Speed Sensor Sensor Return Filter Switch Fuel Sensor Pilot Filter Switch Air Cleaner Indicator...
  • Page 678 Instrument Panel CHECK 02/05 [MO] 11:30 < CONNECTOR AND TERMINAL NO.> 1700 E/G SPEED AMP 040 28P (CN7) (CN6) POWER AUTO FG015472 Figure 10 Electrical System SP002030 Page 20...
  • Page 679 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. Economy Mode Selector Button Hydraulic Oil Temperature Coolant Temperature Warning Gauge Light 15.
  • Page 680 Monitoring System Schematic CN6-1 CN6-3 ILL. CN6-2 CN6-12 CN6-11 CN6-9 CN6-10 R2 B CN6-4 CN6-5 CN2-1 CN6-6 CN6-7 LCD DISPLAY PANEL WATER TEMPERATURE FUEL LEVEL OIL TEMPERATURE CN3-1 CN3-2 CN3-3 CN7-9 GRAPHIC DISPLAY CN5-7 CN3-4 CN7-10 CN2-17 CN7-4 WARNING LAMP CN4-4 CN7-5 CN4-5...
  • Page 681 Reference Reference Description Description Number Number Instrument Panel Return Filter Switch Pilot Buzzer Alternator Light Switch e-EPOS Controller Starter Switch Battery Front Pump Pressure Sensor Battery Relay Rear Pump Pressure Sensor Circuit Breaker Hydraulic Oil Temperature Fusible Link Sensor Fuse Box Fuel Sensor Check Connector Pedal Pressure Switch (Optional)

  • Page 682: 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 683 Sensor Specification Function Display Input Terminal Input Specification N = 162 f / 60 ECU-CAN N = Engine speed (rpm) 1700 Tachometer E/G SPEED Communication f = Frequency of engine speed sensor (Hz) FG000049 28.0 Voltmeter CN2-14 0 - 32 VDC BATTERY VOLT FG000050...

  • Page 684: Warning And Indicator Lights

    WARNING AND INDICATOR LIGHTS Indication of Warning Lights Input Description Symbol Operation Remarks Terminal This symbol appears in case of no charge [voltage of "R(I)" Normally, it lights terminal is below when starting engine Charge CN2 - 14 12 ±1V] or and is out after engine overcharge [voltage starts.
  • Page 685 Input Description Symbol Operation Remarks Terminal This symbol appears Work Light CN2 - 6 when work light turns "ON" (24V applied). HB4O2003 Indication of Multifunction Gauge Input Description Symbol Operation Remarks Terminal When hydraulic oil CN3-9 Hydraulic Oil temperature is above Temperature CN3-10 about 96°C.
  • Page 686 When pilot filter pressure is above Pilot Filter CN2-18 about 1 kg/cm² (14 psi) FG000055 Warning buzzer also It flickers in case of starts when boom 2.71V and above and pressure sensor CN3-5 Overload lights continuously in output voltage is Warning case of 2.8V and CN3-6...

  • Page 687: 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 688: Graphic Information Area Display

    GRAPHIC INFORMATION AREA DISPLAY Overview Many kinds of condition of machine are displayed on the letter information display department. information display department is divided into two menus. One is main menu for user and the other is special menu for specialist. These menus can be moved from normal display mode by the combination of selector buttons.
  • Page 689 Main Menus for the Graphic Display Area Main menu: Language setting, Time setting, Filter/Oil information, Brightness adjustment, Password Special menu: Information of machine status, failure information, Information of machine operation. Menu Selector Buttons Up Arrow Button ( , 1 on Figure 12): Move the cursor to up, left and previous screen.

  • Page 690: 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 Main menu offers sub-menus (language setting, time setting, or 1. Language filter/oil information, brightness adjustment, password) to the 2.
  • Page 691 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 12) in the Main 2. Set Clock Menu after putting cursor on Set Clock brings Set Clock display. 3.
  • Page 692 Menu Display Order and Icon Explanation 1. Fuel Filter 2. Air Cleaner 3. Engine Oil Filter 4. Hyd. Oil Filter 5. Pilot Filter 6. Engine Oil 7. Hydraulic Oil 8. Coolant Water FG001358 Figure 20 Adjust Display M A I N M E N U Pressing the Enter Button ( , 3 on Figure 12) in the main 1.
  • Page 693 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 694 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 695: Special Menu

    Special Menu Screen S P E C 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 696 Analog Inputs Description Analog Input Items Display Remark 1. Pump P/V Current in pump proportional valve. 2. Cooling Fan P/V N.A. Current in flow control proportional 3. Flow Control P/V valve. 4. Dial Indicating dial voltage. 5. TPS N.A. 6. E/G Control Motor N.A.
  • Page 697 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 698 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 699 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 ON / OFF 3.
  • Page 700 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 24) or "DOWN"...
  • Page 701 Input your password with one of No. 1 - 8 switches. DELETE FAIL LOG When "NO" (ESC, 4 on Figure 24) button is pressed, the screen will recover to previous menu without deletion. ENTER PASSWD : Yes ESC: No FG000568 Figure 37 Delete Completed screen will appear 3 seconds and the screen will move to Failure Info screen.
  • Page 702 Failure Information Code at Machine Side Correct Value Measuring Code Failure Component Remarks Points Active Passive CN7-4 It is a Gauge Panel Communication R = 60 ± 5 Ω V201 composite Error CN7-5 resistance of CAN line. This value has to be CN4-4 measured by V202...
  • Page 703 Correct Value Measuring Code Failure Component Remarks Points Active Passive R = 2.45 ± 0.25 kΩ CN3-9 (25°C (77°F)) Hyd. Temperature V222 Sensor R = 320 ± 32 Ω CN3-10 (80°C (176°F)) V223 N.A. Water Temperature Sensor V224 N.A. Engine Speed Sensor Empty: 5 ±...
  • Page 704 Failure Information Code at Engine Side Current Valve Measuring Code Failure Component Remarks Points Active Passive R=186 ± 5 Ω 2-15 E011 Coolant temperature sensor (100°C 2-26 (212°F)) R=186 ± 5 Ω 2-35 E012 Fuel temperature sensor (100°C 2-26 (212°F)) R=186 ±...
  • Page 705 Current Valve Measuring Code Failure Component Remarks Points Active Passive 2-09 E043 E/G speed (Camshaft) 2-10 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 706 Current Valve Measuring Code Failure Component Remarks Points Active Passive Voltage is only measured 1-13 R=40 ± 5 Ω Preheat relay (E/G: Highside when afterheat E068 V = V_volt Power stage 1) (25°C (77°F)) function is 1-07 operating status. 1-13 Preheat light (E/G: Lowside E083 Power stage 2)
  • Page 707 FMIs (Failure Mode Identifier) FMI 0 Above normal range (DATA VALID but ABOVE NORMAL OPERATIONAL RANGE) FMI 1 Below normal range (DATA VALID but BELOW NORMAL OPERATIONAL RANGE) FMI 2 Incorrect signal (DATA ERRATIC, INTERMITTENT OR INCORRECT) FMI 3 Voltage above normal (VOLTAGE ABOVE NORMAL OR SHORTED TO HIGH SOURCE) FMI 4 Voltage below normal (VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE) FMI 5...
  • Page 708 Operating Hours Screen OPERATING HOURS Exiting Sub-menus: If escape button (ESC, 4 on Figure 24) is pressed for more than 1 second, this Operating Hours information screen will be returned to previous screen. Reset Hours : UP : DOWN : SELECT FG000572 Figure 42 Information contents of operation hour...
  • Page 709 Menu Selection of Operation Hour Information 2. Economy Mode 3. Auto Idle 1. Power Mode 4. Travel Speed 1st, 2nd 6. Coolant Temperature Distribution 5. Hydraulic Oil Temperature Distribution FG013856 Figure 43 Example of Machine Operation Info Screen OPERATING HOURS OPERATING HOURS 1.
  • Page 710 Operation hour reset OPERATING HOURS Entering Sub-menus: When cursor is located in "Reset Hrs" of information screen of operating hours Operating Hrs press enter button ( , 3 on Figure 24) and "Machine Operation Info" screen will be displayed. Reset Hrs : UP : DOWN : Yes...
  • Page 711 If you press the "NO" (ESC, 4) button, the previous screen appears without resetting operation periods. OPERATING HOURS PASSWORD ERR !!! : Yes ESC: No FG001086 Figure 49 Electrical System SP002030 Page 53...

  • Page 712: Electronic Hydraulic Control System (E-Epos)

    ELECTRONIC HYDRAULIC CONTROL SYSTEM (e-EPOS) Control System Schematic Main Relief v/v (Wheel) (Pump control signal) (Engine speed sensor signal) (Switch signal) (Throttle signal) (Engine throttle control signal) (Throttle command) CHECK CHECK CHECK CHECK (Coolant water temp. signal) (Mode select signal) 02/05 [MO] 11:30 (Auto idle signal) (Machine information)
  • Page 713 Reference Reference Description Description Number Number Instrument Panel Solenoid Valve (Pressure Up) Engine Control Motor Solenoid Valve (Swing Priority) Engine Solenoid Valve (High Speed) Main Hydraulic Pump Travel Motor Control Pump Engine Throttle Control Control Valve Engine Control Dial Pressure Switch e-EPOS Controller Pump Pressure Sensor Auto Travel Selector Switch...

  • Page 714: Power Mode Control

    POWER MODE CONTROL (Wheel type) (Wheel type) (Pump control signal) POWER AUTO (Engine speed sensor signal) (Throttle Position signal) (Engine throttle control signal) (Throttle signal) (Pump control signal) (Power mode switch signal) FG015515 POWER AUTO (Engine speed sensor signal) Figure 51 (Throttle Position signal) Reference Reference...
  • Page 715 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 start switch is turned "ON," the power mode is automatically defaulted to standard mode.
  • Page 716 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 POWER...
  • Page 717 Standard Mode Standard Mode is used for general work. When this mode is selected it will reduce noise and fuel consumption in comparison with Power Mode. The epos controller compares the target engine speed with the actual engine speed and controls the signal to the E.P.P.R. valve which in turn varies the pump output quantity and it is the same method with power volume.
  • Page 718 FG013633 Figure 56 Reference Reference Description Description Number Number Engine Horsepower (hp) Pump Discharge Volume (lpm) Engine Speed (rpm) Pump Discharge Pressure (kg/cm Electrical System SP002030 Page 60...

  • Page 719: Power Mode Control - Circuit Diagram

    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 720: Engine Control System

    ENGINE CONTROL SYSTEM (Feedback Signal) (Drive Signal) (Command Signal) BATT. RELAY AUTO IDLE COMMAND e-EPOS CONTROLLER OVER HEAT BATTERY RETRACT HIGH ARS1090L Figure 58 Reference Reference Description Description Number Number Engine Control Motor Engine Throttle Controller Engine Engine Control Dial When the engine control dial is moved the output voltage changes according to the dial position.

  • Page 721: Engine Control Motor

    ENGINE CONTROL MOTOR CIRCUIT DIAGRAM (GREEN) P1(Gr) P2(P) P3(L) (YELLOW) (RETRACT) (GRAY) ACCEL (PINK) P4(G) P5(Y) (5.0V) (BLUE) DECEL (EXTEND) Figure 59 ARS1100L Reference Reference Description Description Number Number Motor Assembly Spring Assembly Cable The engine control motor uses a D.C. motor with a built in potentiometer to sense the position of the control cable.

  • Page 722: Engine Control Dial

    ENGINE CONTROL DIAL 7th STEP 1st STEP 13th STEP ( 10 ) ( 10 ) MECHANICAL MECHANICAL STOP STOP 4.0V 2.5V 1.0V SETUP 1ST 2nd 12th 13th STOP STOP VIEW ( POTENTIOMETER BOTTOM) FG000866 Figure 60 Reference Reference Description Description Number Number Knob...

  • Page 723: Engine Control Circuit Diagram

    ENGINE CONTROL CIRCUIT DIAGRAM ARS1110L Figure 61 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 SP002030 Page 65...

  • Page 724: Automatic Deceleration Control (Auto Idle Control)

    AUTOMATIC DECELERATION CONTROL (AUTO IDLE CONTROL) (Feedback Signal) (Drive Signal) (Command Signal) CHECK CHECK CHECK CHECK 02/05 [MO] 11:30 AUTO Auto deceleration Switch Signal 1700 E/G SPEED POWER AUTO FG015517 Figure 62 Reference Reference Description Description Number Number Instrument Panel Pressure Switch (Auto Idle Switch) Engine Throttle Controller...
  • Page 725 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 726: Engine Overheat Protection System

    ENGINE OVERHEAT PROTECTION SYSTEM CHECK CHECK CHECK CHECK (Pump control signal) 02/05 [MO] 11:30 1700 E/G SPEED POWER AUTO Engine overheat signal Engine overheat signal FG015519 Figure 63 Reference Reference Description Description Number Number Instrument Panel E.P.P.R. Valve (Electromagnetic Proportional Pressure Reducing Engine Control Motor Valve) Engine...
  • Page 727 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 728: Power Boost Mode

    POWER BOOST MODE Operation CHECK CHECK CHECK CHECK 02/05 [MO] 11:30 1700 E/G SPEED POWER AUTO Figure 64 FG015520 Reference Reference Description Description Number Number Instrument Panel Solenoid Valve (Boost) e-EPOS Controller Main Relief Valve Engine Controller Breaker/Boost/Shear Selector Switch Main Pump Power Boost Switch Aux Pump...
  • Page 729 Power Boost Control - Circuit Diagram CN6-1 CN6-2 CN6-9 CN6-10 CN1-1 CN7-4 CN4-4 CN1-2 CN7-5 CN4-5 PRESS CN7-6 CN4-6 SHEAR BREAKER (C4) CN1-11 (POWER MAX) CN2-2 CN1-8 CN1-9 (Center) (POWER MAX / BREAKER) (CN2) (CN1) FG000586 Figure 65 Reference Reference Description Description Number...

  • Page 730: Automatic Travel Speed Control

    AUTOMATIC TRAVEL SPEED CONTROL FG000799 Figure 66 Reference Reference Description Description Number Number e-EPOS Controller Pump Pressure Sensor Engine Controller Solenoid Valve (High speed) Main Pump Travel Motor Aux Pump Engine Control Dial Control Valve Selector Switch For Automatic Travel Pressure Switch (Py Port) Electrical System SP002030...
  • Page 731 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 732 Automatic Travel Speed Control - Circuit Diagram CN1-1 CN1-2 CN3-1 CN3-2 (C3) CN1-12 CN3-3 CN3-4 CN2-4 CN2-5 CN3-15 CN1-8 +(5V) CN3-16 CN1-9 CN3-17 HIGH AMP 070 18P AMP MIC 21P AMP 040 20P 15 14 11 10 9 (CN2) (CN1) AMP 040 28P (CN7) (CN6)

  • Page 733: Self-Diagnostic Function

    SELF-DIAGNOSTIC FUNCTION e-EPOS Controller The system operation status and malfunction codes can be checked through the display on top of the e-EPOS controller box the rear cover behind the operator's seat. FG000588 Figure 68 Reference Reference Description Description Number Number Upper Digit Power Monitor (Stays "ON"...
  • Page 734 Normal Operation Display Readout Display Readout Mode Selection Operation Status Upper Digit Lower Digit Normal Operation Power Mode Power Mode HAOH370L HAOH340L Normal Operation Power Mode Standard Mode Standard Mode HAOH370L HAOH350L Normal Operation Economy Mode Economy Mode HAOH370L FG013637 Communication Monitor What are shown in the 7-SEGMENT LED are same as those in the Error Codes.

  • Page 735: Air Conditioner System

    AIR CONDITIONER SYSTEM Outline FG013857 Figure 69 Solid-type heater and air conditioner are installed in the cover behind the operator's seat. Temperature of the operator's room is adjusted automatically to the temperature set by operator. (Please refer to the Operation Manual for detailed full automatic control.
  • Page 736 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 operator's room. Filters should be cleaned every 500 hours. machine operates excessively contaminated environment, filters should be cleaned more frequently and if necessary, replaced with new ones.
  • Page 737 Turn marked knobs (1, Figure 72) at the rear side of the cabin to open the cover. FG000441 Figure 72 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 738 Air-Conditioning System Layout FG007144 Figure 74 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 SP002030 Page 80...
  • Page 739 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 0.5LG...
  • Page 740 Air Conditioner/heater Unit Air Flow Diagram External Air Inlet Vent Rear Cold Box Internal Air Inlet Outlet Outlet Vent Front Outlet Foot Outlet Outlet External Air Internal Air Evaporator Heater Core FG001359 Figure 76 Electrical System SP002030 Page 82...
  • Page 741 Door Open by Vent Modes Mode Door Vent Bi-level Foot Def/foot Vent Foot Main Components Actuator - Temp Relay Control Blower Relay Duct Sensor Air Flow Control Module Actuator Blower -Wind Direction Motor Control Water Temp Sensor Actuator Evaporator - Internal/external Air Exchanger Internal Internal...
  • Page 742 Actuator - Wind Direction Control Change of discharged air flow according to selected wind direction mode Change of wind direction: Direction changes in the order of VENT→ BI-LEVEL → FOOT → FOOT/DEF → VENT. Actuator - Temperature Control Change of discharged air temperature by controlling the position of temperature control door.
  • Page 743 Actuator - Internal/external Air Exchange CN10-20 CN10-2 FG001055 Figure 79 Mode Output Terminal Output Moving of exchange door Intake P1(+), P2(-) by selecting intake. Moving of exchange door Recirculate P1(-), P2(+) by selecting recirculate. Air Flow Control Module Air flow is controlled through the control of voltage between GATE and SOURCE.
  • Page 744 Relay - Blower: Power is supplied to the blower motor when the system is turned "ON." 87 85(-) Specifications Rated voltage Rated current 86(+) FG001057 FG001057 Figure 81 Relay - A/C: Power is supplied to the magnetic clutch of the compressor.
  • Page 745 Water Temperature Sensor: It senses the temperature of coolant water in the heater core. Temperature (°C) Resistance (KΩ) 55.8 ± 1.7 32.9 ± 0.9 15.76 ± 0.5 10.0 ± 0.3 6.5 ± 0.2 Figure 84 Internal Air Temperature Sensor: Built in the internal air filter, it senses the internal temperature.
  • Page 746 Sun Sensor Built beside the socket of spare power, it senses the quantity of the sun radiation to optimize discharge temperature and air flow as set by operator. 83.7 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 87...
  • Page 747 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 748 Categories Inputs System Operation Sensor Set temperature In case of sensor failure, following defaults are applied: compensation 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 749 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 750 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 ambient and internal air temperature ≤ 5°C Internal air temperature sensor (3) Failure of water temperature sensor Auto mode...
  • Page 751 Categories Inputs System Operation Duct sensor Function: Magnetic clutch of compressor is turned "ON/ OFF" depending on temperature of the duct sensor to prevent the freezing of the evaporator with A/C being "ON." Control pattern. 0.5 C 0.5 C Compressor control External temperature Function: Prevention of compressor in winter.
  • Page 752 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 753 Error codes Code Description Normal Internal air temperature sensor short Internal air temperature sensor open Ambient air temperature sensor short Ambient air temperature sensor open Duct sensor short Duct sensor open Sun sensor short Sun sensor open Water temperature sensor short Water temperature sensor open D.P.S open Position error of wind direction actuator...
  • Page 754 Volume of Refrigerant DX225LC 800 ± 20 grams FG001462 Figure 93 DX225NLC 800 ± 20 grams DX300LC 800 ± 20 grams DX300LCA 800 ± 20 grams DX340LC 800 ± 20 grams DX420LC 800 ± 20 grams DX480LC 800 ± 20 grams DX520LC 800 ±...

  • Page 755: 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 94 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 756 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 757: Weight Of R134A Gas Used In Machines

    800 ± 20 grams (28 ± 0.7 oz) DX225NLC 800 ± 20 grams (28 ± 0.7 oz) DX300LC 800 ± 20 grams (28 ± 0.7 oz) DX300LCA 800 ± 20 grams (28 ± 0.7 oz) DX340LC 800 ± 20 grams (28 ± 0.7 oz) DX420LC 800 ±...

  • Page 758: 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 759 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 760 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 761 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 97 NOTE: Be careful not to switch the connections for the low and high-pressure valves.
  • Page 762 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 763 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 764 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 765 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 766: 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 104 Reference Reference Description Description Number Number Battery Wiper Controller Battery Relay Wiper Switch Panel Fusible Link...
  • Page 767 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 768: 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 105 Electrical System SP002030 Page 110...
  • Page 769 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 770: Overload Warning Device

    OVERLOAD WARNING DEVICE Overload Warning Device Circuit Diagram CN1-1 CN1-2 CN2-15 CN1-8 CN1-9 CN1-3 CN1-4 ARS1260L Figure 106 Reference Reference Description Description Number Number Battery e-EPOS Controller Battery Relay OWD Selector Switch Fuse Box Pressure Sensor Electrical System SP002030 Page 112...

  • Page 771: 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 107 Reference Reference Description Description Number Number Battery Audio Control Panel Battery Relay Stereo Fuse Box...
  • Page 772 Operations Via Audio Control Panel Connected Terminal of Switch Measured values Operations switch 4.36 ± 0.2V Stereo ON, OFF 1.24 ± 0.2V Volume up "3-4" 0 + 0.2V Volume down SCAN 2.49 ± 0.2V Frequency selection Electrical System SP002030 Page 114...
  • Page 773 SP002031 ELECTRICAL SCHEMATIC DX300LCASP002031 Electrical Schematic DX300LCA Edition 1 Electrical Schematic DX300LCA SP002031 Page 1...
  • Page 774 MEMO Electrical Schematic DX300LCA SP002031 Page 2...
  • Page 775 Table of Contents Electrical Schematic DX300LCA Safety Precautions ..........5 Applicable Models ..........5 DX300LCA............7 Electrical Schematic DX300LCA SP002031 Page 3...
  • Page 776 MEMO Electrical Schematic DX300LCA SP002031 Page 4...
  • Page 777 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 DX300LCA 5001 and Up Electrical Schematic DX300LCA SP002031 Page 5...
  • Page 778 Electrical Schematic DX300LCA SP002031 Page 6...
  • Page 779 (ON JOYSTICK R.H) 0.85GB 0.5GB 0.85RY 179B 177B 0.85RB 0.85RB 180A 0.85BrW 180G 0.85BrW 180D 0.85RB 0.85RB (SOL2) 0.5WR 0.5B DA3-2 THROTTLE CONTROLLER 0.85GB 2-PUMP SWITCH 180H 0.85BrW 180E (SOL3) DA3-3 FG015521 0.85GB 0.85GB Figure 1 Electrical Schematic DX300LCA SP002031...
  • Page 781 Attachments...
  • Page 783 SP001851 BOOM AND ARM SP001851 Boom and Arm Edition 1 Boom and Arm SP001851 Page 1...
  • Page 784 MEMO Boom and Arm SP001851 Page 2...
  • Page 785 Table of Contents Boom and Arm Safety Precautions ..........5 Applicable Models ..........5 Front Attachment Pin Specifications..... 6 DX300LC ................. 7 DX340LC / DX350LC ............8 DX420LC ................. 9 DX480LC / DX520LC ............ 10 Front Attachment - Removal and Installation..11 Arm Removal Procedure ..........
  • Page 786 MEMO Boom and Arm SP001851 Page 4...

  • Page 787: Boom And Arm

    APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327 and Up...

  • Page 788: 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 789: Dx300Lc

    DX300LC / DX300LCA Criteria Mark Measuring Part Tolerance Remedy Standard Standard Clearan Size Clearance ce Limit Hole 105 mm -0.10 +0.18 Boom Foot 0.13 ~ 0.33 (4.134") -0.15 +0.03 90 mm -0.10 +0.18 Boom Cylinder Head 0.13 ~ 0.33 (3.543") -0.15...

  • Page 790: Dx340Lc / Dx350Lc

    DX340LC / DX350LC Criteria Mark Measuring Part Tolerance Remedy Standard Standard Clearan Size Clearance ce Limit Hole 110 mm -0.10 +0.18 Boom Foot 0.13 ~ 0.33 (4.331") -0.15 +0.03 100 mm -0.10 +0.18 Boom Cylinder Head 0.13 ~ 0.33 (3.937") -0.15 +0.03 100 mm...

  • Page 791: Dx420Lc

    DX420LC Criteria Mark Measuring Part Tolerance Remedy Standard Standard Clearan Size Clearance ce 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...

  • Page 792: Dx480Lc / Dx520Lc

    DX480LC / DX520LC Criteria Mark Measuring Part Tolerance Remedy Standard Standard Clearan Size Clearance ce Limit Hole 125 mm -0.05 +0.18 Boom Foot 0.08 ~ 0.28 (4.921") -0.10 +0.03 110 mm -0.10 +0.18 Boom Cylinder Head 0.13 ~ 0.33 (4.331") -0.15 +0.03 120 mm...

  • Page 793: 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 794 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 795: Boom Removal Procedure

    CAUTION To make sure that the polished surfaces of cylinder rod ends will not suffer accidental damage during disassembly or removal procedures, wrap exposed rod surfaces (especially those of boom cylinders) with a protective covering material. Immediately following disassembly and removal, cylinder rods should always be fully retracted.

  • Page 796: 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 797: Start-Up Procedures

    START-UP PROCEDURES Once the boom has been serviced, it should be lubricated as outlined in the initial start-up procedures of the operation manual. Refer to the appropriate operation and maintenance manual for unit. Boom and Arm SP001851 Page 15...
  • Page 798 Boom and Arm SP001851 Page 16...
  • Page 799 SP001852 BUCKET SP001852 Bucket Edition 1 Bucket SP001852 Page 1...
  • Page 800 MEMO Bucket SP001852 Page 2...
  • Page 801 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 ............
  • Page 802 MEMO Bucket SP001852 Page 4...

  • Page 803: Bucket

    APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX300LC 7440 and Up DX300LCA 5001 and Up DX340LC 5980 and Up DX350LC 5980 and Up DX420LC 5327 and Up...

  • Page 804: 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 805: 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 4 Roll the old O-ring (1, Figure 5) onto the boss (2) around the bucket pin (3).
  • Page 806 Roll the new O-ring (1, Figure 7) into the O-ring groove. ARO1392L Figure 7 Bucket SP001852 Page 8...

  • Page 807: 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 808 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 809: 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 810: Reversing The Bucket

    Reversing the Bucket Follow instructions for "Detaching the Bucket" and remove both the bucket and link pins. Rotate the bucket 180° to change bucket configuration. This procedure is greatly simplified if some type of rotating or swiveling support can be used, on the ground underneath bucket.

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