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Doosan Dx140w Dx160w Wheel Excavator Service Repair Manual – PDF Download
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Description
Doosan Dx140w Dx160w Wheel Excavator Service Repair Manual
FILE DETAILS:
Doosan Dx140w Dx160w Wheel Excavator Service Repair Manual
LANGUAGE:ENGLISH
PAGES:1180
DOWNLOADABLE:YES
FILE TYPE:PDF
DOOSAN DX140W DX160W WHEEL EXCAVATOR SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
Doosan Dx140w Dx160w Wheel Excavator Service Repair Manual
DOOSAN reserves the right to improve its products continuously, delivering the best possible product to the marketplace. These improvements can be implemented at any time with no obligation to change materials previously sold. It is recommended that consumers periodically contact their distributors for most recent documentation on purchased equipment. This documentation may include attachments and optional equipment 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.
TABLE OF CONTENTS:
Doosan Dx140w Dx160w Wheel Excavator Service Repair Manual
DX140W/DX160W........................................................................................................... 1 Table of Contents....................................................................................................... 5 Safety.................................................................................................................. 7 Wheel Excavator Safety SP000909..................................................................................... 9 Safety Precautions.............................................................................................. 13 Applicable Models............................................................................................... 13 To the Operator of a DOOSAN Excavator........................................................................... 15 Learn the Signal Words Used with the Safety Alert Symbol.................................................... 17 General Safety Essentials....................................................................................... 19 Accessory Applications...................................................................................... 19 Lifting Capacity Rating Configuration....................................................................... 19 Location of Safety Labels....................................................................................... 20 Summary of Safety Precautions for Lifting in Digging Mode....................................................... 21 Unauthorized Modifications...................................................................................... 22 General Hazard Information...................................................................................... 22 Safety Rules................................................................................................ 22 Safety Features............................................................................................. 22 Inside Operator's Cabin..................................................................................... 23 Clothing and Personal Protective Items...................................................................... 23 Breathing Masks, Ear Protection May Be Required............................................................. 24 Vibration Level Information................................................................................. 24 Recommendations for Limiting Vibrations..................................................................... 24 Mounting and Dismounting.................................................................................... 25 Fuel, Oil and Hydraulic Fluid Fire Hazards.................................................................. 26 Precautions When Handling Fluids at High Temperature........................................................ 26 Asbestos Dust Hazard Prevention............................................................................. 27 Injury from Work Equipment.................................................................................. 27 Fire Extinguisher and First Aid Kit......................................................................... 27 Protection from Falling or Flying Objects................................................................... 28 Attachment Precautions...................................................................................... 29 Accumulator................................................................................................. 29 Indoor Ventilation.......................................................................................... 30 Emergency Exit.............................................................................................. 30 Before Starting Engine.......................................................................................... 31 Work Site Precautions....................................................................................... 31 Checks Before Starting Engine............................................................................... 32 Engine Starting............................................................................................. 33 Before Operating Machine.................................................................................... 33 Machine Operation............................................................................................... 35 When Swinging or Changing Direction of Travel............................................................... 35 Travel Precautions.......................................................................................... 36 Traveling on Slopes......................................................................................... 37 Prohibited Operations....................................................................................... 37 Precautions for Operation................................................................................... 38 Avoid Highvoltage Cables................................................................................... 39 Protecting Cabin from Falling Object (Optional)............................................................. 39 Operate Carefully on Snow, Ice and in Very Cold Temperatures................................................ 40 Operations on Slopes........................................................................................ 40 Parking Machine............................................................................................. 41 Never Let Anyone Ride on Attachment......................................................................... 41 Maintenance..................................................................................................... 42 Warning Tag................................................................................................. 42 Clean Before Inspection or Maintenance...................................................................... 42 Proper Tools................................................................................................ 43 Use of Lighting............................................................................................. 43 Fire Prevention and Explosion Prevention.................................................................... 43 Burn Prevention............................................................................................. 44 Welding Repairs............................................................................................. 44 Treatment for Electrical Welding to the Body Structure.................................................. 45 Warning for Counterweight and Front Attachment Removal...................................................... 46 Precautions for Removal, Installation, and Storage of Attachments........................................... 46 Precautions When Working on Machine......................................................................... 47 Lock Inspection Covers...................................................................................... 47 Prevention of Crushing and Cutting.......................................................................... 47 Supports and Blocking for Work Equipment.................................................................... 48 Action When Abnormality Is Found During Inspection.......................................................... 48 Precautions with Highpressure Lines, Tubes and Hoses....................................................... 49 Waste Materials............................................................................................. 50 Battery......................................................................................................... 51 Battery Hazard Prevention................................................................................... 51 Boost Starting or Charging Engine Batteries................................................................. 52 Towing.......................................................................................................... 53 Precautions When Towing..................................................................................... 53 Shipping and Transportation..................................................................................... 54 Obey State and Local OvertheRoad Regulations.............................................................. 54 Lifting with Sling.............................................................................................. 54 Specifications.......................................................................................................... 55 Specification for DX140W/DX160W SP000911............................................................................ 57 Safety Precautions.............................................................................................. 61 Applicable Models............................................................................................... 61 General Description............................................................................................. 63 Component Locations............................................................................................. 64 General Dimensions.............................................................................................. 66 4.3m OnePiece Boom........................................................................................ 66 4.6m OnePiece Boom........................................................................................ 67 4.988m TwoPiece Boom...................................................................................... 68 Working Range................................................................................................... 69 4.3m OnePiece Boom........................................................................................ 70 4.6m OnePiece Boom........................................................................................ 71 4.988m TwoPiece Boom...................................................................................... 72 General Specifications.......................................................................................... 73 Engine Performance Curves (Per DIN6270 Standard)............................................................... 74 Approximate Weight of Workload Materials........................................................................ 76 Performance Tests and Standards................................................................................. 78 Standards................................................................................................... 78 Excavator Performance Standards................................................................................. 79 Test Conditions............................................................................................. 79 Travel Speed Tests.......................................................................................... 80 Swing Speed and Deceleration Force Test..................................................................... 81 Swing Speed Test........................................................................................ 81 Swing Deceleration Force Test........................................................................... 82 Cylinder Performance Tests.................................................................................. 83 Boom Cylinders Test..................................................................................... 83 Arm Cylinder Test....................................................................................... 83 Bucket Cylinder Test.................................................................................... 83 Hydraulic Cylinder Natural Drop Test.................................................................... 83 General Maintenance..................................................................................................... 85 General Maintenance Procedures SP000016............................................................................. 87 Safety Precautions.............................................................................................. 91 Applicable Models............................................................................................... 91 Welding Precautions and Guidelines.............................................................................. 92 Hydraulic System General Precautions.......................................................................... 93 Maintenance Service and Repair Procedure........................................................................ 95 General Precautions......................................................................................... 95 Hydraulic System Cleanliness and Oil Leaks...................................................................... 96 Maintenance Precautions for Hydraulic System Service........................................................ 96 Oil Leakage Precautions..................................................................................... 97 Cleaning and Inspection......................................................................................... 98 General Guidelines.......................................................................................... 98 Bearing Inspection.......................................................................................... 99 Normal Bearing.......................................................................................... 100 Bent Cage............................................................................................... 100 Galling................................................................................................. 101 Abrasive Step Wear...................................................................................... 101 Etching................................................................................................. 102 Misalignment............................................................................................ 102 Indentations............................................................................................ 102 Fatigue Spalling........................................................................................ 103 Brinelling.............................................................................................. 103 Cage Wear............................................................................................... 103 Abrasive Roller Wear.................................................................................... 104 Cracked Inner Race...................................................................................... 104 Smears.................................................................................................. 104 Frettage................................................................................................ 105 Heat Discoloration...................................................................................... 105 Stain Discoloration..................................................................................... 105 Standard Torques SP000813........................................................................................... 107 Safety Precautions.............................................................................................. 111 Applicable Models............................................................................................... 111 Torque Values for Standard Metric Fasteners..................................................................... 113 Torque Values for Standard U.S. Fasteners....................................................................... 114 Type 8 Phosphate Coated Hardware................................................................................ 116 Torque Values for Hose Clamps................................................................................... 117 Torque Values for Split Flanges................................................................................. 118 Torque Wrench Extension Tools................................................................................... 119 Torque Multiplication....................................................................................... 119 Other Uses for Torque Wrench Extension Tools................................................................ 120 Tightening Torque Specifications (Metric)................................................................... 120 I. "Loctite" Fastener Adhesives......................................................................... 122 II. "Loctite" Pipe Thread Sealant....................................................................... 122 III. "Loctite" gasket/flange sealer..................................................................... 122 IV. "Loctite" retaining compounds....................................................................... 123 V. "Loctite" Adhesives.................................................................................. 123 Upper Structure......................................................................................................... 125 Cabin SP000916...................................................................................................... 127 Safety Precautions.............................................................................................. 131 Applicable Models............................................................................................... 131 Removal......................................................................................................... 133 Installation.................................................................................................... 136 Counterweight SP000917.............................................................................................. 139 Safety Precautions.............................................................................................. 143 Applicable Models............................................................................................... 143 General......................................................................................................... 145 Warning for Counterweight and Front Attachment Removal...................................................... 145 Removal......................................................................................................... 147 Reassembly...................................................................................................... 149 Fuel Tank SP000918.................................................................................................. 151 Safety Precautions.............................................................................................. 155 Applicable Models............................................................................................... 155 General Description............................................................................................. 157 Parts List.................................................................................................. 158 Specifications.............................................................................................. 159 Removal......................................................................................................... 160 Installation.................................................................................................... 165 Startup Procedures............................................................................................. 168 Fuel Transfer Pump SP000021......................................................................................... 169 Safety Precautions.............................................................................................. 173 Applicable Models............................................................................................... 173 General Description............................................................................................. 175 Theory of Operation......................................................................................... 175 Troubleshooting................................................................................................. 176 Replacement of Rotor and Vane................................................................................... 176 Replacement of Rear Cover....................................................................................... 177 Replacement of Armature......................................................................................... 177 Swing Bearing SP000920.............................................................................................. 179 Safety Precautions.............................................................................................. 183 Applicable Models............................................................................................... 183 Swing Bearing Maintenance....................................................................................... 185 Operating Recommendation.................................................................................... 185 Measuring Swing Bearing Axial Play.......................................................................... 185 Measuring Bearing Lateral Play.............................................................................. 185 Swing Bearing Basic Operation............................................................................... 186 Rebuilding Swing Bearing.................................................................................... 186 Swing Reduction Gear SP000921....................................................................................... 189 Safety Precautions.............................................................................................. 193 Applicable Models............................................................................................... 193 General Description............................................................................................. 195 Theory of Operation......................................................................................... 195 Reassembly...................................................................................................... 196 Parts List.................................................................................................. 196 Shrinkage Fitting of Shaft and Flexible Bearing................................................................. 198 Reassembly of Carrier Sub....................................................................................... 201 Assembly of the Main............................................................................................ 208 Test............................................................................................................ 220 Reassembly of motor............................................................................................. 223 Lower Structure and Chassis............................................................................................. 231 Ram Lock Valve SP000923............................................................................................. 233 Safety Precautions.............................................................................................. 237 Applicable Models............................................................................................... 237 Sectional Drawing and Part Names................................................................................ 239 Hydraulic Circuit............................................................................................... 239 Operational Principle........................................................................................... 240 In Case of No Pilot Pressure at PI Port..................................................................... 240 In Case of Pilot Pressure (Approx. 20kg•cm2) at PI Port.................................................... 240 Disassembly and Assembly........................................................................................ 240 General Cautions............................................................................................ 240 Assembly and Disassembly of Chocking Valve.................................................................. 241 Performance Test................................................................................................ 242 Oil Leakage Test............................................................................................ 242 Operational Test............................................................................................ 242 Selector Valve SP000926............................................................................................. 243 Safety Precautions.............................................................................................. 247 Applicable Models............................................................................................... 247 Sectional Drawing and Part Names................................................................................ 249 Hydraulic Circuit............................................................................................... 249 Operational Principle........................................................................................... 250 Neutral Position : A → B.................................................................................... 250 Selective Position : A → C.................................................................................. 250 Disassembly and Assembly........................................................................................ 251 General Cautions............................................................................................ 251 Assembly and Disassembly of Selector Valve.................................................................. 251 Performance Test................................................................................................ 253 Oil Leakage Test............................................................................................ 253 Operational Test............................................................................................ 253 Double Pilot Check Valve SP000927................................................................................... 255 Safety Precautions.............................................................................................. 259 Applicable Models............................................................................................... 259 Sectional Drawing and Parts..................................................................................... 261 Hydraulic Diagram............................................................................................... 262 Operational Principle........................................................................................... 263 A → C, D → B................................................................................................ 263 B → D, C → A................................................................................................ 263 Disassembly and Assembly........................................................................................ 264 General Cautions............................................................................................ 264 Assembly and Disassembly of Double Pilot Check Valve........................................................ 265 Performance Test................................................................................................ 267 Cracking Pressure Test for Check Cartridge Ass'y............................................................ 267 Pilot Cracking Pressure Test................................................................................ 267 Oil Leakage Test............................................................................................ 268 Solenoid Valve SP000928............................................................................................. 269 Safety Precautions.............................................................................................. 273 Applicable Models............................................................................................... 273 Single Solenoid Valve Diagram................................................................................... 275 Functions of Single Solenoid Valve.............................................................................. 276 Disassembly and Reassembly Diagrams............................................................................. 277 Troubleshooting of Each Part.................................................................................... 278 Double Solenoid Valve Diagram................................................................................... 279 Functions of Double Solenoid Valve.............................................................................. 280 Disassembly and Reassembly Diagrams............................................................................. 281 Troubleshooting of Each Part.................................................................................... 282 Front Axle SP000929................................................................................................. 283 Safety Precautions.............................................................................................. 287 Applicable Models............................................................................................... 287 Examples of Gear ToothContact Patterns for the Gleason Gear Tooth System................................... 289 Lubrication and Maintenance Specifications for Axle MSE 3050/3060/3070......................................... 292 Oil Grade................................................................................................... 292 Oil Change.................................................................................................. 292 Oil Change Interval......................................................................................... 293 Oil Level Check............................................................................................. 293 Brake....................................................................................................... 294 Brake Wear Measurement on Axles of MT/MSE 3050/ 3060/3070 Range................................................ 295 Lining Wear Measurement of Multidisk Brake.................................................................. 296 Disassembly..................................................................................................... 297 Steering.................................................................................................... 297 Output...................................................................................................... 301 Planetary Carrier....................................................................................... 302 Brake / Hub............................................................................................. 303 Knuckle Housing......................................................................................... 306 Differential Input........................................................................................ 309 Differential Version "D500" and "D750"................................................................ 310 Input................................................................................................... 312 Pivot Bearing............................................................................................... 314 Reassembly...................................................................................................... 315 Input....................................................................................................... 315 Determine Shim for Pinion Positioning to Obtain An Optimum Contact Pattern of Crown Wheel/pinion ....... 315 Adjust Rolling Moment of Drive Pinion Bearing 1.0 2.0Nm (Without Seal Ring):......................... 317 Differential Version "D500" and "D750"................................................................ 319 Adjust Backlash of Bevel Gear Set and Bearing Rolling Moment of Differential Bearing.................... 322 Backlash and Contact Pattern Check...................................................................... 324 Input Flange................................................................................................ 327 Output...................................................................................................... 328 Preassemble Axle Housim................................................................................. 329 Knuckle Housing......................................................................................... 330 Hub..................................................................................................... 335 Multidisk Brake......................................................................................... 339 Planetary Carrier....................................................................................... 345 Pivot Bearing............................................................................................... 347 Steering.................................................................................................... 348 Steering Setting and Checking........................................................................... 354 Oil DrainOil Filler and Oil Control Plugs and Grease Lubrication Points.................................... 357 Rear Axle SP000930.................................................................................................. 359 Safety Precautions.............................................................................................. 363 Applicable Models............................................................................................... 363 Examples of Gear ToothContact Patterns for the Gleason Gear Tooth System................................... 365 Lubrication and Maintenance Specifications for Axle MTE 3050/3060/3070......................................... 368 Oil Grade................................................................................................... 368 Oil Change.................................................................................................. 368 Oil Change Interval......................................................................................... 369 Oil Level Check............................................................................................. 369 Brake....................................................................................................... 370 Brake Wear Measurement on Axles of MT/MSE 3050/ 3060/3070 Range................................................ 371 Lining Wear Measurement of Multidisk Brake.................................................................. 372 Disassembly..................................................................................................... 373 Reassembly...................................................................................................... 379 Hub Carrier / Hub........................................................................................... 379 Multidisk Brake............................................................................................. 383 Make Leakage Test of Multidisk Brake.................................................................... 386 Adjust and Check Disk Clearance/Piston Stroke........................................................... 387 Planetary Carrier........................................................................................... 388 Assembly of An Output Ass'y (Figure 78)..................................................................... 390 Disassembly..................................................................................................... 391 Differential / Input........................................................................................ 391 Input HL Transmission..................................................................................... 392 Differential Type "D 500" and "D750"....................................................................... 394 Reassembly...................................................................................................... 396 Differential / Input........................................................................................ 396 Differential Type "D500" and "D750"................................................................. 396 Determine Shim for Backlash (Crown Wheel/Drive Pinion).................................................. 399 Check Backlash and Contact Pattern...................................................................... 403 Reassembly of Output Ass'y (Figure 123 125)............................................................... 405 Engine and Drivetrain................................................................................................... 407 Transmission SP000962............................................................................................... 409 Safety Precautions.............................................................................................. 413 Applicable Models............................................................................................... 413 Layout 2 HL 250/270/290 Axle Attachment......................................................................... 415 Layout 2 HL 250/270/290 Separate Installation................................................................... 416 Measuring Points and Connections or Installation View 2 HL 250/ 270/290 Layout "Axle Attachment"................ 417 Measuring Points and Connections on the 2 HL 250/270/290 Transmission Version "Separate Install............... 419 Notes to the Required Oil Quality and Oil Filling Capacity...................................................... 420 Oil Quality / Oil Grade..................................................................................... 420 Oil Filling Capacity for Power Shift Transmissions (2 HL250/270/290)....................................... 420 For the Version "Axle Attachment"........................................................................... 420 Separate the HLTransmission from the Axle Casing............................................................... 421 Disassembly Brake / Clutch / Planet Carrier................................................................... 422 Lube Oil Pump/Downshift Interlock........................................................................... 422 Version "Lube Oil Pump"................................................................................. 422 Speed Transmitter........................................................................................... 423 Emergency Release (Parking Brake)........................................................................... 423 Input Housing and Modulation Valve.......................................................................... 424 Brake / Clutch.............................................................................................. 425 Planet Carrier.............................................................................................. 431 Disassembly Output............................................................................................ 435 Version Axle Attachment................................................................................... 435 Version "Separate Installation"........................................................................... 439 Reassembly Output............................................................................................. 443 Version Axle Attachment................................................................................... 443 Determine Adjusting Shim for Pinion Gap................................................................. 445 Determine the Adjusting Ring for Rolling Moment/Pinion Bearing.......................................... 450 Check the Rolling Moment of the Pinion Bearing.......................................................... 451 Shaft Seal/Output Flange................................................................................ 452 Check the Pinion Gap.................................................................................... 453 Version Separate Installation........................................................................... 455 Shaft Seal/Output Flange................................................................................ 459 Reassembly Brake / Clutch / Planet Carrier.................................................................... 462 Planet Carrier.............................................................................................. 462 Brake/Clutch................................................................................................ 468 Disk Components Brake and Clutch........................................................................ 470 Adjust and check the Disk Clearance/Piston Stroke of Brake and Clutch................................... 472 Modulation Valve and Input Housing.......................................................................... 481 Emergency Release (Parking Brake)........................................................................... 483 Check the Emergency Release for Leak Tightness.......................................................... 485 Check the Multidisk Brake and Multidisk Clutch for Leak Tightness and Closing Pressure.................. 487 Speed Transmitter........................................................................................... 488 Lube Oil Pump/Downshift Interlock........................................................................... 489 Disassembly Lube Oil Pump/Downshift Interlock................................................................. 490 Version "with" Lube Oil Pump................................................................................ 490 Version "with" hydr. Downshift Interlock.................................................................... 493 Version "with" electr. Downshift Interlock mounted to Transmission......................................... 496 Reassembly Lube Oil Pump/Downshift Interlock.................................................................. 497 Version "with" Lube Oil Pump................................................................................ 497 Version "with" hydr. Downshift Interlock.................................................................... 503 Version "with" electr. Downshift Interlock mounted to the Transmission.................................... 510 Attach the HLTransmission to the Axle.......................................................................... 511 Drive Coupling (Main Pump) SP000963................................................................................. 513 Safety Precautions.............................................................................................. 517 Applicable Models............................................................................................... 517 Drive Coupling.................................................................................................. 519 Special Tools................................................................................................... 520 Drive Coupling Installation..................................................................................... 522 Installation Procedure...................................................................................... 524 Hydraulics.............................................................................................................. 525 Hydraulic System Troubleshooting, Testing and Adjustment SP000983................................................... 527 Safety Precautions.............................................................................................. 533 Applicable Models............................................................................................... 533 Hydraulic System General Notes................................................................................ 534 Hydraulic Schematic............................................................................................. 535 General Notes............................................................................................... 535 Operation of Working Components................................................................................. 537 Boom Operating Circuit...................................................................................... 537 Boom Up Circuit............................................................................................. 537 Boom Down Circuit........................................................................................... 538 Arm Operating Circuit....................................................................................... 538 Arm Crowd Circuit........................................................................................... 539 Arm Dump Circuit............................................................................................ 539 Bucket Operating Circuit.................................................................................... 539 Bucket Crowd Circuit........................................................................................ 540 Bucket Dump Circuit......................................................................................... 540 Swing Operating Circuit..................................................................................... 540 Right Swing Operating Circuit............................................................................... 540 Left Swing Operating Circuit................................................................................ 541 Swing Relief Valve and Makeup Valve......................................................................... 541 Procedural Troubleshooting Baseline Recommendations............................................................. 542 Initial Checks and Tests to Establish Operating Condition of the Excavator.................................. 542 Triage Summary.......................................................................................... 542 Pilot Pressure.................................................................................................. 544 Adjustment and Testing...................................................................................... 544 Power Mode Valve................................................................................................ 545 Current Signal and Hydraulic Pressure Adjustments........................................................... 545 Swing Priority Valve............................................................................................ 546 Control Valve Pressure and Current Adjustments.............................................................. 546 Pressure Up Valve............................................................................................... 547 Checks and Adjustments...................................................................................... 547 Pump Input Power Control........................................................................................ 549 Pump Regulator Adjustment................................................................................... 549 Flow Meter and Flow Meter Kit Installation and Testing.......................................................... 552 Installation and Testing Procedure.......................................................................... 552 Swing System Troubleshooting.................................................................................... 554 Precautions/Initial Checks.................................................................................. 554 Swing Relief Valve Checking and Adjustment.................................................................. 555 Troubleshooting – Swing Gearbox................................................................................. 557 Troubleshooting – Hydraulic Problems............................................................................ 558 Troubleshooting – Control Valve................................................................................. 560 Troubleshooting – Travel Control Valve.......................................................................... 561 Troubleshooting – Joystick Control Valve........................................................................ 562 Accumulator SP000984................................................................................................ 563 Safety Precautions.............................................................................................. 567 Applicable Models............................................................................................... 567 General Description............................................................................................. 569 Specifications.............................................................................................. 571 Center Joint (Swivel) SP000919...................................................................................... 573 Safety Precautions.............................................................................................. 577 Applicable Models............................................................................................... 577 General Description............................................................................................. 579 Parts List.................................................................................................. 580 Troubleshooting, Testing and Adjustment......................................................................... 581 Inspection.................................................................................................. 581 Testing..................................................................................................... 581 Disassembly..................................................................................................... 582 Reassembly...................................................................................................... 586 Cylinders SP000030.................................................................................................. 587 Safety Precautions.............................................................................................. 591 Applicable Models............................................................................................... 591 General Description............................................................................................. 593 Theory of Operation......................................................................................... 593 Parts List.................................................................................................. 595 Arm Cylinder............................................................................................ 595 Boom and Bucket Cylinder................................................................................ 595 Dozer Cylinder.......................................................................................... 597 Outrigger Cylinder...................................................................................... 598 Ram Cylinder............................................................................................ 599 Special Tools and Materials..................................................................................... 600 Piston Nut.................................................................................................. 600 Piston Jig.................................................................................................. 602 Steel Bushing Jig........................................................................................... 604 Dust Wiper Jig.............................................................................................. 606 Slipper Seal Jig............................................................................................ 608 Slipper Seal Straightening Jig.............................................................................. 610 Disassembly..................................................................................................... 612 Reassembly...................................................................................................... 617 Main Control Valve SP001059......................................................................................... 621 Safety Precautions.............................................................................................. 625 Applicable Models............................................................................................... 625 Control Valve Operation......................................................................................... 627 Boom Priority Circuitry..................................................................................... 628 Bucket (Junction) Circuitry................................................................................. 629 Plunger Replacement......................................................................................... 630 Main Relief Valve........................................................................................... 631 Overload Relief Valve....................................................................................... 632 Arm Load Holding Valve...................................................................................... 633 Boom Load Holding Valve..................................................................................... 636 Arm Regeneration............................................................................................ 638 Foot Relief Valve........................................................................................... 640 Parts List.................................................................................................. 641 Main Plunger Element.................................................................................... 641 Main Relief Valve....................................................................................... 642 Overload Relief Valve................................................................................... 642 Boom Load Holding Valve................................................................................. 643 Boom Unity Check........................................................................................ 643 Arm Regeneration Valve.................................................................................. 643 Foot Relief Valve....................................................................................... 644 Boom Priority Valve (BP Valve).......................................................................... 644 Check Valve (Tr, Am2).................................................................................. 644 Check Valve (Opt, Bkt, Bm1, Bm2, Am1)................................................................ 645 Check Valve............................................................................................. 645 Cap..................................................................................................... 645 Check Valve (Tl)........................................................................................ 646 Check Valve (Sw)........................................................................................ 646 Straight Travel Selector Valve.......................................................................... 646 Center Bypass Valve (Cb Valve).......................................................................... 647 Arm Load Holding Valve.................................................................................. 647 Specifications.............................................................................................. 648 Control Valve Drawing and Hydraulic Circuit..................................................................... 649 Disassembly and Reassembly...................................................................................... 655 General Disassembly......................................................................................... 655 General Reassembly.......................................................................................... 655 Main Plunger Element........................................................................................ 656 Special Tool............................................................................................ 656 Service................................................................................................. 656 Main Relief Valve........................................................................................... 659 Main Relief Valve Adjustment................................................................................ 660 Main Relief Valve Reassembly.......................................................................... 660 Highpressure Adjustment................................................................................ 660 Lowpressure Adjustment................................................................................. 661 Overload Relief Valve....................................................................................... 661 Overload Relief Valve (BM UP)............................................................................... 663 Arm Load Holding Valve...................................................................................... 665 Check Valve Main Body................................................................................... 665 Cover Assembly.......................................................................................... 666 Boom Load Holding Valve..................................................................................... 667 Arm Regeneration Valve...................................................................................... 669 Foot Relief Valve........................................................................................... 670 Center Bypass Valve (CB Valve).............................................................................. 671 Boom Parallel Switch Valve.................................................................................. 672 Special Tool............................................................................................ 672 Service................................................................................................. 672 Boom Unity Check Valve...................................................................................... 674 Straight Travel Selector Valve.............................................................................. 675 Check Valve Locations..................................................................................... 676 Check Valve................................................................................................. 677 A : Check Valve (TR, AM2)............................................................................... 677 B : Check Valve (OPT, BKT, BM1, BM2, AM1)............................................................... 677 C : Check Valve (Main Relief Valve)..................................................................... 678 D : Check Valve (SW).................................................................................... 678 E : Check Valve (TL).................................................................................... 679 Swing Motor SP000985................................................................................................ 681 Safety Precautions.............................................................................................. 685 Applicable Models............................................................................................... 685 Instruction Manual.............................................................................................. 687 Indication of Type.......................................................................................... 687 Specifications.............................................................................................. 688 Construction and Principles of Working...................................................................... 689 Construction............................................................................................ 689 Principles of Working................................................................................... 691 Precaution in Use........................................................................................... 696 Inspection.............................................................................................. 696 Rotation Direction...................................................................................... 696 External Load of Shaft.................................................................................. 697 Hydraulic Fluids and Range of Temperature............................................................... 697 Filter.................................................................................................. 698 Installation and Piping................................................................................. 698 Oil Filling and Air Bleeder............................................................................. 700 Precaution in Starting Operations....................................................................... 700 Troubleshooting............................................................................................. 701 General Cautions........................................................................................ 701 Investigation Manner of the Motor Body.................................................................. 701 Condition and Countermeasures of Troubles............................................................... 702 Maintenance Manual.............................................................................................. 704 Disassembling and Assembling................................................................................ 704 Tightening Torque of Bolts.............................................................................. 704 Necessary Tools......................................................................................... 705 Procedures for Disassembly.............................................................................. 707 Procedures for Assembly................................................................................. 711 Maintenance Standards....................................................................................... 717 Standards for Replacement of Worn Parts................................................................. 717 Standard for Correcting Sliding Surfaces................................................................ 717 Travel Motor SP000986............................................................................................... 719 Safety Precautions.............................................................................................. 723 Applicable Models............................................................................................... 723 General Repair Guidelines....................................................................................... 725 Seal Kits and Subassemblies.................................................................................... 726 Replace Seal Nut............................................................................................ 728 Disassembly..................................................................................................... 729 Sealing the Driveshaft...................................................................................... 729 Seal of the Control Parts................................................................................... 730 Seal of the Relief Valve / Counterbalance Valve............................................................. 732 Spare Parts List............................................................................................ 734 Counterbalance Valve.................................................................................... 734 Brake Release Valve (Pos.50)............................................................................ 735 Shuttle Valve (Pos.25).................................................................................. 735 Diassembly of the Port Plate................................................................................ 736 Remove of the Positioning Piston............................................................................ 737 Remove Rotary Group......................................................................................... 739 Exchanging of the Rotary Group.............................................................................. 740 Inspection Notes............................................................................................ 741 Assembly........................................................................................................ 744 Rotary Group Assembly....................................................................................... 744 Rotary Group Adjustment (See Service Information)........................................................... 746 Assembly of the Port Plate.................................................................................. 748 Tightening Torques.............................................................................................. 750 Shaft Bolts................................................................................................. 750 Locking Screws VSTI......................................................................................... 750 SealLocknuts............................................................................................... 751 Crossslotted Lens Head Screws DIN 7985..................................................................... 751 Test Procedure.................................................................................................. 752 Hydraulics Schematic........................................................................................ 754 Counterbalance Valve SP000991....................................................................................... 755 Safety Precautions.............................................................................................. 759 Applicable Models............................................................................................... 759 General Description............................................................................................. 761 While Operating to Run Forward.............................................................................. 761 While Operating to Stop..................................................................................... 761 While Operating to Back..................................................................................... 762 Adjustment of Relief Valve.................................................................................. 763 Troubleshooting................................................................................................. 764 Counterbalance Valve............................................................................................ 765 Recommended Tools........................................................................................... 765 Disassembly................................................................................................. 765 Order of Disassembly and Torque Values...................................................................... 766 Reassembly.................................................................................................. 767 Main Pump and PTO SP000988.......................................................................................... 773 Safety Precautions.............................................................................................. 777 Applicable Models............................................................................................... 777 Section......................................................................................................... 779 General Repair Guidelines....................................................................................... 780 Seal Kits and Subassemblies.................................................................................... 781 Disassembly..................................................................................................... 785 Sealing the Driveshaft...................................................................................... 785 Gear Pump Sealing........................................................................................... 787 Control Housing............................................................................................. 788 Control Module LR........................................................................................... 791 Control Module H............................................................................................ 792 Controller.................................................................................................. 793 Rotary Groups............................................................................................... 795 Intermediate Wheel.......................................................................................... 798 Auxiliary Drive............................................................................................. 800 Inspection Hints................................................................................................ 803 Assembly........................................................................................................ 808 Rotary Group................................................................................................ 808 Pump........................................................................................................ 809 Assembly Guideline...................................................................................... 811 Hydraulic Component Measurement "D"....................................................................... 812 Control Housing............................................................................................. 815 Intermediate Wheel.......................................................................................... 818 Gear Pump................................................................................................... 819 Cover / Auxiliary Drive..................................................................................... 820 Assembly Guidelines for Tightening Torques...................................................................... 821 Bolts (to N 08.001)......................................................................................... 821 Plugs with Internal Hexagon and Profile Seal Ring (to N 02.009)............................................. 822 SealLock Sealing Nuts (to N 02.100)...................................................................... 822 Gear Pump SP000989.................................................................................................. 823 Safety Precautions.............................................................................................. 827 Applicable Models............................................................................................... 827 Single Gear Pump................................................................................................ 829 Disassembly................................................................................................. 829 Reassembly.................................................................................................. 831 Double Gear Pump................................................................................................ 835 Disassembly................................................................................................. 835 Reassembly.................................................................................................. 837 Service Brake Supply Valve SP000990................................................................................. 841 Safety Precautions.............................................................................................. 845 Applicable Models............................................................................................... 845 Diagram of Brake Supply Valve Assembly Package.............................................................. 847 Functions of Brake Supply Valve Assembly Package............................................................ 848 Functions............................................................................................... 848 Functions of Each Valve................................................................................. 848 Detailed Functions and Application of Brake Supply Valve Assembly Package............................... 848 Exploded View and Tools..................................................................................... 850 Cautions for Disassembly and Reassembly.................................................................... 851 Troubleshooting Guide....................................................................................... 852 How to Check Brake Pressure................................................................................. 853 Dozer Control Valve SP000992........................................................................................ 855 Safety Precautions.............................................................................................. 859 Applicable Models............................................................................................... 859 Structure....................................................................................................... 861 Parts List...................................................................................................... 862 Performance Curve............................................................................................... 863 Hydraulics Symbol............................................................................................... 863 Disassembly and Assembly Tools.................................................................................. 863 Disassembly..................................................................................................... 864 Assembly........................................................................................................ 867 Steering Valve SP000993............................................................................................. 873 Safety Precautions.............................................................................................. 877 Applicable Models............................................................................................... 877 General Description............................................................................................. 879 Theory of Operation......................................................................................... 880 OSPC / OSPF................................................................................................. 881 TOOLS........................................................................................................... 883 Disassembly..................................................................................................... 885 Dismantling the Shock Valves for OSPC/ OSPC LS.............................................................. 889 Dismantling the Pressure Relief Valve for OSPC.............................................................. 890 Dismantling the Pressure Relief Valve (cartridge) for OSPC LS/OSPC LSR...................................... 891 Cleaning.................................................................................................... 892 Inspection and Replacement.................................................................................. 892 Lubrication................................................................................................. 892 Assembly........................................................................................................ 893 Assembly Pattern for Standard Bearing....................................................................... 895 Assembly Pattern for Double Bearing......................................................................... 896 Installation Instructions for Oring/Kinring /Roto Glyd.................................................... 896 Installation Instructions for Lip Seal...................................................................... 897 Assembly of the Pressure Relief Valve for OSPC.............................................................. 902 Assembly of the Shock Valves for OSPC/ OSPC LS/OSPC LSR..................................................... 903 Hydraulic Connections....................................................................................... 905 Accelerator Pedal Valve (Hydraulic) SP000995........................................................................ 907 Safety Precautions.............................................................................................. 911 Applicable Models............................................................................................... 911 STructure....................................................................................................... 913 Parts List...................................................................................................... 913 Performance Curve............................................................................................... 914 Hydraulics Symbol............................................................................................... 914 Disassembly and Assembly Tools.................................................................................. 914 Disassembly..................................................................................................... 915 Assembly........................................................................................................ 916 One Spool Valve SP000996............................................................................................ 919 Safety Precautions.............................................................................................. 923 Applicable Models............................................................................................... 923 Outside Drawing................................................................................................. 925 Hydraulic Circuit............................................................................................... 925 Operational Principle........................................................................................... 926 In the Neutral Condition.................................................................................... 926 Spool Operation............................................................................................. 926 Disassembly and Assembly........................................................................................ 927 General Cautions............................................................................................ 927 Replacement of Spool Ass'y (Pilot Type)..................................................................... 928 Replacement of Main Relief Valve............................................................................ 930 Replacement of Overload Relief Valve........................................................................ 931 Replacement of SubBlock Ass'y.............................................................................. 932 Remote Control Valve (Work Lever / Joystick) SP000069............................................................... 935 Safety Precautions.............................................................................................. 939 Applicable Models............................................................................................... 939 General Description............................................................................................. 941 Theory of Operation......................................................................................... 941 Structure............................................................................................... 941 Function................................................................................................ 941 Parts List.................................................................................................. 942 Specifications.............................................................................................. 944 Performance............................................................................................. 944 Torques..................................................................................................... 944 Tools and Materials............................................................................................. 944 Disassembly..................................................................................................... 945 Cleaning and Inspection (Wear Limits and Tolerances)............................................................ 949 Reassembly...................................................................................................... 949 Startup Procedures............................................................................................. 955 Breaker EPPR Valve (Opt) SP000192................................................................................... 957 Safety Precautions.............................................................................................. 961 Applicable Models............................................................................................... 961 Structure....................................................................................................... 962 Numbers and Names of Parts.................................................................................. 962 Functions and Operation......................................................................................... 963 Cautions for Operation.......................................................................................... 963 Maintenance Instructions........................................................................................ 964 Maintenance................................................................................................. 964 Bolt Tightening Torque.................................................................................. 964 Tools Used for Disassembly and Assembly................................................................. 964 Disassembly................................................................................................. 965 Assembly.................................................................................................... 966 Service Brake Pedal Valve SP001006.................................................................................. 969 Safety Precautions.............................................................................................. 973 Applicable Models............................................................................................... 973 Functions of Brake Pedal........................................................................................ 975 Internal Structure and Operation Principles..................................................................... 976 Internal Structure.......................................................................................... 976 Operation Principles........................................................................................ 978 Disassembly..................................................................................................... 979 Reassembly...................................................................................................... 979 Reassembly of the Lower Part................................................................................ 979 Reassembly of the Upper Part................................................................................ 981 Assembly of Pedal Plate..................................................................................... 984 Solenoid Valve Assembly SP000997.................................................................................... 991 Safety Precautions.............................................................................................. 995 Applicable Models............................................................................................... 995 2Solenoid Valve................................................................................................ 997 Diagram of 2Solenoid Valve Assembly Package................................................................ 997 Exploded View and Tools..................................................................................... 998 Assembly, Reassembly of Solenoid Valve Package, and Necessary Tools.................................... 998 Cautions for Disassembly and Reassembly.................................................................... 999 Solenoid Valve Diagram..................................................................................1000 Troubleshooting Guide.......................................................................................1000 6Solenoid Valve................................................................................................1001 Diagram of 6Solenoid Valve Assembly Package................................................................1001 Functions of 6Solenoid Valve Assembly Package..............................................................1002 Functions...............................................................................................1002 Application by Function of Each Solenoid Valve..........................................................1002 Detailed Functions and Application of Each Solenoid Valve...............................................1002 Exploded View and Tools.....................................................................................1004 Disassembly, Reassembly of Solenoid Valve Package, and Necessary Tools.................................1004 Cautions for Disassembly and Reassembly....................................................................1005 Solenoid Valve Diagram..................................................................................1006 Troubleshooting Guide.......................................................................................1006 Parts...................................................................................................1006 How to Check Pilot Pressure.............................................................................1007 4Solenoid Valve................................................................................................1008 Diagram of 4Solenoid Valve Assembly Package................................................................1008 Functions of 4 Solenoid Valve Assembly Package..............................................................1009 Functions...............................................................................................1009 Application by Function of Each Solenoid Valve..........................................................1009 Detailed Function and Application Descriptions by Solenoid Valve........................................1009 Exploded View and Tools.....................................................................................1011 Disassembly, Reassembly of Solenoid Valve Package, and Necessary Tools.................................1011 Cautions for Disassembly and Reassembly....................................................................1012 Solenoid Valve Diagram..................................................................................1013 Troubleshooting Guide.......................................................................................1014 Parts...................................................................................................1014 How to Check Pilot Pressure.............................................................................1014 3Solenoid......................................................................................................1015 Diagram of 3Solenoid Valve Assembly Package................................................................1015 Functions of 3 Solenoid Valve Assembly Package..............................................................1016 Functions...............................................................................................1016 Application by Function of Each Solenoid Valve..........................................................1016 Detailed Function and Application Descriptions by Solenoid Valve........................................1016 Exploded View and Tools.....................................................................................1018 Disassembly, Reassembly of Solenoid Valve Package, and Necessary Tools.................................1018 Cautions for Disassembly and ReAssembly....................................................................1019 Solenoid Valve Diagram..................................................................................1020 Troubleshooting Guide.......................................................................................1021 Parts...................................................................................................1021 How to Check Pilot Pressure.............................................................................1021 Hydraulic Schematic SP001002........................................................................................1023 Safety Precautions..............................................................................................1027 Applicable Models...............................................................................................1027 Electrical System.......................................................................................................1030 Electrical System SP000998..........................................................................................1032 Safety Precautions..............................................................................................1038 Applicable Models...............................................................................................1038 Introduction....................................................................................................1040 Electrical Wire Color.......................................................................................1040 Electrical Supply System........................................................................................1041 Engine Starting Circuit.........................................................................................1043 Start Operation.............................................................................................1043 After Start.................................................................................................1045 Operation of the Start Circuit (2) Immediately after Start............................................1046 Engine Preheating System........................................................................................1047 Engine Stop.....................................................................................................1049 Charging System.................................................................................................1051 Monitoring System...............................................................................................1052 Instrument Panel............................................................................................1053 Monitoring System Schematic.................................................................................1054 Operation.......................................................................................................1056 Instruments.................................................................................................1056 Warning and Indicator Lights....................................................................................1058 Indication of Warning Lights................................................................................1058 Indication of Multifunction Gauge and Letter Information Area...............................................1059 Initial Operation...............................................................................................1061 Mode Selector Switch............................................................................................1062 Power Mode..................................................................................................1062 Trenching Mode Switch.......................................................................................1062 Auto Idle Switch............................................................................................1062 Graphic Information Area Display................................................................................1063 Overview....................................................................................................1063 Main Menus for the Graphic Display Area.....................................................................1064 Menu Selector Buttons.......................................................................................1064 Menu Selector Buttons.......................................................................................1064 Main Menu.......................................................................................................1065 Language....................................................................................................1065 Set Clock...................................................................................................1066 Filter/Oil Info.............................................................................................1066 Menu Display Order and Icon Explanation.................................................................1067 Adjust Display..............................................................................................1067 Set Password................................................................................................1068 Special Menu....................................................................................................1069 Entering/Accessing and Exiting/Escaping Menus...............................................................1069 Entering/Accessing Menus................................................................................1069 Exiting/Escaping Menus..................................................................................1070 Special Menu Selections.....................................................................................1070 Information of Machine Status...........................................................................1070 Failure Information.....................................................................................1074 Information of Machine Operation........................................................................1082 Machine Operation Info Screen...........................................................................1085 Electronic control system of Hydraulic System (eEPOS)..........................................................1086 Control System Diagram......................................................................................1086 Power Mode Control..............................................................................................1088 Operation...................................................................................................1090 1. Power Mode...........................................................................................1090 2. Standard Mode........................................................................................1092 3) Operation in case of failure in the control system (Aux mode operation)..............................1092 Power Mode Control Circuit Diagram............................................................................1093 Work Mode Control...............................................................................................1095 Operation...................................................................................................1096 1. Digging Mode.........................................................................................1096 2. Trenching Mode.......................................................................................1096 Work Mode Control Circuit Diagram.............................................................................1097 Engine Control System...........................................................................................1098 Engine Control Dial.............................................................................................1099 Acceleration pedal..............................................................................................1101 Engine Control Circuit Diagram..................................................................................1102 Automatic Deceleration Control (Auto Idle Control)..............................................................1104 Engine Overheat Protection System...............................................................................1106 Power Boost Mode................................................................................................1108 Operation...................................................................................................1108 Power Boost Control Circuit Diagram.......................................................................1110 cruise control..................................................................................................1111 Operation...................................................................................................1111 Cruise Control Circuit......................................................................................1113 Selfdiagnostic Function........................................................................................1115 eEPOS Controller...........................................................................................1115 Air Conditioner System..........................................................................................1117 Outline.....................................................................................................1117 Internal and External Filters...............................................................................1118 How to check Indoor air filter..........................................................................1118 How to check outdoor air filter.........................................................................1118 AirConditioning System Layout..............................................................................1120 Air Conditioner/Heater Circuit Diagram......................................................................1121 Air Conditioner/Heater Unit.................................................................................1122 Airflow Diagram.........................................................................................1122 Door Open by Vent Modes.................................................................................1123 Main Components.........................................................................................1123 Actuator Internal/external air exchange...............................................................1125 Airflow Control Module..................................................................................1125 Relay Blower..............................................................................................1126 Relay A/C.................................................................................................1126 Duct Sensor.................................................................................................1126 Water Temp Sensor...........................................................................................1127 Internal Air Temp Sensor....................................................................................1127 Ambient Air Temperature Sensor..............................................................................1127 Sun Sensor..................................................................................................1128 Control Panel...............................................................................................1128 Appearance and Terminal Arrangement.....................................................................1128 Terminal Terms..........................................................................................1129 Control Logic...........................................................................................1129 Selfdiagnossi..........................................................................................1133 Ambient Temp Display....................................................................................1134 Compressor..................................................................................................1135 Receiver Dryer..............................................................................................1135 Wiper System....................................................................................................1136 Wiper Circuit...............................................................................................1136 Wiper operation.............................................................................................1137 Continuous operation....................................................................................1137 Intermittent operation..................................................................................1137 Lighting System.................................................................................................1139 Lighting System Circuit Diagram.............................................................................1139 Type........................................................................................................1140 Operation...................................................................................................1140 Overload Warning Device.........................................................................................1142 Overload Warning Device Circuit Diagram.....................................................................1142 Audio Controller................................................................................................1143 Audio Controller Circuit Diagram............................................................................1143 Operations Via Audio Control Panel......................................................................1144 ram lock device.................................................................................................1145 Ram Lock Control Circuit....................................................................................1145 Operation...................................................................................................1146 Electrical Schematic SP001003.......................................................................................1148 Safety Precautions..............................................................................................1152 Applicable Models...............................................................................................1152 Attachments.............................................................................................................1155 Boom and Arm SP001000...............................................................................................1157 Safety Precautions..............................................................................................1161 Applicable Models...............................................................................................1161 Front Attachment Pin Specifications.............................................................................1163 Front Attachment Removal and Installation.....................................................................1164 Arm Removal Procedure.......................................................................................1164 Boom Removal Procedure......................................................................................1166 Installation....................................................................................................1167 Arm Installation Procedure..................................................................................1167 Boom Installation Procedure.................................................................................1167 Startup Procedures.............................................................................................1167 Bucket SP001001.....................................................................................................1169 Safety Precautions..............................................................................................1173 Applicable Models...............................................................................................1173 Bucket Tooth Inspection and Replacement.........................................................................1175 Bucket Oring Replacement.......................................................................................1176 Bucket Attachment, Removal and Reversal.........................................................................1178 Detaching the Bucket........................................................................................1178 Attaching the Bucket........................................................................................1178 Reversing the Bucket........................................................................................1179
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Arturo Christopher –
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