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Doosan DX490LC-3 DX530LC-3 Excavator Shop Manual 950106-00259E – PDF DOWNLOAD
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Doosan DX490LC-3 DX530LC-3 Excavator Shop Manual 950106-00259E – PDF DOWNLOAD
Serial Number 10001 and Up
950106-00259E
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Description
Doosan DX490LC-3 DX530LC-3 Excavator Shop Manual 950106-00259E – PDF DOWNLOAD
DESCRIPTION:
Doosan DX490LC-3 DX530LC-3 Excavator Shop Manual 950106-00259E – PDF DOWNLOAD
Serial Number 10001 and Up
950106-00259E
GENERAL
Safe Operation is Operator’s Responsibility:
- Only trained and authorized personnel should operate and maintain the machine. Follow all safety rules, regulations and instructions when operating or performing maintenance on machine.
- Do not operate machine if you are under the influence of drugs or alcohol. An operator who is taking prescription drugs must get medical advice to determine if he or she can safely operate a machine.
- When working with other personnel on a work site, be sure that all personnel know nature of work and understand all hand signals that are to be used.
- Be sure that all guards and shields are installed in their proper location. Have guards and shields repaired or replaced immediately if damaged.
- Be sure that you understand the use and maintenance of all safety features such as safety lock lever and seat belt. Use them properly.
- Never remove, modify or disable any safety features. Always keep them in good operating condition.
- Always check for and know the location of underground and overhead utility lines before excavating.
- Failure to use and maintain safety features according to instructions in this manual, Safety Manual and Shop Manual can result in death or serious injury
Know Your Machine:
- Know how to operate your machine. Know the purpose of all controls, gauges, signals, indicators and monitor displays. Know the rated load capacity, speed range, braking and steering characteristics, turning radius and operating clearances.
- Keep in mind that rain, snow, ice, loose gravel, soft ground, slopes etc., can change operating capabilities of your machine
.
TABLE OF CONTENTS:
Doosan DX490LC-3 DX530LC-3 Excavator Shop Manual 950106-00259E – PDF DOWNLOAD
DX490LC-3/DX530LC-3........................................................................................... 0 Table of Contents......................................................................................... 7 Safety.................................................................................................... 9 Track Excavator Maintenance Safety SP002618........................................................... 11 Safety Instructions............................................................................... 15 Applicable Models................................................................................. 15 Safety Messages................................................................................... 16 Signal Words.................................................................................. 16 Safety Decals..................................................................................... 17 General........................................................................................... 17 Safe Operation is Operator's Responsibility................................................... 17 Know Your Machine............................................................................. 17 Proper Work Tools and Attachments............................................................. 18 Pressurized Fluids............................................................................ 18 Flying or Falling Objects..................................................................... 19 Personal Protective Equipment (PPE)........................................................... 20 Correction of Machine Problems................................................................ 20 Crushing and Cutting.......................................................................... 20 Hot Coolant and Oils - Burn Prevention........................................................ 21 Fire and Explosion Prevention................................................................. 22 Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)................................... 25 Electrical System and Electrical Shock........................................................ 25 Rollover Protective Structure (ROPS).......................................................... 26 Transportation.................................................................................... 30 Obey State and Local Over-the-Road Regulations................................................ 30 Loading and Unloading......................................................................... 30 Transporting Machine.......................................................................... 31 Operation......................................................................................... 32 Before Engine Starting........................................................................ 32 Work Site..................................................................................... 33 Mounting/Dismounting.......................................................................... 34 Cleaning...................................................................................... 35 Operator Station.............................................................................. 35 Seat Belt..................................................................................... 36 Visibility Information........................................................................ 37 Boost Starting or Charging Engine Batteries................................................... 38 Starting Engine............................................................................... 39 Swinging or Traveling......................................................................... 40 Lifting and Digging........................................................................... 42 Operation on Slopes........................................................................... 43 Towing........................................................................................ 44 Attachment.................................................................................... 45 Equipment Lowering with Engine Stopped........................................................ 45 Engine Stop................................................................................... 45 Parking Machine............................................................................... 46 Preservation/Storing Machine.................................................................. 47 Maintenance....................................................................................... 49 Warning Tag................................................................................... 52 Cleaning...................................................................................... 53 Proper Tools and Clothing..................................................................... 53 Disassembling Precautions..................................................................... 53 Use of Lighting............................................................................... 54 Fire and Explosion Prevention................................................................. 54 Burn Prevention............................................................................... 55 Rubber That Contains Fluorides................................................................ 56 Rubber and Plastics........................................................................... 57 Welding Repairs............................................................................... 58 Warning for Counterweight and Front Attachment Removal........................................ 59 Working on Machine............................................................................ 60 Lock Inspection Covers........................................................................ 60 Accumulator................................................................................... 61 Compressed Air................................................................................ 61 Track Tension Adjustments..................................................................... 62 Supports and Blocking for Work Equipment...................................................... 62 High-pressure Lines, Tubes and Hoses.......................................................... 63 Battery....................................................................................... 64 Environment and Circumstances..................................................................... 66 Work Site Areas Requiring Extra Caution....................................................... 66 High-voltage Cables........................................................................... 68 Underground Operation......................................................................... 69 Working in Water.............................................................................. 69 Working in Contaminated Environment........................................................... 69 Operation in Extreme Conditions............................................................... 70 Exhaust Ventilation........................................................................... 74 Asbestos Information.......................................................................... 74 Silica Dust Information....................................................................... 75 Disposal of Hazardous Materials............................................................... 75 Sound......................................................................................... 76 Vibration..................................................................................... 76 Specifications............................................................................................ 77 Specification for DX490LC-3/ DX530LC-3 SP002557....................................................... 79 Safety Instructions............................................................................... 83 Applicable Models................................................................................. 83 General Description............................................................................... 85 Component Locations............................................................................... 86 General Dimensions................................................................................ 88 Variable Track................................................................................ 88 Fixed Track................................................................................... 89 Working Range..................................................................................... 90 Variable Track................................................................................ 91 Fixed Track................................................................................... 93 General Specifications............................................................................ 94 DX490LC-3..................................................................................... 94 DX530LC-3..................................................................................... 96 Engine Performance Curves (Per KS-R1004 Standard)................................................. 98 Approximate Weight of Workload Materials.......................................................... 100 Performance Tests................................................................................. 102 Excavator Performance Measurements................................................................ 103 Test Conditions............................................................................... 103 Travel Speed and Travel Motor Balance (Steering Deviation) Tests.............................. 103 Speed Test................................................................................ 103 Travel Deviation.......................................................................... 105 Swing Speed and Deceleration Force Test....................................................... 105 Swing Speed Test.......................................................................... 105 Swing Deceleration Force Test............................................................. 106 Cylinder Performance Tests.................................................................... 107 Boom Cylinders Test....................................................................... 107 Arm Cylinder Test......................................................................... 107 Bucket Cylinder Test...................................................................... 107 Hydraulic Cylinder Natural Drop Test...................................................... 107 Travel Motor Jack-up Test................................................................. 107 General Maintenance....................................................................................... 109 General Maintenance Instructions SP002454............................................................. 111 Safety Instructions............................................................................... 115 Applicable Models................................................................................. 115 Welding Precautions and Instructions.............................................................. 116 Hydraulic System - General Precautions............................................................ 117 Maintenance Service and Repair Procedure.......................................................... 119 General Precautions........................................................................... 119 Hydraulic System Cleanliness and Oil Leaks........................................................ 120 Maintenance Precautions for Hydraulic System Service.......................................... 120 Oil Leakage Precautions....................................................................... 121 Cleaning and Inspection........................................................................... 122 General Instructions.......................................................................... 122 Bearing Inspection............................................................................ 123 Standard Torques SP002404............................................................................. 131 Safety Instructions............................................................................... 135 Applicable Models................................................................................. 135 Torque Values for Standard Metric Fasteners....................................................... 136 Torque Values for Standard U.S. Fasteners......................................................... 137 Type 8 Phosphate Coated Hardware.................................................................. 139 Torque Values for Hose Clamps..................................................................... 140 ORFS Swivel Nut Recommended Torque................................................................ 140 Torque Values for Split Flanges................................................................... 141 Torque Wrench Extension Tools..................................................................... 142 Torque Multiplication......................................................................... 142 Other Uses for Torque Wrench Extension Tools.................................................. 143 Tightening Torque Specifications (Metric)..................................................... 144 Upper Structure........................................................................................... 147 Cabin SP002324........................................................................................ 149 Safety Instructions............................................................................... 153 Applicable Models................................................................................. 153 Cabin Identification.............................................................................. 154 Rollover Protective Structure (ROPS).......................................................... 154 Removal........................................................................................... 156 Installation...................................................................................... 160 Counterweight SP002558................................................................................ 163 Safety Instructions............................................................................... 167 Applicable Models................................................................................. 167 General........................................................................................... 168 Warning for Counterweight and Front Attachment Removal........................................ 168 Removal........................................................................................... 170 Installation...................................................................................... 171 Fuel Tank SP002559.................................................................................... 173 Safety Instructions............................................................................... 177 Applicable Models................................................................................. 177 General Description............................................................................... 178 Parts List.................................................................................... 178 Specifications................................................................................ 179 Removal........................................................................................... 180 Installation...................................................................................... 184 Start-up Procedures............................................................................... 187 Fuel Transfer Pump (Option) SP002560.................................................................. 189 Safety Instructions............................................................................... 193 Applicable Models................................................................................. 193 General Description............................................................................... 194 Theory of Operation........................................................................... 194 Troubleshooting................................................................................... 196 Replacement of Rotor and Vane..................................................................... 196 Replacement of Rear Cover......................................................................... 197 Replacement of Armature........................................................................... 197 Swing Bearing SP002329................................................................................ 199 Safety Instructions............................................................................... 203 Applicable Models................................................................................. 203 Swing Bearing Maintenance......................................................................... 204 Operating Recommendation...................................................................... 204 Measuring Swing Bearing Axial Play............................................................ 204 Measuring Bearing Lateral Play................................................................ 204 Swing Bearing Basic Operation................................................................. 205 Disassembly................................................................................... 205 Assembly...................................................................................... 207 Lower Structure and Chassis............................................................................... 209 Track Assembly SP002561............................................................................... 211 Safety Instructions............................................................................... 215 Applicable Models................................................................................. 215 General Description............................................................................... 216 Track Tension..................................................................................... 217 Cleaning and Inspection (Wear Limits and Tolerances).............................................. 219 Track Shoe.................................................................................... 220 Lower Roller.................................................................................. 222 Upper Roller.................................................................................. 223 Front Idler................................................................................... 224 Track Shoes and Links............................................................................. 225 Track Removal................................................................................. 225 Track Installation............................................................................ 226 Front Idler Roller................................................................................ 228 Parts List.................................................................................... 228 Front Idler Roller Disassembly................................................................ 229 Front Idler Roller Reassembly................................................................. 231 Lower Roller...................................................................................... 232 Parts List.................................................................................... 232 Lower Roller Removal.......................................................................... 233 Lower Roller Disassembly...................................................................... 233 Lower Roller Reassembly....................................................................... 234 Lower Roller Installation..................................................................... 235 Upper Roller...................................................................................... 236 Parts List.................................................................................... 236 Upper Roller Removal.......................................................................... 237 Upper Roller Disassembly...................................................................... 237 Upper Roller Reassembly....................................................................... 239 Track Spring and Track Adjusting Cylinder......................................................... 240 Parts List.................................................................................... 240 Engine and Drivetrain..................................................................................... 243 Engine SP002540....................................................................................... 245 Safety Instructions............................................................................... 249 Applicable Models................................................................................. 249 Introduction...................................................................................... 250 Safety Information............................................................................ 250 Service Information Guide......................................................................... 251 Contents Included in Service Information...................................................... 251 Plastic Gauge................................................................................. 254 Recommended Liquid Gasket..................................................................... 255 Thread Locking Adhesive Agent................................................................. 258 Term.......................................................................................... 259 Abbreviations................................................................................. 260 Standard Bolts................................................................................ 263 Maintenance Information........................................................................... 268 Maintenance Precautions....................................................................... 268 Primary Specifications........................................................................ 273 Function, Structure, Operation................................................................ 276 Introduction to the Trouble Diagnosis......................................................... 333 Functional Inspection............................................................................. 346 Engine Compression Pressure Inspection........................................................ 346 Fuel System Check............................................................................. 348 Air Intake System Check....................................................................... 349 Exhaust System Check.......................................................................... 349 DPD Control System Check...................................................................... 350 EGR Control System Check...................................................................... 353 Starting System Check......................................................................... 354 Glow Control System Check..................................................................... 356 OBD System Check.............................................................................. 358 Inspection of the Diagnostic Light Warning Light Illumination Circuit System.................. 360 Inspection of the Diagnostic Light Warning Light Blinking Circuit System...................... 360 Inspection of the Starter Circuit System...................................................... 362 Symptom........................................................................................... 364 Engine Start Failure.......................................................................... 364 Engine stalling............................................................................... 366 Engine Hunching, Rough Idling................................................................. 369 Excessive White Smoke in the Exhaust Gas...................................................... 370 Excessive Black Smoke in the Exhaust Gas...................................................... 372 Abnormal Noise................................................................................ 373 Large Fuel Consumption........................................................................ 374 Large Oil Consumption......................................................................... 376 Insufficient Engine Output.................................................................... 378 DPD System Manual Regeneration Frequently..................................................... 380 DPD System Regeneration Long Time............................................................. 383 DTC Information................................................................................... 385 DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft Position Correlation................. 385 DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit......................... 385 DTC P0087 (Flash Code 225) Fuel Rail/ System Pressure - Too Low............................... 386 DTC P0103 (Flash Code 91) Mass Airflow Circuit High Input..................................... 387 DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low........................... 388 DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High.......................... 388 DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low....................... 389 DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High...................... 390 DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low................................ 391 DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High............................... 391 DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low................................ 392 DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High............................... 393 DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low.............................. 394 DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High............................. 395 DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1...................................... 396 DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2...................................... 396 DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3...................................... 397 DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4...................................... 398 DTC P0205 (Flash Code 275) Injector Circuit - Cylinder 5...................................... 399 DTC P0206 (Flash Code 276) Injector Circuit - Cylinder 6...................................... 399 DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition.......................... 400 DTC P0219 (Flash Code 543) Engine Overspeed Condition......................................... 401 DTC P0234 (Flash Code 42) Turbocharger Overboost Condition.................................... 401 DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low.............................. 402 DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High............................. 403 DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit.................................. 403 DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/ Performance............... 404 DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit.................................... 405 DTC P0341 (Flash Code 14) Camshaft Position Sensor Circuit Range/ Performance................. 406 DTC P0404 (Flash Code 45) Exhaust Gas Recirculation 1 Control Circuit Range/ Performance...... 406 DTC P0409 (Flash Code 44) Exhaust Gas Recirculation 1 Sensor Circuit.......................... 407 DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High..................... 408 DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low...................... 409 DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/ Performance Sensor 1.... 409 DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1.................... 410 DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1................... 411 DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/ Performance Sensor 2.... 412 DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2.................... 413 DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2................... 413 DTC P0522 (Flash Code 295) Oil Pressure Sensor Circuit Low.................................... 414 DTC P0523 (Flash Code 295) Oil Pressure Sensor Circuit High................................... 415 DTC P0560 (Flash Code 155) System Voltage..................................................... 416 DTC P0563 (Flash Code 35) System Voltage High................................................. 416 DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error...................... 417 DTC P0602 (Flash Code 154) Control Module Programming Error................................... 417 DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (Ram) Error........... 418 DTC P0606 (Flash Code 51) ECM/PCM Processor................................................... 418 DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance.................. 419 DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance......................... 419 DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit.................................. 420 DTC P0650 (Flash Code 77) Malfunction Indicator Light (MIL) Control Circuit................... 421 DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit.................................. 421 DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open........................... 422 DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High........................... 423 DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit.................................. 423 DTC P1062 (Flash Code 257) Fuel Pressure Regulator 1 Solenoid Control Circuit................. 424 DTC P1063 (Flash Code 258) Fuel Pressure Regulator 2 Solenoid Control Circuit................. 425 DTC P1093 (Flash Code 226) Fuel Rail Pressure (FRP) Too Low................................... 425 DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low............................... 426 DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High.............................. 427 DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group1.................... 428 DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group2.................... 428 DTC P1293 (Flash Code 221) Fuel Filter Pressure Sensor Circuit Low............................ 429 DTC P1294 (Flash Code 221) Fuel Filter Pressure Sensor Circuit High........................... 430 DTC P1404 (Flash Code 45) Exhaust Gas Recirculation 1 Closed Position Performance............. 430 DTC P140A (Flash Code 345) Exhaust Gas Recirculation 2 Control Circuit Range/ Performance..... 431 DTC P140B (Flash Code 344) Exhaust Gas Recirculation 2 Sensor Circuit......................... 432 DTC P140C (Flash Code 345) Exhaust Gas Recirculation 2 Closed Position Performance............ 433 DTC P1455 (Flash Code 132) PM Over Accumulation............................................... 434 DTC P1471 (Flash Code 149) DPD Insufficient Regeneration...................................... 434 DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance......................... 435 DTC P1655 (Flash Code 59) Sensor Reference Voltage 4 Circuit.................................. 435 DTC P1669 (Flash Code 75) DPD Light Control Circuit........................................... 436 DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input.......................... 437 DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input......................... 438 DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input.......................... 438 DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input......................... 439 DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2 Voltage Correlation.................... 440 DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit....................... 441 DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit....................... 441 DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low..................................... 442 DTC P2229 (Flash Code 71) Barometric Pressure Circuit High.................................... 443 DTC P2295 (Flash Code 248) Fuel Pressure Regulator 2 Solenoid Control Circuit Low............. 444 DTC P2296 (Flash Code 218) Fuel Pressure Regulator 2 Solenoid Control Circuit High............ 445 DTC P242F (Flash Code 131) DPD Restriction.................................................... 446 DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit........................... 446 DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance......... 447 DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low........................ 448 DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High....................... 449 DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position................... 450 DTC P2458 (Flash Code 139) DPD Regeneration Duration.......................................... 450 DTC U0001 (Flash Code 84) CAN-Bus Malfunction (ISO-CAN)....................................... 451 DTC U0073 (Flash Code 84) CAN-Bus Malfunction (J1939)......................................... 452 DTC U0101 (Flash Code 85) Lost Communication with TCM......................................... 452 DTC U0110 (Flash Code 87) Lost Communication with VNT System.................................. 453 DTC U0411 (Flash code 87) Turbo Charger Control Module Signal Malfunction..................... 453 DTC Mapping Table............................................................................. 454 Engine Control.................................................................................... 457 DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft Position Correlation................. 457 DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit......................... 458 DTC P0087 (Flash Code 225) Fuel Rail/ System Pressure - Too Low............................... 461 DTC P0088 (Flash Code 118) Fuel Rail/ System Pressure - Too High.............................. 465 DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance................................ 468 DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low........................ 471 DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low........................ 473 DTC P0092 (Flash Code 217) Fuel Pressure Regulator Control Circuit High....................... 474 DTC P0093 (Flash Code 227) Fuel System Leak Detected.......................................... 475 DTC P0102 (Flash Code 91) Mass Airflow Circuit Low Input...................................... 478 DTC P0103 (Flash Code 91) Mass Airflow Circuit High Input..................................... 479 DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low........................... 480 DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High.......................... 481 DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low....................... 483 DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High...................... 484 DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low................................ 485 DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High............................... 487 DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low................................ 488 DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High............................... 489 DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low.............................. 490 DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High............................. 492 DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1...................................... 493 DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2...................................... 495 DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3...................................... 497 DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4...................................... 499 DTC P0205 (Flash Code 275) Injector Circuit - Cylinder 5...................................... 500 DTC P0206 (Flash Code 276) Injector Circuit - Cylinder 6...................................... 502 DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition.......................... 504 DTC P0219 (Flash Code 543) Engine Overspeed Condition......................................... 505 DTC P0234 (Flash Code 42) Turbocharger Overboost Condition.................................... 506 DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low.............................. 508 DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High............................. 509 DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit.................................. 510 DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/ Performance............... 512 DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit.................................... 513 DTC P0341 (Flash Code 14) Camshaft Position Sensor Circuit Range/ Performance................. 515 DTC P0404 (Flash Code 45) Exhaust Gas Recirculation 1 Control Circuit Range/ Performance...... 516 DTC P0409 (Flash Code 44) Exhaust Gas Recirculation 1 Sensor Circuit.......................... 517 DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High..................... 519 DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low...................... 520 DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/ Performance Sensor 1.... 521 DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1.................... 522 DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1................... 523 DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/ Performance Sensor 2.... 525 DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2.................... 526 DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2................... 527 DTC P0522 (Flash Code 295) Oil Pressure Sensor Circuit Low.................................... 529 DTC P0523 (Flash Code 295) Oil Pressure Sensor Circuit High................................... 530 DTC P0560 (Flash Code 155) System Voltage..................................................... 531 DTC P0563 (Flash Code 35) System Voltage High................................................. 533 DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error...................... 534 DTC P0602 (Flash Code 154) Control Module Programming Error................................... 534 DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM) Error........... 535 DTC P0606 (Flash Code 51) ECM/PCM Processor................................................... 535 DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance.................. 536 DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance......................... 536 DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit.................................. 538 DTC P0650 (Flash Code 77) Malfunction Indicator Light (MIL) Control Circuit................... 540 DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit.................................. 541 DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open........................... 543 DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High........................... 544 DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit.................................. 545 DTC P1062 (Flash Code 257) Fuel Pressure Regulator 1 Solenoid Control Circuit................. 546 DTC P1063 (Flash Code 258) Fuel Pressure Regulator 2 Solenoid Control Circuit................. 547 DTC P1093 (Flash Code 226) Fuel Rail Pressure (FRP) Too Low................................... 548 DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low............................... 550 DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High.............................. 551 DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1................... 552 DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2................... 553 DTC P1293 (Flash Code 221) Fuel Filter Pressure Sensor Circuit Low............................ 553 DTC P1294 (Flash Code 221) Fuel Filter Pressure Sensor Circuit High........................... 555 DTC P1404 (Flash Code 45) Exhaust Gas Recirculation 1 Closed Position Performance............. 556 DTC P140A (Flash Code 345) Exhaust Gas Recirculation 2 Control Circuit Range/ Performance..... 557 DTC P140B (Flash Code 344) Exhaust Gas Recirculation 2 Sensor Circuit......................... 558 DTC P140C (Flash Code 345) Exhaust Gas Recirculation 2 Closed Position Performance............ 560 DTC P1455 (Flash Code 132) PM Over Accumulation............................................... 561 DTC P1471 (Flash Code 149) DPD Insufficient Regeneration...................................... 563 DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance......................... 565 DTC P1655 (Flash Code 59) Sensor Reference Voltage 4 Circuit.................................. 565 DTC P1669 (Flash Code 75) DPD Light Control Circuit........................................... 567 DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input.......................... 569 DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input......................... 570 DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input.......................... 572 DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input......................... 573 DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2 Voltage Correlation.................... 574 DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit....................... 576 DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit....................... 577 DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low..................................... 579 DTC P2229 (Flash Code 71) Barometric Pressure Circuit High.................................... 581 DTC P2295 (Flash Code 248) Fuel Pressure Regulator 2 Solenoid Control Circuit Low............. 582 DTC P2296 (Flash Code 218) Fuel Pressure Regulator 2 Solenoid Control Circuit High............ 583 DTC P242F (Flash Code 131) DPD Restriction.................................................... 584 DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit........................... 586 DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance......... 588 DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low........................ 590 DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High....................... 592 DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position................... 593 DTC P2458 (Flash Code 139) DPD Regeneration Duration.......................................... 594 DTC U0001 (Flash Code 84) CAN-Bus Malfunction (ISO-CAN)....................................... 597 DTC U0073 (Flash Code 84) CAN-Bus Malfunction (J1939)......................................... 598 DTC U0101 (Flash Code 85) Lost Communication with TCM......................................... 599 DTC U0110 (Flash Code 87) Lost Communication with VNT System.................................. 600 DTC U0411 (Flash code 87) Turbo Charger Control Module Signal Malfunction..................... 601 Mechanical........................................................................................ 603 Cylinder Head Cover........................................................................... 603 Cylinder Head Assembly........................................................................ 604 Idle Gear..................................................................................... 662 Cylinder Block................................................................................ 709 Crankshaft.................................................................................... 789 Piston........................................................................................ 869 Camshaft...................................................................................... 928 Flywheel...................................................................................... 942 Rocker Arm Shaft.............................................................................. 945 CMP Sensor.................................................................................... 956 Flywheel Housing.............................................................................. 957 Intake Throttle Valve......................................................................... 966 CKP Sensor.................................................................................... 968 Timing Gear Case.............................................................................. 969 Supplementary Information.....................................................................1020 Fuel System.......................................................................................1037 Fuel Supply Pump..............................................................................1037 Injector......................................................................................1049 Fuel Filter...................................................................................1090 Pressure Limiter..............................................................................1098 Fuel Pressure Sensor..........................................................................1102 Fuel Filter Pressure Sensor...................................................................1104 Fuel Temperature Sensor.......................................................................1105 Supplementary Information.....................................................................1109 Cooling...........................................................................................1110 Water Pump Assembly...........................................................................1110 Thermostat....................................................................................1122 Radiator......................................................................................1127 Overheat Switch...............................................................................1129 Engine Coolant Temperature Sensor.............................................................1130 Coolant.......................................................................................1133 Generator Drive Belt..........................................................................1135 Supplementary Information.....................................................................1137 Lubrication.......................................................................................1140 Oil Pan.......................................................................................1140 Oil Pump Assembly.............................................................................1144 Oil Level Switch..............................................................................1155 Oil Cooler Assembly...........................................................................1156 Engine Oil....................................................................................1170 Piston Oil Jet................................................................................1171 Oil Filter....................................................................................1176 Oil Pressure Sensor...........................................................................1177 Supplementary Information.....................................................................1178 Induction.........................................................................................1185 Boost Temperature Sensor......................................................................1185 Turbocharger Assembly.........................................................................1186 Intercooler...................................................................................1194 Air Cleaner Filter............................................................................1196 IMT Sensor....................................................................................1196 Boost Sensor..................................................................................1196 MAF Sensor....................................................................................1198 Exhaust...........................................................................................1199 DPD Assembly..................................................................................1199 Exhaust Differential Pressure Sensor..........................................................1206 Exhaust Gas Temperature Sensor................................................................1210 Supplementary Information.....................................................................1214 Aux. Emission Control Devices.....................................................................1215 EGR Valve.....................................................................................1215 EGR Cooler....................................................................................1226 Supplementary Information.....................................................................1237 Electrical........................................................................................1240 Glow Plug.....................................................................................1240 Starter Assembly..............................................................................1261 ECM...........................................................................................1273 Supplementary Information.....................................................................1274 Wiring Diagram....................................................................................1280 Using the Wiring Diagram......................................................................1280 Location Diagram..............................................................................1282 Engine........................................................................................1287 Location Diagram..............................................................................1292 Connector List................................................................................1294 Engine Coolant Heater (Option) SP002328...............................................................1309 Safety Instructions...............................................................................1313 Applicable Models.................................................................................1313 Disassembly and Assembly..........................................................................1314 Changing the Circulating Pump.................................................................1314 Changing the Temperature Limiter..............................................................1316 Changing the Temperature Sensor...............................................................1317 Changing the Combustion Air Fan...............................................................1319 Changing the Burner, Flame Monitor and Glow Plug..............................................1321 Changing the Burner Head......................................................................1323 Changing the Heat Exchanger...................................................................1325 Drive Coupling (Main Pump) SP002562...................................................................1327 Safety Instructions...............................................................................1331 Applicable Models.................................................................................1331 Mounting Instructions for BoWEX FLE - PA Couplings................................................1332 Use of the BoWEX FLE - PA Coupling............................................................1332 Hydraulics................................................................................................1335 Hydraulic System Troubleshooting, Testing and Adjustment SP002563.....................................1337 Safety Instructions...............................................................................1341 Applicable Models.................................................................................1341 Hydraulic System - General Notes..................................................................1342 Hydraulic Schematic...............................................................................1343 General Notes.................................................................................1343 Operation of Working Components...................................................................1345 Boom Operating Circuit........................................................................1345 Boom Up Circuit...............................................................................1345 Boom Down Circuit.............................................................................1346 Arm Operating Circuit.........................................................................1346 Arm Crowd Circuit.............................................................................1347 Arm Dump Circuit..............................................................................1347 Bucket Operating Circuit......................................................................1348 Bucket Crowd Circuit..........................................................................1348 Bucket Dump Circuit...........................................................................1348 Swing Operating Circuit.......................................................................1349 Right Swing Operating Circuit.................................................................1349 Left Swing Operating Circuit..................................................................1349 Swing Relief Valve and Makeup Valve...........................................................1349 Travel Operating Circuit......................................................................1350 Forward Travel Circuit........................................................................1350 Reverse Travel Circuit........................................................................1350 Procedural Troubleshooting Baseline Recommendations...............................................1351 Initial Checks and Tests to Establish Operating Condition of the Excavator....................1351 Troubleshooting Summary...................................................................1351 Pilot Pressure....................................................................................1353 Adjustment and Testing........................................................................1353 Power Mode Valve..................................................................................1354 Current Signal and Hydraulic Pressure Adjustments.............................................1354 Europe....................................................................................1355 North America.............................................................................1355 Pressure Up Valve.................................................................................1356 Checks and Adjustments........................................................................1356 Pump Input Power Control..........................................................................1358 Pump Regulator Adjustment.....................................................................1358 Flow Meter and Flow Meter Kit Installation and Testing............................................1361 Installation and Testing Procedure............................................................1361 Swing System Troubleshooting......................................................................1363 Precautions/Initial Checks....................................................................1363 Swing Relief Valve Checking and Adjustment....................................................1364 Troubleshooting - Swing Gearbox...................................................................1366 Troubleshooting - Hydraulic Problems..............................................................1367 Troubleshooting - Hydraulic Fan Drive System......................................................1369 Troubleshooting - Control Valve...................................................................1370 Troubleshooting - Travel Control Valve............................................................1371 Troubleshooting - Joystick Control Valve..........................................................1371 Accumulator SP002455..................................................................................1373 Safety Instructions...............................................................................1377 Applicable Models.................................................................................1377 General Description...............................................................................1378 Specifications................................................................................1380 Center Joint (Swivel) SP002545........................................................................1381 Safety Instructions...............................................................................1385 Applicable Models.................................................................................1385 General Description...............................................................................1387 Center Joint Disassembly Diagram..............................................................1387 Troubleshooting, Testing and Adjustment...........................................................1388 Inspection....................................................................................1388 Testing.......................................................................................1388 Disassembly.......................................................................................1389 Reassembly........................................................................................1392 Cylinders SP002564....................................................................................1395 Safety Instructions...............................................................................1399 Applicable Models.................................................................................1399 General Description...............................................................................1400 Theory of Operation...........................................................................1400 Parts List....................................................................................1402 Special Tools and Materials.......................................................................1404 Piston Nut....................................................................................1404 Piston Jig....................................................................................1406 Steel Bushing Jig.............................................................................1409 Dust Wiper Jig................................................................................1412 Slipper Seal Jig..............................................................................1415 Slipper Seal Straightening Jig................................................................1418 Disassembly.......................................................................................1421 Reassembly........................................................................................1426 Swing Device SP002565.................................................................................1431 Safety Instructions...............................................................................1435 Applicable Models.................................................................................1435 Indication of Type................................................................................1436 Specifications....................................................................................1437 Structure and Principle of Operation..............................................................1438 Structure.....................................................................................1438 Principles of Operation.......................................................................1442 Valve Casing..................................................................................1443 Brake Part....................................................................................1446 Cautions for Operation............................................................................1447 Inspection....................................................................................1447 Direction of Rotation.........................................................................1447 External Load at the End of Shaft.............................................................1448 Hydraulic Oil and Temperature Range...........................................................1448 Filter........................................................................................1449 Installation and Piping.......................................................................1449 Oil Filling and Air Breather..................................................................1450 Instructions before Starting to Operate.......................................................1450 Troubleshooting...................................................................................1451 General Pre-caustions.........................................................................1451 Examination of Hydraulic Motor................................................................1451 Troubleshooting...............................................................................1452 Disassembly and Reassembly........................................................................1455 Disassemble Swing Motor.......................................................................1457 Reassemble Swing Motor........................................................................1462 Disassemble the Reduction Gear................................................................1468 Reassemble the Reduction Gear.................................................................1472 Maintenance Instructions......................................................................1479 Travel Device SP002566................................................................................1481 Safety Instructions...............................................................................1485 Applicable Models.................................................................................1485 TM100VD Operation Manual..........................................................................1486 Indication of Type............................................................................1486 Specifications................................................................................1487 Structure and Operation.......................................................................1488 Basic Structure...........................................................................1488 Operation of the Hydraulic Motor..........................................................1489 Operation of the Reduction Gear...........................................................1496 Cautions for Use..............................................................................1497 Checking..................................................................................1497 Piping....................................................................................1497 Gear Oil..................................................................................1497 General Cautions..........................................................................1498 Troubleshooting...............................................................................1498 General Cautions..........................................................................1498 Cause and Corrective Action of Failure....................................................1498 Basic Structure and Diagrams..................................................................1500 Assembly Cross-Section....................................................................1500 Tools List for Disassembly and Reassembly.................................................1502 Disassembly...................................................................................1505 General Cautions..........................................................................1505 Disassembly Sequence......................................................................1505 Assembly......................................................................................1516 General Cautions..........................................................................1516 Assembly Sequence.........................................................................1516 Matters to Check after Assembly...............................................................1534 Performance Test..............................................................................1534 Main Pump SP002567....................................................................................1537 Safety Instructions...............................................................................1541 Applicable Models.................................................................................1541 Sectional View....................................................................................1542 A8VO200LA1KH1/63..............................................................................1542 General Repair Guidelines.........................................................................1544 Seal Kits and SUBASSEMBLIES.......................................................................1546 Sealing the DRIVESHAFT............................................................................1550 Gear Pump Sealing.................................................................................1552 REMOVING Control Housing..........................................................................1554 Control Module....................................................................................1558 Control Module LR.............................................................................1558 Control Module H..............................................................................1559 Removing the Controller...........................................................................1560 Valve Plate With Valves...........................................................................1562 REMOVE Rotary Groups..............................................................................1563 REMOVE Intermediate Wheel.........................................................................1566 Remove Auxiliary Drive............................................................................1568 Inspection........................................................................................1571 Assembling the Rotary Group.......................................................................1576 Pump Assembly.....................................................................................1578 Assembly Guideline............................................................................1579 Adjustment of the Hydraulic Component of the Rotary Group.....................................1580 Hydraulic Component - Measurement "D".............................................................1581 Measuring Device - Hydraulic Component 452 269................................................1581 Mounting Position.............................................................................1582 Measuring Procedure...........................................................................1584 Installation of Control Housing...................................................................1585 Assembly of Intermediate Wheel....................................................................1588 Installation of Gear Pump.........................................................................1589 Installation of Cover / Auxiliary Drive...........................................................1590 Assembly Guidelines for Tightening Torques........................................................1591 Bolts (To N 08.001)...........................................................................1591 Plugs with Internal Hexagon and Profile Seal Ring (to N 02.009)...............................1592 Seal-lock - Sealing Nuts (to N 02.100)........................................................1592 Gear Pump SP002568....................................................................................1593 Safety Instructions...............................................................................1597 Applicable Models.................................................................................1597 Disassembling Single Gear Pump (Opt)..............................................................1598 Reassembling Single Gear Pump (Opt)...............................................................1601 Main Control Valve SP002569...........................................................................1605 Safety Instructions...............................................................................1609 Applicable Models.................................................................................1609 General Description...............................................................................1610 When All Spools are in Neutral................................................................1610 Neutral Passage (Figure 1 and Figure 2)...................................................1610 Signal Passage (Figure 2).................................................................1612 Single Operation..............................................................................1614 Travel Spool Shifting (Figure 3 and Figure 4).............................................1614 Swing Spool Shifting (Figure 4)...........................................................1616 Boom Spool Shifting.......................................................................1617 Spare Spool Shifting (Figure 8)...........................................................1620 Bucket Spool Shifting (Figure 8)..........................................................1620 Arm Spool Shifting........................................................................1621 Neutral-cut Spool Shifting (Figure 11)....................................................1624 Parallel Throttle for Arm (Figure 11).....................................................1624 Relief Valve..............................................................................1625 Combined Operation............................................................................1626 Travel Combined Operation (Figure 13).....................................................1626 Swing Combined Operation (Figure 14)......................................................1628 Antidrift Valve...............................................................................1629 Main Relief Valve.............................................................................1629 Overload Relief Valve.........................................................................1630 Low-pressure Relief Valve.....................................................................1632 Parts List....................................................................................1633 Spool Assembly (4, Bucket)................................................................1637 Spool Assembly (5, Boom)..................................................................1637 Spool Assembly (6, Travel)................................................................1637 Spool Assembly (7, Straight Travel).......................................................1638 Spool Assembly (8, Arm1)..................................................................1638 Spool Assembly (9, Service)...............................................................1638 Spool Assembly (10, Boom 2)...............................................................1639 Spool Assembly (11, Swing)................................................................1639 Spool Assembly (3, Arm 2).................................................................1639 Spool Assembly (20, Arm Regeneration Release Valve........................................1639 Spool Assembly (24).......................................................................1640 Poppet Assembly (36)......................................................................1640 Plug Assembly (51)........................................................................1640 Plug Assembly (58)........................................................................1640 Relief Valve Assembly (48)................................................................1641 Relief Valve Assembly (49)................................................................1641 Relief Valve Assembly (50)................................................................1642 Specifications................................................................................1642 Troubleshooting, Testing and Adjustment...........................................................1643 General.......................................................................................1643 Relief Valve..................................................................................1644 Hydraulic System..............................................................................1644 Adjustment of Relief Valve....................................................................1645 Main Relief Valve.........................................................................1645 Overload Relief Valve.....................................................................1645 Disassembly.......................................................................................1646 General Instructions for Disassembly..........................................................1646 Disassembly of Main Spool (3) - (11)..........................................................1647 Disassembly of Subspool (24)..................................................................1648 Disassembly of Subspool (20)..................................................................1648 Disassembly of Antidrift Valve of Boom and Arm................................................1648 Disassembly of Swing Load Check...............................................................1649 Disassembly of Load Check.....................................................................1649 Disassembly of Other Check Valves.............................................................1650 Disassembly Of Flange.........................................................................1650 Disassembly of Relief Valve...................................................................1650 Disassembly of Other Flange...................................................................1650 Disassembly of Main Relief Valve..............................................................1651 Disassembly of Low-pressure Relief Valve......................................................1652 Disassembly of Low Pressure Relief Valve......................................................1652 Cleaning and Inspection (Wear Limits and Tolerances)..............................................1653 Cleaning......................................................................................1653 Inspection....................................................................................1653 Reassembly........................................................................................1654 Subassembly...................................................................................1654 Main Spool (3) - (11).....................................................................1654 Subspool (20).............................................................................1654 Subspool (24).............................................................................1655 Boom, Arm Antidrift Valve.................................................................1655 Swing Load Check..........................................................................1655 Reassembly of Control Valve...................................................................1656 Reassembly of Load Check Valve............................................................1656 Reassembly of Swing Load Check............................................................1656 Reassembly of Other Check Valve...........................................................1656 Reassembly of Flange......................................................................1657 Reassembly of Boom and Arm Antidrift Valve................................................1657 Reassembly of Relief Valve................................................................1657 Reassembly of Subspool (24)...............................................................1658 Reassembly of Subspool (20)...............................................................1658 Reassembly of Main Spool (3) - (11).......................................................1658 Reassembly of Other Plugs.................................................................1659 Reassembly of Main Relief Valve...........................................................1660 Reassembly of Overload Relief Valve.......................................................1661 Reassembly of Low-pressure Relief Valve...................................................1661 Installation......................................................................................1662 Start-up Procedures...............................................................................1662 Fan Motor for Oil Cooler SP002576.....................................................................1663 Safety Instructions...............................................................................1667 Applicable Models.................................................................................1667 Disassembly.......................................................................................1669 Assembly..........................................................................................1672 Preassemble...................................................................................1672 Assembling....................................................................................1673 Fan Motor for Radiator SP002577.......................................................................1675 Safety Instructions...............................................................................1679 Applicable Models.................................................................................1679 View..............................................................................................1681 Option........................................................................................1681 General Repair Guidelines.........................................................................1682 Sealing Driveshaft................................................................................1683 Disassemble the Motor.............................................................................1686 Inspection Hints..................................................................................1693 Motor Assembly....................................................................................1694 Disassembly of the Flushing Valve.................................................................1699 Tools/Auxiliary Tools/ Tightening Torques.........................................................1700 Fan Pump SP002583.....................................................................................1701 Safety Instructions...............................................................................1705 Applicable Models.................................................................................1705 Repair Instruction................................................................................1707 Section.......................................................................................1707 Adjustment of Taper Roller Bearing Set........................................................1720 Remote Control Valve (Work Lever / Joystick)..........................................................1723 Safety Instructions...............................................................................1727 Applicable Models.................................................................................1727 General Description...............................................................................1729 Theory of Operation...........................................................................1729 Structure.................................................................................1729 Function..................................................................................1729 Parts List....................................................................................1730 Specifications................................................................................1732 Performance...............................................................................1732 Torques.......................................................................................1732 Tools and Materials...............................................................................1732 Disassembly.......................................................................................1733 Reassembly........................................................................................1736 Start-up Procedures...............................................................................1744 Travel Control Valve (with Damper) SP002381...........................................................1745 Safety Instructions...............................................................................1749 Applicable Models.................................................................................1749 General Description...............................................................................1750 Theory of Operation...........................................................................1750 Pressure Reducing Valve.......................................................................1751 Operating Theory of Damper Mechanism..........................................................1752 Causes of Faults and Measures.....................................................................1753 Parts List....................................................................................1754 Specification.................................................................................1756 Torques.......................................................................................1756 Removal...........................................................................................1757 Disassembly.......................................................................................1760 Cleaning and Inspection (Wear Limits and Tolerances)..............................................1762 Reassembly........................................................................................1763 Installation......................................................................................1768 Start-up Procedures...............................................................................1771 Solenoid Valve Assembly SP002406......................................................................1773 Safety Instructions...............................................................................1777 Applicable Models.................................................................................1777 5-Solenoid Valve..................................................................................1778 Parts List....................................................................................1778 Functions of 5-Solenoid Valve Assembly........................................................1779 Assembly Diagram and Tools Required...........................................................1780 Cautions During Disassembly and Reassembly....................................................1781 Solenoid Valve Diagram........................................................................1782 Check Points and Solutions for Problems.......................................................1783 Breaker EPPR Valve (Option) SP002458..................................................................1785 Safety Instructions...............................................................................1789 Applicable Models.................................................................................1789 Structure.........................................................................................1790 Parts List....................................................................................1790 Functions and Operation...........................................................................1791 Cautions for Operation............................................................................1791 Maintenance Instructions..........................................................................1792 Maintenance...................................................................................1792 Disassembly...................................................................................1793 Assembly......................................................................................1794 Hydraulic Schematic SP002570..........................................................................1797 Safety Instructions...............................................................................1801 Applicable Models.................................................................................1801 DX490LC-3/DX530LC-3...............................................................................1803 Electrical System.........................................................................................1805 Electrical System SP002571............................................................................1807 Safety Instructions...............................................................................1813 Applicable Models.................................................................................1813 Introduction......................................................................................1815 Electrical Supply System..........................................................................1816 Engine Starting Circuit...........................................................................1818 Start Operation...............................................................................1818 After Start...................................................................................1820 Engine Preheating System..........................................................................1822 Engine Stop.......................................................................................1824 Charging System...................................................................................1826 Monitoring System.................................................................................1827 Instrument Panel..............................................................................1828 Functional Check..............................................................................1828 Monitoring System Schematic...................................................................1830 Operation.........................................................................................1832 Instruments...................................................................................1832 Warning and Indicator Lights......................................................................1834 Indication of Warning Lights..................................................................1834 Indication of Multifunction Gauge.............................................................1836 Initial Operation.................................................................................1837 Graphic Information Area Display..................................................................1838 Overview......................................................................................1838 Main Menus for the Graphic Display Area.......................................................1838 Menu Selector Buttons.........................................................................1838 User Menu.........................................................................................1839 User Menu - Access and Escape Methods.........................................................1839 Special Menu......................................................................................1871 Entering/Accessing and Exiting/Escaping Menus.................................................1871 Special Menu Selections.......................................................................1872 Electronic Hydraulic Control System (EPOS)........................................................1896 Control System Schematic......................................................................1896 Power Plus Mode Control...........................................................................1898 Operation.....................................................................................1900 Power Mode Control - Circuit Diagram..............................................................1902 Engine Control System.............................................................................1904 Engine Control Dial...............................................................................1905 Engine Control Circuit Diagram....................................................................1906 Automatic Deceleration Control (Auto Idle Control)................................................1908 Engine Overheat Protection System.................................................................1910 Power Boost Mode..................................................................................1912 Operation.....................................................................................1912 Power Boost Control - Circuit Diagram.........................................................1914 Automatic Travel Speed Control....................................................................1916 Automatic Travel Speed Control - Circuit Diagram..............................................1918 Self-diagnostic Function..........................................................................1919 EPOS Controller...............................................................................1919 Air Conditioner System............................................................................1921 Outline.......................................................................................1921 Internal and External Filters.................................................................1922 Air-Conditioning System Layout................................................................1924 Air Conditioner/heater Circuit Diagram........................................................1925 Air Conditioner/heater Unit...................................................................1926 Ambient Air Temperature Sensor................................................................1931 Sun Sensor....................................................................................1932 Control Panel.................................................................................1932 Compressor....................................................................................1940 Receiver Dryer................................................................................1940 Troubleshooting...................................................................................1941 Weight of R134a Gas Used In Machines..............................................................1943 Refrigerant System Repairs........................................................................1944 Refrigerant Safe Handling Procedures..........................................................1944 Repair and Replacement Procedure..............................................................1945 Refrigerant Recovery..........................................................................1947 Vacuuming Refrigerant System..................................................................1947 Leakage Check.................................................................................1949 Refrigerant Charging..........................................................................1949 Inspecting System For Leakage.................................................................1951 Wiper System......................................................................................1952 Wiper Circuit.................................................................................1952 Wiper operation...............................................................................1953 Lighting System...................................................................................1956 Lighting System Circuit Diagram...............................................................1956 Kind of Light.................................................................................1957 Operation.....................................................................................1957 Overload Warning Device...........................................................................1958 Overload Warning Device Circuit Diagram.......................................................1958 Audio Controller..................................................................................1959 Audio Controller Circuit Diagram..............................................................1959 Electrical Schematic SP002572.........................................................................1961 Safety Instructions...............................................................................1965 Applicable Models.................................................................................1965 DX420LC-3/DX490LC-3/DX530LC-3.....................................................................1967 Attachments...............................................................................................1969 Boom and Arm SP002573.................................................................................1971 Safety Instructions...............................................................................1975 Applicable Models.................................................................................1975 Front Attachment Pin Specifications...............................................................1976 DX490LC-3/DX530LC-3...........................................................................1977 Front Attachment - Removal and Installation.......................................................1978 Arm Removal Procedure.........................................................................1978 Boom Removal Procedure........................................................................1980 Installation......................................................................................1981 Arm Installation Procedure....................................................................1981 Boom Installation Procedure...................................................................1981 Start-up Procedures...............................................................................1982 Bucket SP002574.......................................................................................1983 Safety Instructions...............................................................................1987 Applicable Models.................................................................................1987 Bucket Tooth Inspection and Replacement...........................................................1988 Bucket O-ring Replacement.........................................................................1989 Attachments.......................................................................................1991 Bucket Replacement and Reversal...............................................................1991 Replacement...................................................................................1992 Reversal......................................................................................1993 Quick Coupler Operation (Optional)............................................................1994 Securing Work Tool........................................................................1994 Attaching Quick Coupler to Excavator......................................................1994 Releasing the Work Tool...................................................................1996
DOOSAN DX490LC-3 DX530LC-3 EXCAVATOR SHOP MANUAL 950106-00259E – PDF DOWNLOAD:
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