Professional Documents
Culture Documents
Shop Manual
K1009096E
Serial Number 5001 and Up
Daewoo reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
Specifications
Specification for DX420LC.................................................................... SP000257
General Maintenance
General Maintenance Procedures ........................................................ SP000016
Standard Torques ................................................................................. SP000017
Upper Structure
Cabin .................................................................................................... SP000018
Counterweight....................................................................................... SP000265
Fuel Tank.............................................................................................. SP000264
Swing Bearing....................................................................................... SP000262
Swing Reduction Gear.......................................................................... SP000249
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ............... SP000273
Accumulator.......................................................................................... SP000028
Center Joint (Swivel)............................................................................. SP000181
Cylinders............................................................................................... SP000030
Table of Contents
Page I
Swing Motor.......................................................................................... SP000261
Travel Motor (With Gearbox) ................................................................ SP000266
Main Pump............................................................................................ SP000186
Control Valve (KVMG-400-DA)............................................................. SP000187
Remote Control Valve (Work Lever / Joystick) ..................................... SP000189
Travel Control Valve (With Damper)..................................................... SP000070
Solenoid Valve Assembly ..................................................................... SP000191
Breaker EPPR Valve (Opt) ................................................................... SP000192
Fan Motor (Vane Type)......................................................................... SP000209
Gear Pump (Fan Cooling Drive) ........................................................... SP000208
Fan Cooling Flow In-Out Change Valve ............................................... SP000207
Hydraulic Schematic (DX420LC) .......................................................... SP000274
Electrical System
Electrical System .................................................................................. SP000269
Electrical Schematic (DX420LC) .......................................................... SP000275
Attachments
Boom and Arm...................................................................................... SP000040
Bucket................................................................................................... SP000041
Table of Contents
Page II
1Safety
SP000256
TRACK EXCAVATOR SAFETYSP000256
Track
Excavator
Safety
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
DANGER!
Unsafe use of the excavator could lead to serious injury or
death. Operating procedures, maintenance and equipment
practices or traveling or shipping methods that do not
follow the safety guidelines on the following pages could
cause serious, potentially fatal injuries or extensive damage
to the machine or nearby property.
CAUTION!
This word is used on safety messages and safety labels and
indicates potential of a hazardous situation that, if not
avoided, could result in minor or moderate injury. It may
also be used to alert against a generally unsafe practice.
WARNING!
This word is used on safety messages and safety labels and
indicates potential of a hazardous situation that, if not
avoided, could result in serious injury or death. It may also
be used to alert against a highly unsafe practice.
DANGER!
This word is used on safety messages and safety labels and
indicates an imminent hazard of a situation that, if not
avoided, is very likely to cause death or extremely serious
injury. It may also be used to alert against equipment that
may explode or detonate if handled or treated carelessly.
Accessory Applications
The excavator has been primarily designed for moving earth
with a bucket. For use as a grapple or for other object handling,
contact DOOSAN for proper installation and application. Lifting-
work applications (unless restricted or prohibited by local
regulations) are permitted in approved lift configuration, to rated
capacity only, with no side-loading. DO NOT use the machine for
activities for which it was not intended. DO NOT use the bucket
for lifting work, unless lift slings are used in the approved
configuration.
Use of an accessory hydraulic hammer (breaker), work in rough
terrain, demolition applications or other hazardous operation
may require installation of additional protective structures to
safeguard the operator.
IMPORTANT
Before using the excavator to make lifts check municipal
and regional regulations or statutes that could apply.
Governing ordinances may require that all heavy lifting be
done with single purpose equipment specifically designed
for making lifts, or other local restrictions may apply.
Making heavy lifts with a general purpose excavator that
can be used for digging, loading, grading or other work may
be expressly forbidden by a regional injunction or other
legal prohibition. Always follow all of the other instructions,
guidelines and restrictions for Safe Lifting in the Operation
and Maintenance Manuals.
11 9 11 14 10
3 1 2 6
15
12
2190-3311
13 8 7
16
0
4
FG001823
Figure 1
DANGER!
Unsafe use of the excavator while making rated lifts could
cause serious, potentially fatal injuries or extensive damage
to the machine or nearby property. Do not let anyone
operate the machine unless they've been properly trained
and understand the information in the Operation and
Maintenance Manual.
WARNING!
NEVER wrap a tag line around your hands or body.
NEVER rely on tag lines or make rated lifts when wind gusts
are more than 48.3 km/h (30 MPH). Be prepared for any type
of wind gust when working with loads that have a large
surface area.
WARNING!
If you need more information or have any questions or
concerns about safe operating procedures or working the
excavator correctly in a particular application or in the
specific conditions of your individual operating
environment, please consult your local DOOSAN
representative.
GENERAL HAZARD
INFORMATION
Safety Rules
Only trained and authorized personnel can operate and maintain
the machine.
Follow all safety rules, precautions and instructions when
operating or performing maintenance on the machine.
Do not operate the machine if you are not feeling well, if you are
taking medication that makes you feel sleepy, if you have been
drinking, or if you are suffering from emotional problems. These
problems will interfere with your sense of judgement in
emergencies and may cause accidents.
When working with another operator or with a person on work
site traffic duty, be sure that all personnel know the nature of the
work and understand all hand signals that are to be used.
Always observe strictly any other rules related to safety.
Safety Features
Be sure that all guards and covers are installed in their proper
position. Have guards and covers repaired immediately if
damaged.
Be sure that you understand the method of use of safety
features such as safety lock lever and the seat belt, and use
them properly.
Never remove any safety features. Always keep them in good
operating condition.
Failure to use safety features according to the instructions in the
Operation and Maintenance Manual could result in serious
bodily injury.
FG000355
Figure 3
To prevent hot coolant from spurting out, shut down engine, wait
for the coolant to cool, then loosen the cap slowly to relieve the
pressure.
To prevent hot oil from spurting out, shut down engine, wait for
the oil to cool, then loosen the cap slowly to relieve the pressure.
HAOA060L
Figure 6
Accumulator
The pilot control system is equipped with an accumulator. For a
brief period of time after the engine has been shut down, the
accumulator will store a pressure charge that may enable
hydraulic controls to be activated. Activation of any controls may
enable the selected function to operate under force of gravity.
When performing maintenance on the pilot control system, the
hydraulic pressure in the system must be released as describe
in "Handling of Accumulator" in the Operation and Maintenance
Manual.
The accumulator is charged with high-pressure nitrogen gas, so
it is extremely dangerous if it is handled in the wrong way.
Always observe the following precautions:
Do not drill or make any holes in the accumulator or
expose it any flame, fire or heat source.
Do not weld on the accumulator, or try attaching
anything to it.
When carrying out disassembly or maintenance of
the accumulator, or when disposing of the
accumulator, the charged gas must be properly
released. Contact your DOOSAN distributor.
Wear safety goggles and protective gloves when
working on an accumulator. Hydraulic oil under
pressure can penetrate the skin and cause serious
injuries.
Indoor Ventilation
Engine exhaust gases can cause fatal accidents, and
unconsciousness, loss of alertness, judgement and motor
control and serious injury.
Make sure there is adequate ventilation before starting the
engine in any enclosed area.
You should also be aware of open windows, doors or ductwork
into which exhaust may be carried, or blown by the wind,
exposing others to danger. ARO1770L
Figure 12
WARNING!
FG000178
Protect your eyes when breaking the glass. Figure 13
Check the condition of the river bed, and the depth and flow of
the water before operating in water or crossing a river. NEVER
be in water that is in excess of the permissible water depth.
Any type of object in the vicinity of the boom could represent a
potential hazard, or cause the operator to react suddenly and
cause an accident. Use a spotter or signal person working near
bridges, phone lines, work site scaffolds, or other obstructions.
FG000363
Figure 15
Engine Starting
Walk around your machine before getting in the operator's cabin.
Look for evidence of leaking fluid, loose fasteners, misaligned
assemblies or any other indications of possible equipment
hazard.
All equipment covers and machinery safety guards must be in
place, to protect against injury while the machine is being
operated.
FG000365
Figure 19
Prohibited Operations
Do not dig the work face under an overhang. This may cause the
overhang to collapse and fall on top of the machine.
FG000368
Figure 20
FG000112
Figure 25
Operations on Slopes
When working on slopes. there is danger that the machine may
lose its balance and turn over, when swinging, or when work
equipment is operated. Always carry out these operations
carefully.
Do not swing the work equipment from the uphill side to the
downhill side when the bucket is loaded. This operation is
dangerous.
If the machine has to be used on a slope, pile the soil to make a FG000212
platform that will keep the machine as horizontal as possible.
Figure 27
In addition, lower the bucket as far as possible, keep it pulled
into the front, and keep the swing speed as low as possible.
ARO1310L
Figure 29
Warning Tag
Alert others that service or maintenance is being performed and
tag operator's cabin controls and other machine areas if
required with a warning notice. OSHA mandated control lever WARNING
lockout can be made with any OSHA certified lockout device and
DO NOT OPERATE
a length of chain or cable to keep the safety lever in the fully
lowered, nonactive position. when performing inspection
or maintenance
Warning tags, for controls are available from DOOSAN
distributors.
190-00695
ARO1320L
Figure 30
HDO1037L
Figure 32
Use of Lighting
When checking fuel, oil, battery electrolyte, or window washing
fluid, always use lighting with antiexplosion specifications. If
such lighting equipment is not used, there is danger of an
explosion.
If work is carried out in dark places without using lighting, it may
lead to injury, so always use proper lighting.
Even if the place is dark, never use a lighter or flame instead of
lighting. There is danger of fire. There is also danger that the HDO1040L
battery gas may catch fire and cause and explosion.
Figure 33
Burn Prevention
When checking the radiator coolant level, shut down engine, let
the engine and radiator cool down, then check the coolant
recovery tank. If the coolant level in the coolant recovery tank is
near the upper limit, there is enough coolant in the radiator.
Loosen the radiator cap gradually to release the internal
pressure before removing the radiator cap.
If the coolant level in the coolant recovery tank is below the
lower limit, add coolant.
Cooling system conditioner contains alkali. Alkali can cause
personal injury. Do not allow alkali to contact the skin, the eyes,
or the mouth.
Allow cooling system components to cool before you drain the
cooling system.
Hot oil and hot components can cause personal injury. Do not
allow hot oil or hot components to contact the skin.
Remove the hydraulic tank filter plug only after the engine has
been stopped. Make sure that the hydraulic tank filter plug is
cool before you remove it with your bare hand. Remove the
hydraulic tank filter plug slowly to relieve pressure.
Relieve all pressure in the hydraulic oil system, in the fuel
system, or in the cooling system before you disconnect any
lines, fittings, or related items.
HAAE1980
Batteries give off flammable fumes that can explode.
Figure 35
Do not smoke while you are checking the battery electrolyte
levels.
Electrolyte is an acid. Electrolyte can cause personal injury. Do
not allow electrolyte to contact the skin or the eyes.
Always wear protective glasses when you work on batteries.
Welding Repairs
CAUTION!
When you connect or disconnect connectors between ECU
and Engine or connector between ECU and the machine,
always disconnect the source power to protect damage of
the ECU.
If you don't observe this procedure, the ECU would be
damaged or the engine would operate abnormally.
FG001446
Figure 37
DANGER!
DOOSAN warns any user, that the removal of the
counterweight from the machine, front attachment or any
other part, may affect the stability of the machine. This
could cause unexpected movement, resulting in death or
serious injuries. DOOSAN is not liable for any misuse.
Never remove the counterweight or front attachment unless
the upper structure is in-line with the lower structure.
FG000371
Never rotate the upper structure once the counterweight or
Figure 38
front attachment has been removed.
WARNING!
Improper lifting can allow load to shift and cause injury or
damage.
Specification
for DX420LC
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
40
39
38
37
36
21
35
34
33 22
32
31
30 23
29 27
28
24
25
26
FG001806
Figure 1
A
H
I J B C
O G
F
N
M
D
K
L E
FG001798
Figure 2
z
DIMENSION 6.7 M (22 FT) BOOM
2.6 M (8.5 FT) 3.25 M (10.7 FT) 3.95 M (13 FT) 3.25 M (10.7 FT)
ARM ARM ARM HD ARM
2.16 m3 (2.83 yd3) 1.9 m3 (2.49 yd3) 1.44 m3 (1.88 yd3) 1.51 m3 (1.98 yd3)
BUCKET BUCKET BUCKET BUCKET
A 11,770 mm (38' 7") 11,660 mm (38' 3")
B 3,660 mm (12')
C 8,110 mm (26' 7") 8,000 mm (26' 3")
D 4,250 mm (13' 11")
E 5,200 mm (17' 1") * 5,205 mm (17' 1")
F 1,265 mm (4' 2") * 1,275 mm (4' 2")
G 3,680 mm (12' 1") 3,480 mm (11' 5") 3,500 mm (11' 6") * 3,480 mm (11' 5")
H 2,990 mm (9' 10")
I 1,500 mm (4' 11")
J 1,490 mm (4' 11")
K 2,750 mm (9' 0")
L 3,550 mm (11' 8")
M 800 mm (2' 7")
N 540 mm (1' 9") * 555 mm (1' 10")
O 3,154 mm (10' 4") * 3,270 mm (10' 9")
WARNING!
The actual value for dimension "L" Digging Reach, depends
on the stability and support provided by ground conditions.
Digging too far underneath the excavator if soil conditions
are wet, loose or unstable can collapse ground support,
which could cause injury and/or equipment damage.
11
10
6
C
5
4 D
0
0 1 2 3 4 5 6 7 8 9 10 11 12
-1
-2
-3
-4 B
-5
-6
-7
-8
A
FG001799
Figure 3
Medium Weight or
Low Weight or Density High Weight or Density
Density
Material 1,100 kg/m3 2,000 kg/m3
1,600 kg/m3
(1,850 lb/yd3), or Less (3,370 lb/yd3), or Less
(2,700 lb/yd3), or Less
401 kg/m3
Charcoal --------------------- ---------------------
(695 lb/yd3)
433 kg/m3
Coke, blast furnace size --------------------- ---------------------
(729 lb/yd3)
449 kg/m3
Coke, foundry size --------------------- ---------------------
(756 lb/yd3)
Coal, bituminous slack, 801 kg/m3
--------------------- ---------------------
piled (1,350 lb/yd3)
Coal, bituminous r. of m., 881 kg/m3
--------------------- ---------------------
piled (1,485 lb/yd3)
897 kg/m3
Coal, anthracite --------------------- ---------------------
(1,512 lb/yd3)
Clay, DRY, in broken 1,009 kg/m3
--------------------- ---------------------
lumps (1,701 lb/yd3)
1,746 kg/m3
Clay, DAMP, natural bed --------------------- ---------------------
(2,943 lb/yd3)
Cement, Portland, DRY 1,506 kg/m3
--------------------- ---------------------
granular (2,583 lb/yd3)
Cement, Portland, DRY 1,362 kg/m3
--------------------- ---------------------
clinkers (2,295 lb/yd3)
1,522 kg/m3
Dolomite, crushed --------------------- ---------------------
(2,565 lb/yd3)
1,202 kg/m3
Earth, loamy, DRY, loose --------------------- ---------------------
(2,025 lb/yd3)
1,522 kg/m3
Earth, DRY, packed --------------------- ---------------------
(2,565 lb/yd3)
Test Conditions
1. All tests should be performed on a flat, level, firm
supporting ground surface.
2. All recommended, applicable maintenance and adjustment
service should be completed before testing.
3. Hydraulic fluid and engine oil should be of appropriate
viscosity for ambient weather conditions. Warm up
hydraulic oil to standard operating temperature, between
45 - 55C (112 - 135F).
4. Run all tests with the engine speed control set to maximum
rpm.
5. Repeat tests with Power Mode engine control settings at
both Standard Mode (standard work mode) and Power
Mode (high speed mode). Travel speed tests should also
be repeated at both high and low speed.
Speed Test
Prepare the excavator for travel speed tests by extending all
hydraulic cylinders - boom, arm and bucket - to the fully
extended position, shown in Figure 4.
FG000466
Figure 4
The lowest part of the bucket linkage should be 0.3 - 0.5 m (1' -
2') off the ground.
Mark off a 20 m (65' 7-1/2") test distance, with a 3 - 5 m (10' -
15') run-up area, and a 3 - 5 m (10' - 15', or longer) speed run-off
distance.
Travel the excavator back and forth to be sure steering is
centered and side frames are parallel with the test course.
Operate both travel levers at the fully engaged position and
measure the time it takes to cross 20 m (65' 7-1/2"). Compare
measured results against the standard for new machines:
Time
Rate of Travel
Standard Mode Power Mode
High Speed 15.3 1.0 sec 14.3 1.0 sec
Low Speed 26.1 1.5 sec 24.3 1.5 sec
3M - 5M
3M - 5M 20M
(10' - 15')
(10' - 15') (65' 7-1/2'')
FG000467
Figure 5
1.0M
FG004993
Figure 6
Record how far the turntable drifts past the stop point,
measuring the distance between paint marks. Maximum
distance should be less than 1000 mm (39.4"), in both Power
Mode and Standard Mode.
Reference
Description
Number
1 Start Swing
1
2 90 Swing
FG005122
3 Swing Force
Figure 7
4 Swing Stop
General
Maintenance
Procedures
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
WARNING!
Structural elements of the machine may be built from a
variety of steels. These could contain unique alloys or may
have been heat treated to obtain particular strength
characteristics. It is extremely important that welding
repairs on these types of steel are performed with the
proper procedures and equipment. If repairs are performed
incorrectly, structural weakening or other damage to the
machine (that is not always readily visible) could be
caused. Always consult DOOSAN After Sales Service
before welding on integral components (loader arm, frames,
car body, track frames, turntable, attachment, etc.) of the
machine. It is possible that some types of structurally
critical repairs may require Magnetic Particle or Liquid
Penetrant testing, to make sure there are no hidden cracks
or damage, before the machine can be returned to service.
CAUTION!
Always perform welding procedures with the proper safety
equipment on hand. Adequate ventilation and a dry work
area are absolutely essential. Keep a fire extinguisher
nearby and always wear protective clothing and the
recommended type of eye protection.
HYDRAULIC SYSTEM -
GENERAL PRECAUTIONS
Always maintain oil level in the system at recommended levels.
Assemblies that operate under heavy loads, at high speed, with
extremely precise dimensional tolerances between moving parts
- pistons and cylinders, or shoes and swash plates, for example -
can be severely damaged if oil supply runs dry.
Assemblies can be run dry and damaged severely in a very
short time when piping or hoses are disconnected to repair leaks
and/or replace damaged components. Hoses that are
inadvertently switched during disassembly (inlet for outlet and
vice versa), air introduced into the system or assemblies that are
low on oil due to neglect or careless maintenance, could all
produce sufficient fluid loss to cause damage.
When starting the engine (particularly after long layoff or storage
intervals), make sure that all hydraulic controls and operating
IMPORTANT
Hydraulic system operating conditions (repetitive cycling,
heavy work loads, fluid circulating under high-pressure)
make it extremely critical that dust, grit or any other type of
contamination be kept out of the system. Observe fluid and
filter change maintenance interval recommendations and
always preclean any exterior surface of the system before it
is exposed to air. For example, the reservoir fill cap and
neck area, hoses that have to be disassembled, and the
covers and external surfaces of filter canisters should all be
cleaned before disassembly.
General Precautions
Fluid level and condition should always be checked whenever
any other type of maintenance service or repair is being
performed.
NOTE: If the unit is being used in an extreme temperature
environment (in sub-freezing climates or in high
temperature, high humidity tropical conditions),
frequent purging of moisture condensation from the
hydraulic reservoir drain tap should be a regular and
frequent part of the operating routine. In more
moderate, temperate climates, draining reservoir
sediment and moisture may not be required more
than once or twice every few months.
Inspect drained oil and used filters for signs of abnormal coloring
or visible fluid contamination at every oil change. Abrasive grit or
dust particles will cause discoloration and darkening of the fluid.
Visible accumulations of dirt or grit could be an indication that
filter elements are overloaded (and will require more frequent
replacement) or that disintegrating bearings or other component
failures in the hydraulic circuit may be imminent or have already
occurred. Open the drain plugs on the main pump casings and
check and compare drain oil in the pumps. Look for evidence of
grit or metallic particles.
Vibration or unusual noise during operation could be an
indication of air leaking into the circuit (Refer to the appropriate
Troubleshooting section for component or unit for procedures.),
or it may be evidence of a defective pump. The gear type pilot
pump could be defective, causing low pilot pressure, or a main
pump broken shoe or piston could be responsible.
NOTE: If equipped, indicated operating pressure, as shown
on the multidisplay digital gauge on the Instrument
Panel ("F-Pump" and "R-Pump") will be reduced as a
result of a mechanical problem inside the pump.
However, pressure loss could also be due to
cavitation or air leakage, or other faults in the
hydraulic system.
Check the exterior case drain oil in the main pumps. If no
metallic particles are found, make sure there is no air in the
system. Unbolt and remove the tank return drain line from the
top part of the swing motor, both travel motors and each main
pump. If there is air in any one of the drain lines, carefully prefill
the assembly before bolting together the drain line piping
connections. Run the system at low rpm.
IMPORTANT
Make sure that cleaning solvents will be compatible with
rubber materials used in the hydraulic system. Many
petroleum based compounds can cause swelling,
softening, or other deterioration of system sealing
elements, such as O-rings, caps and other seals.
Figure 1
General Guidelines
All parts must be clean to permit an effective inspection. During
assembly, it is very important that no dirt or foreign material
enters unit being assembled. Even minute particles can cause
malfunction of close fitting parts such as thrust bearing, matched
parts, etc.
WARNING!
Care should be exercised to avoid inhalation of vapors,
exposure to skin and creating fire hazards when using
solvent type cleaners.
Bearing inspection
The conditions of the bearing are vital to the smooth and
efficient operation of the machinery. When any component
containing bearings is disassembled, always carefully examine
the condition of the bearings and all of its components for wear
and damage.
Once the bearing is removed, clean all parts thoroughly using a
suitable cleaning solution. If the bearing is excessively dirty soak
the bearing assembly in a light solution and move the bearing
around until all lubricants and or foreign materials are dissolved
and the parts are thoroughly clean.
When drying bearings, moisture free compressed air can be
used. Be careful not to direct the air in a direction which will force
the bearing to dry spin while not being properly lubricated.
After the bearings have been cleaned and dried, carefully
inspect all bearing rollers, cages and cups for wear, chipping or
nicks. If the bearing cannot be removed and is to be inspected in
place, check foe roughness of rotation, scoring, pitting, cracked
or chipped races. If any of these defects are found replace the
whole bearing assembly. NEVER replace the bearing alone
without replacing the mating cup or the cone at the same time.
Normal Bearing
Smooth even surfaces with no discoloration or marks.
Figure 2
Bent Cage
Cage damage due to improper handling or tool usage.
Figure 3
Figure 4
Galling
Metal smears on roller ends due to overheat, lubricant failure or
overload.
Replace bearing - check seals and check for proper lubrication.
Figure 5
Figure 6
Figure 7
Misalignment
Outer race misalignment due to foreign object.
Clean related parts and replace bearing. Make sure races are
properly seated.
Figure 8
Indentations
Surface depressions on race and rollers caused by hard
particles of foreign materials.
Clean all parts and housings, check seals and replace bearings
if rough or noisy.
Figure 9
Figure 10
Brinelling
Surface indentations in raceway caused by rollers either under
impact loading or vibration while the bearing is not rotating.
Replace bearing if rough or noisy.
Figure 11
Cage Wear
Wear around outside diameter of cage and roller pockets caused
by abrasive material and inefficient lubrication.
Replace bearings - check seals.
Figure 12
Figure 13
Figure 14
Smears
Smearing of metal due to slippage caused by poor fitting,
lubrication, overheating, overloads or handling damage.
Replace bearings, clean related parts and check for proper fit
and lubrication.
Replace shaft if damaged.
Figure 15
Figure 16
Heat Discoloration
Heat discoloration can range from faint yellow to dark blue
resulting from overload or incorrect lubrication.
Excessive heat can cause softening of races or rollers.
To check for loss of temper on races or rollers, a simple file test
may be made. A file drawn over a tempered part will grab and
cut metal, whereas a file drawn over a hard part will glide readily
with no metal cutting.
Replace bearing if over heating damage is indicated. Check
seals and other related parts for damage.
Figure 17
Stain Discoloration
Discoloration can range from light brown to black caused by
incorrect lubrication or moisture.
if the stain can be removed by light polishing or if no evidence of
overheating is visible, the bearing can be reused.
Check seals and other related parts for damage.
Figure 18
Standard
Torques
Edition 1
Standard Torques
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
Torque Values for Standard Metric Fasteners...... 6
Torque Values for Standard U.S. Fasteners ........ 7
Type 8 Phosphate Coated Hardware ................... 9
Torque Values for Hose Clamps ........................ 10
Torque Values for Split Flanges ......................... 11
Torque Wrench Extension Tools ........................ 12
Torque Multiplication ..................................................... 12
Other Uses for Torque Wrench Extension Tools........... 13
Tightening Torque Specifications (Metric) ..................... 13
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Grade
Dia. x Pitc
h (mm)
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
(4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5 x Std.
(1.08) (1.15) (1.80) (1.59) (2.24) (2.02) (3.11) (3.47) (3.61) (5.42) (6.50)
0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 1.50
M6 x Std.
(2.02) (2.16) (3.25) (2.89) (3.97) (3.39) (5.56) (6.14) (6.50) (9.04) (10.84)
0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M7 x Std.
(3.11) (3.32) (5.06) (4.55) (6.00) (5.64) (8.67) (9.40) (10.12) (14.10) (16.99)
0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80
M8 x Std.
(5.06) (5.42) (7.95) (7.23) (10.12) (9.04) (13.74) (15.18) (15.91) (22.42) (27.48)
0.73 0.80 1.20 1.00 1.50 1.35 2.10 2.30 2.40 3.35 4.10
M8 x 1
(5.28) (5.78) (8.67) (7.23) (10.84) (9.76) (15.18) (16.63) (17.35) (24.23) (29.65)
1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.20
M10 x Std.
(9.76) (10.12) (15.91) (13.74) (19.52) (19.99) (26.76) (30.37) (31.18) (44.84) (52.07)
1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40
M10 x 1
(10.84) (11.57) (18.08) (15.18) (22.42) (20.25) (31.10) (35.44) (36.16) (50.63) (60.75)
2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50
M12 x Std.
(17.35) (18.08) (26.76) (23.86) (33.99) (30.37) (45.56) (52.07) (54.24) (75.94) (90.41)
2.55 2.70 4.00 3.50 5.00 4.50 6.80 7.70 8.00 11.20 13.40
M12 x 1.5
(18.44) (19.52) (28.93) (25.31) (36.16) (32.54) (49.18) (55.69) (57.86) (81.00) (96.92)
3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14 x Std.
(26.76) (28.20) (13.23) (37.61) (54.24) (50.63) (72.33) (83.17) (86.79) (122.96) (144.66)
4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M14 x 1.5
(29.65) (31.10) (47.73) (41.22) (60.03) (54.24) (80.28) (90.41) (94.02) (11.26) (158.12)
5.60 6.00 9.00 8.00 11.50 10.50 15.50 17.90 18.50 26.00 31.00
M16 x Std.
(40.50) (43.39) (65.09) (57.86) (83.17) (75.94) (112.11) (129.47) (133.81) (188.05) (224.22)
6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 35.50
M16 x 1.5
(44.84) (47.01) (70.16) (62.20) (90.41) (81.73) (122.96) (141.04) (144.66) (202.52) (256.77)
7.80 8.30 12.50 11.00 16.00 14.50 21.00 27.50 28.50 41.00 43.00
M18 x Std.
(56.41) (60.03) (90.41) (79.56) (115.72) (104.87) (151.89) (198.90) (206.14) (296.55) (311.01)
9.10 9.50 14.40 12.50 18.50 16.70 24.50 27.50 28.50 41.00 49.00
M18 x 1.5
(65.82) (68.71) (104.15) (90.41) (133.81) (120.79) (177.20) (198.90) (206.14) (296.55) (354.41)
11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00
M20 x Std.
(83.17) (86.79) (130.19) (115.72) (159.12) (137.42) (227.83) (253.15) (260.38) (368.88) (433.98)
12.80 13.50 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M20 x 1.5
(92.58) (97.64) (148.27) (130.19) (180.82) (162.74) (253.15) (285.70) (296.55) (419.51) (491.84)
15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00
M22 x Std.
(112.11) (115.72) (177.20) (151.89) (216.99) (188.05) (303.78) (332.71) (354.41) (484.61) (542.47)
17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00
M22 x 1.5
(122.96) (133.81) (202.52) (173.59) (245.92) (209.75) (339.95) (44.76) (405.04) (542.47) (614.80)
20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24 x Std.
(148.27) (155.50) (238.68) (195.29) (289.32) (245.92) (397.81) (419.51) (455.67) (593.10) (655.43)
23.00 35.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00
M24 x 1.5
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)
NOTE: Torque values listed throughout this manual are lubricated (wet) threads; values should be
increased 1/3 for nonlubricated (dry) threads.
Heat Treated Material Grade 5 and Grade 8
Grade 5 Grade 8
Thread Size (3 Radial Dashes On Head) (6 Radial Dashes On Head)
Foot Pounds Newton Meter Foot Pounds Newton Meter
(ft lb) (Nm) (ft lb) (Nm)
1/4" - 20 6 8 9 12
1/4" - 28 7 9 11 15
5/16" - 18 13 18 18 24
5/16" - 24 15 20 21 28
3/8" - 16 24 33 34 46
3/8" - 24 27 37 38 52
7/16" - 14 38 52 54 73
7/16" - 20 42 57 60 81
1/2" - 13 58 79 82 111
1/2" - 20 65 88 90 122
9/16" - 12 84 114 120 163
9/16" - 18 93 126 132 179
5/8" - 11 115 156 165 224
5/8" - 18 130 176 185 251
3/4" - 10 205 278 290 393
3/4" - 16 240 312 320 434
7/8" - 9 305 414 455 617
7/8" - 14 334 454 515 698
1" - 8 455 617 695 942
1" - 14 510 691 785 1064
1 1/8" - 7 610 827 990 1342
1 1/8" - 12 685 929 1110 1505
1 1/4" - 7 860 1166 1400 1898
1 1/4" - 12 955 1295 1550 2102
1 3/8" - 6 1130 1532 1830 2481
1 3/8" - 12 1290 1749 2085 2827
1 1/2" - 6 1400 2034 2430 3295
1 1/2" - 12 1690 2291 2730 3701
1 3/4" - 5 2370 3213 3810 5166
2" - 4 1/2 3550 4813 5760 7810
NOTE: If any bolts and nuts are found loose or at
values less than what the chart states, it is
recommended that the loose bolt and/or nut be
replaced with a new one.
Torque
Radiator, Air Cleaner, Boots, Etc. Hydraulic System
Clamp Type And Size
Kilogram Meter Inch Pounds Kilogram Meter Inch Pounds
(kgm) (in lb) (kgm) (in lb)
"T" Bolt (Any Diameter) 0.68 - 0.72 59 - 63 ------- ------
Worm Drive - Under
44 mm (1-3/4 in) Open 0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50
Diameter
Worm Drive - Over 44 mm
0.5 - 0.6 40 - 50 ------- ------
(1-3/4 in) Open Diameter
Worm Drive - All "Ultra-
0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50
Tite"
Bolt Torque
Flange Bolt
Kilogram Meter Foot Pounds
Size (*) Size
(kgm) (ft lb)
1/2" 5/16" 2.1 - 2.5 15 - 18
3/4" 3/8" 3.0 - 3.7 22 - 27
1" 3/8" 3.7 - 4.8 27 - 35
1 - 1/4" 7/16" 4.8 - 6.2 35 - 45
1 - 1/2" 1/2" 6.4 - 8.0 46 - 58
2" 1/2" 7.6 - 9.0 55 - 65
2 - 1/2" 1/2" 10.9 - 12.6 79 - 91
3" 5/8" 19.1 - 20.7 138 - 150
3 - 1/2" 5/8" 16.2 - 18.4 117 - 133
Torque Multiplication
A wrench extension tool can be used to increase the tightening
force on a high capacity nut or bolt.
For example, doubling the distance between the bolt and the
back (handle) end of the torque wrench doubles the tightening
force on the bolt. It also halves the indicated reading on the
scale or dial of the torque wrench. To accurately adjust or
convert indicated scale or dial readings, use the following
formula:
I = A x T / A + B where:
I = Indicated force shown on the torque wrench scale or dial.
T = Tightening force applied to the nut or bolt (actual Torque). Figure 1
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of
fastener adhesives, with Thread locker sealers 222, 242/243,
262, 271, 272, or 277.
Breakaway Cure
Product Application Color Removal Strength (in lb) of
Sealer Alone
Low strength for 6 mm (1/4") or
222 Purple Hand tools 45
smaller fasteners.
Medium strength for 6 mm (1/4") and
242 or 243 Blue Hand tools 80
larger fasteners.
Heat/260C (500F)
High strength for high grade fasteners Remove HOT
262 Red 160
subject to shock, stress and vibration.
(NO solvent)
Extra high strength for fine thread Heat/260C (500F)
271 Red 160
fasteners up to 25 mm (1") diameter. Remove HOT
High temperature/high strength for
Heat/316C (600F)
272 hostile environments to 232C Red 180
Remove HOT
(450F).
Extra high strength for coarse thread
Heat/260C (500F)
277 fasteners 25 mm (1") diameter and Red 210
Remove HOT
larger.
V. "Loctite" Adhesives
Cabin
Edition 1
Cabin SP000018
Page 1
MEMO
SP000018 Cabin
Page 2
Table of Contents
Cabin
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
Removal ............................................................... 6
Installation ............................................................ 8
Cabin SP000018
Page 3
MEMO
SP000018 Cabin
Page 4
SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
SP000018 Cabin
Page 5
REMOVAL
CAUTION!
Avoid disassembling cabin if there are strong wind gusts,
which could catch large surface area of cabin shell and
push it sideways during lift.
WARNING!
DON'T TOUCH WHEN
PERFORMING INSPECTION
OR MAINTENANCE
FG003015
If engine must be run while performing maintenance, Figure 1
use extreme care. Always have one person in the
cabin at all times. Never leave the cabin with the
engine running.
Cabin SP000018
Page 6
12. Remove floor mat.
1
13. Remove operator's seat (1, Figure 2).
5
NOTE: Be careful not to damage seat covering. 4
14. Remove duct covers (2, 3 and 4, Figure 2). When 6
removing cover (2) disconnect hour meter connector and
7
cigar lighter connector. Disconnect main harness
connector before removing cover (4).
1
15. Remove pocket (5, Figure 2) before removing side panel
(6, Figure 2). FG000540
Figure 2
2 FG000667
Figure 3
18. Remove cover (5, Figure 4) on left side dash cover (3) and
bolts (1, Figure 5).
NOTE: When removing cover, disconnect speaker wire.
2 1 2
19. Remove two rubber stops (2, Figure 4) used in storing the
front lower glass. Remove bolts (1) from the rear left and 3
ARS1530L
Figure 4
ARS1540L
Figure 5
SP000018 Cabin
Page 7
24. Remove four mounting nuts from four corners of cabin floor
(2, Figure 6). 1
25. Remove four hex bolts (3, Figure 6) from door side of cabin
floor.
26. Remove two hex bolts (1, Figure 6) from right side of cabin 2
floor and one bolt (4) from front of cabin floor.
4
Quantity Description
4 16 mm hex nuts at each corner of the
cabin.
4 10 mm x 1.5 hex bolts at the door side
of the cabin.
3
3 10 mm x 1.5 mm hex head bolts, 2 on
HAOF270L
the right side of the cabin and 1 under
the front window. Figure 6
FG000541
Figure 7
INSTALLATION
1. Using a suitable lifting device, attach slings to four lift
points on top of cabin (Figure 7).
NOTE: Cabin weighs approximately 290 kg (639 lb).
2. Lower cabin into position on cabin floor.
FG000541
Figure 8
Cabin SP000018
Page 8
3. Install four mounting nuts on four corners of cabin floor (2,
Figure 9). 1
NOTE: Mounting nut torque 20.2 kgm (146 ft lb)
4. Install four hex bolts (3, Figure 9) in door side of cabin
floor. 2
5. Install two hex bolts (1, Figure 9) in right side of cabin floor
and one bolt (4) in front of cabin floor. 4
Quantity Description
4 16 mm hex nuts at each corner of the
cabin.
4 10 mm x 1.5 hex bolts at the door side 3
of the cabin. HAOF270L
3 10 mm x 1.5 mm hex head bolts, 2 on Figure 9
the right side of the cabin and 1 under
the front window.
ARS1540L
Figure 10
10. Install right side dash cover (4, Figure 11) with bolts (1,
Figure 10).
11. Install left side dash cover (3, Figure 11) with bolts (1,
1
Figure 10). Install two rubber stops (2, Figure 11). 2 2
12. Install cover (5, Figure 11) on left side dash cover (3). 3
ARS1530L
Figure 11
SP000018 Cabin
Page 9
14. Install air duct (3, 2 and 1, Figure 12) at right side of cabin.
NOTE: Connect wire connector of duct (2, Figure 12). 3
2 FG000667
Figure 12
15. Install side panel (6, Figure 13) and pocket (5).
1
16. Install cover (4, Figure 13) and connect main harness.
Install cover (3). Connect hour meter connector and cigar 5
lighter connector of cover (2). 4
6
17. Install cover (2, Figure 13).
7
18. Install operator's seat (1, Figure 13).
NOTE: Be careful not to damage seat covering. 1
19. Install floor mat.
FG000540
20. Connect negative (-) battery cable leading to frame from
Figure 13
battery.
Cabin SP000018
Page 10
SP000265
COUNTERWEIGHT SP000265
Counterweight
Edition 1
Counterweight SP000265
Page 1
MEMO
SP000265 Counterweight
Page 2
Table of Contents
Counterweight
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General ................................................................. 6
Warning for Counterweight and Front Attachment
Removal ......................................................................... 6
Removal ............................................................... 8
Installation .......................................................... 10
Counterweight SP000265
Page 3
MEMO
SP000265 Counterweight
Page 4
SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
SP000265 Counterweight
Page 5
GENERAL
DANGER!
DOOSAN warns any user, that the removal of the
counterweight from the machine, front attachment or any
other part, may affect the stability of the machine. This
could cause unexpected movement, resulting in death or
serious injuries. DOOSAN is not liable for any misuse.
Never remove the counterweight or front attachment unless
the upper structure is in-line with the lower structure.
FG000371
Never rotate the upper structure once the counterweight or
Figure 1
front attachment has been removed.
WARNING!
The weight of counterweight is given in the following table.
Use only rated and approved slings and hardware when
removal or installation lifts are being made. Lifting slings,
shackles and all other hardware must be rigged safely. An
assist crane that is rated above weight capacity is required.
Counterweight SP000265
Page 6
WARNING!
If the turntable deck has been unbalanced by removal of
weight from one end only, traveling the excavator, swinging
the turntable, movement over bumps or sloping and uneven
surfaces could cause loss of control and possible
accidents or injuries.
90 ~ 110
15 FG000325
Figure 1
15
FG000326
Figure 2
SP000265 Counterweight
Page 7
REMOVAL
1. Park on firm and level ground. O I
2. Lower front attachment (bucket) to the ground.
3. Shut down engine.
4. Set safety lever on "RELEASED" position.
5. Turn starter switch to "I" (ON) position.
WARNING
WARNING!
DON'T TOUCH WHEN
PERFORMING INSPECTION
OR MAINTENANCE
FG003015
If engine must be run while performing maintenance, Figure 3
use extreme care. Always have one person in the
cabin at all times. Never leave the cabin with the
engine running.
Counterweight SP000265
Page 8
12. Remove two caps (1, Figure 4) from counterweight (2).
13. Install two lifting eyes in lifting holes (3, Figure 4).
FG005138
Figure 4
SP000265 Counterweight
Page 9
INSTALLATION
1. Using suitable lifting device capable of handling a heavy
load, raise counterweight (2, Figure 5) into position just
above support frame (6) leaving counterweight suspended.
Verify that counterweight is level and even.
NOTE: Leave counterweight (2, Figure 5) suspended 3 1
3 mm (0.125") above support frame (6) until all 2
Counterweight SP000265
Page 10
SP000264
FUEL TANK SP000264
Fuel Tank
Edition 1
Fuel Tank
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 6
Parts List ......................................................................... 8
Specifications .................................................................. 9
Removal ............................................................. 10
Installation .......................................................... 14
Start-up Procedures ........................................... 16
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
WARNING!
Engine fuel is highly flammable and potentially explosive.
To prevent possible injury and/or damage to equipment,
extinguish or move to a safe distance all potential fire
hazards.
12
FR
ON
T
11
22
1
23
22
21 23
16 20
15 19
2
51
18 52
17
18
17
14
9
13
8 10
3
13
4
8
5 7
25
24
Figure 1
Specifications
Fuel tank capacity is 550 liters (145 U.S. gal).
FG000471
Figure 3
WARNING! WARNING
FG005137
Figure 5
FG005130
Figure 6
14. Tag and disconnect fuel supply line (26, Figure 7) and fuel
1
return line (27) from fuel tank (1) and carefully drain
remaining fuel from lines.
15. Remove clamp (28, Figure 7) holding fuel return line (27) to 27
tank (1).
28
26
FG005131
Figure 7
16. Remove components from fuel filler pump port (29, Figure 29 1
8) on side of fuel tank (1).
FG005132
Figure 8
FG005134
Figure 9
18. Remove eight bolts (32 and 33, Figure 10) and stay (34)
from fuel tank and frame.
Remove four bolts (35 and 36) and fuel tank cover (37)
from fuel tank. 35
33
Remove two bolts (38) and bracket (39) from tank. 34
Remove four bolts (40) and battery cover (41) from frame.
36 40
39
38
37
32
41
FG005133
Figure 10
19. Tag and disconnect wires leading to fuel sender (2, Figure
11) on side of fuel tank (1).
1
FG005135
Figure 11
21. Remove six bolts and spacers (8 and 13, Figure 12)
holding tank (1) to frame. Lift tank 25 mm (1") and make
sure it is balanced. Make sure that there are no other
electrical wires or hoses connected to tank. Completely
remove tank after inspection.
NOTE: The clear level gauge on the side of the tank is 10
easily damaged. Be careful of obstacles and 13
wind gusts. 8
Figure 12
NOTE: If tank is to be reused note position and amount
of shims used for each mounting bolt location.
2. Set fuel tank (1, Figure 13) into position. Install six bolts
and spacers (8 and 13, Figure 13) finger tight, to secure
tank to frame.
NOTE: The clear level gauge on the side of the tank is
easily damaged. Be careful of obstacles and
wind gusts. 10
FG005136
4. Tighten mounting bolts (8, Figure 13) after shims are
Figure 13
installed.
NOTE: Bolt torque is 27 kgm (200 ft lb).
5. Connect wires as tagged to fuel sender (2, Figure 14) on
side of fuel tank (1).
1
FG005135
Figure 14
6. Install four bolts (40, Figure 15) and battery cover (41) on
frame.
Install two bolts (38) and bracket (39) on fuel tank.
Install four bolts (35 and 36) and fuel tank cover on fuel 33
35
tank. 34
Install eight bolts (32 and 33) and stay (34) on fuel tank and
frame. 36 40
39
38
37
32
41
FG005133
Figure 15
FG005134
Figure 16
FG005132
Figure 17
9. Connect as tagged, fuel supply line (26, Figure 18) and fuel
1
return line (27) to fuel tank (1).
10. Install clamp (28, Figure 18) to hold fuel return line (27) to
tank (1). 27
28
26
FG005131
Figure 18
11. Make sure fuel tank drain valve (7, Figure 19) on bottom of
tank is closed.
12. Fill fuel tank and check for signs of leaks. Correct any
problems found.
13. Connect negative (-) battery cable to battery.
7
FG005130
Figure 19
FG004960
Figure 20
Swing Bearing
Edition 1
Swing Bearing
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
Swing Bearing Maintenance ................................. 6
Operating Recommendation ........................................... 6
Measuring Swing Bearing Axial Play............................... 6
Measuring Bearing Lateral Play ...................................... 6
Swing Bearing Basic Operation....................................... 7
Disassembly .................................................................... 7
Assembly......................................................................... 9
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Operating Recommendation
The service life of the swing bearing may be extended if a
conscious, daily effort is made to equalize usage over both ends
of the excavator. If the excavator is used in the same operating
configuration day in and day out (for example, with the travel
motors always under the counterweight, or with the attachment
over one side of the machine more than the other), the bearing's
service life could be reduced. Taking a few minutes in the middle
of each work shift to reposition the excavator, to work the
opposite end of the bearing, will provide a payoff in terms of
more even, gradual rate of wear and extended service life.
Reference
Description
Number
1 Outer Ring
2 Inner Ring
3 Tapered Pin
4 Plug
5 Ball
6 Retainer
7 Seal A
Figure 2
Disassembly
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
3. Top plug (4) into outer race (1) and then, drive pin (3) into
the pin hole.
Caulk the head of pin (3) with a punch.
Fill grease through the grease fitting.
Figure 10
Swing
Reduction Gear
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Theory of Operation
The swing reduction gearbox is a two-step planetary gearbox
with three planet gears, one sun gear and 2-step output
reduction. The planetary gear engages with the ring gear. The
pinion gear is connected with the output shaft and spline.
The gearbox reduces swing motor rpm to increase swing motor
output torque. The available maximum swing speed provides a
fast turning rate for efficient, rapid work cycling with more than
adequate power for good acceleration.
Figure 1
WARNING!
DON'T TOUCH WHEN
PERFORMING INSPECTION
OR MAINTENANCE
FG003015
If engine must be running while performing Figure 2
maintenance, always use extreme caution. Always
have one person in cab at all times. Never leave cab
with engine running.
Figure 3
IMPORTANT
Use a clean, dry container (with at least 11 liters, or 2.9
gallons capacity) to catch gear oil. A clean container
allows an evaluation to be made of the used oil. The
presence or relative lack of metal wear shavings in the
used oil or obvious deterioration or contamination of
the oil can provide a useful indicator of the motors Figure 4
general condition.
2. Remove the socket cap screws that hold the cover to the
gearbox housing. Remove the cover from the housing.
3. Remove the sun gear.
4. Thread an eye bolt into each of the three shafts that
support the 1st level planetary gears. Loop lifting straps
through the eye bolts and lift the planetary gears and the
first planetary mounting plate out of the gearbox.
5. Slide sun gear off the shaft and out of the gearbox.
Figure 5
Figure 6
Figure 7
8. Hold the planetary gear and thrust plate with one hand and
slide the gear shaft out of the housing. Use this method to
remove the two remaining gear shafts, gears, and thrust
plates.
Use the punch to drive the spring pins out of the shafts.
Use new spring pins when assembling the gearbox.
Figure 8
9. Sealant has been applied to the joint where the ring gear
and the gear case meet. It will be necessary to pry the ring
gear from the gear case, to separate the two parts.
Figure 9
10. Use a screwdriver to pry the snap ring from the output side
of the gear case.
Figure 10
Figure 11
12. Reach into the gear case and remove the roller bearing.
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 18
Figure 20
Figure 21
2. Put the pin assembly No.1 on the pin hole correctly and
insert it with a press.
Figure 22
Figure 23
Figure 24
Figure 25
5. Turn over the carrier in which the pin is inserted and put the
thrust washer No.1 on 4 pins as shown in the figure below.
Figure 26
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Figure 34
3. Hold the gear with both hands and the thrust washer facing
downward, insert it in the carrier, and arrange both gauges
of the carrier and the bush.
Figure 35
Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
Figure 42
Figure 43
Figure 44
Figure 45
Figure 46
Figure 47
Figure 49
Figure 50
CAUTION!
Care should be taken not to have drive shaft drop to
floor when it is pressed out of case.
Figure 51
Figure 53
Figure 54
5. Put the lock plate on it, engage the bolt applied Loctite
#262 (M16x40, torque: 2,700 kgfcm), and complete the
procedure by tying it with wire as shown in the figure below.
Figure 55
Figure 57
Figure 58
Figure 59
Figure 61
Figure 62
Figure 63
Figure 64
CAUTION!
Take care to prevent contamination by foreign substance
or damage to the lip area, and check the press fitting of the
seal visually. Figure 65
Figure 66
Figure 68
Figure 69
Figure 70
Figure 72
Figure 73
Figure 74
Figure 76
Figure 77
5. Insert plugs in the PT3/8 and PT1/8 taps of the drain port.
Figure 78
Figure 80
FG000936
Figure 81
FG000937
Figure 82
FG000938
Figure 83
FG001353
Figure 84
Figure 85
Figure 86
FG000942
Figure 87
Figure 88
2. Insert the sun gear No.2 in the middle of the carrier No.2 as
shown in the figure below and put the thrust plate on it.
Figure 89
Figure 91
Figure 92
4. Insert the sun gear No.1 in the middle of the carrier No.1.
Figure 93
Figure 95
FG000950
Figure 96
FG000954
Figure 98
Figure 99
Figure 101
Pneumatic Test
1. After the completion of the cover assembly, engage the
pneumatic test jig as shown in the figure below.
Figure 102
Figure 103
Figure 104
Figure 105
Figure 106
Figure 107
Figure 109
Figure 110
Figure 111
2. Use a hoist to lift the motor, wipe its assembling part with a
clean cloth, check the O-ring of the motor shaft, and
assemble it at the tap of the PT3/4 of the cover with the
brake valve of the motor facing to the left.
Figure 112
Figure 113
FG000973
Figure 114
Figure 115
Figure 116
Figure 117
5. Remove the plug, engage the level pipe sealed with Teflon
tape, and check the oil level.
Figure 118
Figure 119
6. Supply of Grease
A. Assemble the caulk in the grease inlet, and put the
nipple to supply grease until it flows out of the
opposite hole.
FG000978
Figure 121
FG000979
Figure 122
FG000980
Figure 123
FG000981
Figure 124
Figure 125
1Track
Assembly
Edition 1
Track Assembly
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 6
Track Tension ....................................................... 6
Cleaning and Inspection (Wear Limits and
Tolerances)........................................................... 9
Track Shoe .................................................................... 10
Lower Roller .................................................................. 12
Upper Roller .................................................................. 13
Front Idler ...................................................................... 14
Track Shoes and Links ....................................... 15
Track Removal .............................................................. 15
Track Installation ........................................................... 16
Front Idler Roller ................................................. 18
Parts List ....................................................................... 18
Front Idler Roller Disassembly ...................................... 19
Front Idler Roller Reassembly....................................... 20
Lower Roller ....................................................... 22
Parts List ....................................................................... 22
Lower Roller Removal ................................................... 23
Lower Roller Disassembly............................................. 23
Lower Roller Reassembly ............................................. 24
Lower Roller Installation ................................................ 25
Upper Roller ....................................................... 26
Parts List ....................................................................... 26
Upper Roller Removal ................................................... 27
Upper Roller Disassembly............................................. 27
Upper Roller Reassembly ............................................. 30
Track Spring and Track Adjusting Cylinder ........ 32
Under Carrige Track Spring................................ 33
Track Spring Assembly Diagram .................................. 33
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
TRACK TENSION
WARNING!
Safely measuring track tension requires two people. One
person must be in the operator's seat, running the controls
to keep one side frame in the air, while the other person
makes dimensional checks. Take all necessary precautions
to make sure the machine won't move or shift position
during service. Warm up the engine to prevent stalls, travel
the excavator to an area that provides level, uniform ground
support and/or use support blocks when necessary.
The track adjusting mechanism is under very high-
pressure. NEVER release pressure too suddenly. The
grease cylinder valve should never be backed off more than
1 complete turn from the fully tightened down position.
Bleed off pressure slowly and keep your body away from
the valve at all times.
Track shoe link pins and bushings wear with normal usage,
reducing track tension. Periodic adjustment is necessary to
compensate for wear and it may also be required by working
conditions.
1. Track tension is checked by jacking up one side of the
excavator. See Figure 1. Place blocking under frame while
taking measurement.
90 ~ 110
FG000345
Figure 1
Distance "A"
Terrain Type
DX420LC
Normal "B" 380 - 430 mm
(14.96 - 16.93 in)
Minimum "C" 380 mm
(14.96 in)
Muddy "D" 430 - 460 mm
(16.93 - 18.11 in)
Gravel, Rocky, Sand or 460 mm
Snow "E" (18.11 in)
WARNING!
The track adjusting mechanism is under very high-
pressure. NEVER release pressure too suddenly. The
grease cylinder valve should never be backed off more than
1 complete turn from the fully tightened down position.
Bleed off pressure slowly and keep your body away from
the valve at all times.
CAUTION!
Refer to the "Welding Precautions and Guidelines"
information in "General Maintenance Procedures" section
for general recommendations and specific safety
precautions, before starting any lower travel frame
component rebuilding procedure.
8 10
7
2 11
9
1
3
6
4 5
FG004347
Figure 4
*Check and record the pitch of at least 5 links. Use average of all
measruements to assess requried service ar action. Master links
must be replaced, they cannot be renewed or rebuilt.
3 4
1
FG004351
Figure 5
4 3
1
FG004352
Figure 6
4
3 5
1
2
FG000510
Figure 7
Track Removal
1. Position machine on a smooth level surface with adequate
room for forward and reverse travel.
2. Relieve track tension. Refer to "Track Tension" in this
section for procedure. 4
3. Move machine until master link (1, Figure 8) is positioned 3
at approximately 10 o'clock from top position on front idle 1
roller.
2
4. Remove four nuts and bolts (2, Figure 8) holding shoe to
link. Remove enough shoes to make access to lock pin
easier.
NOTE: Support track shoes with blocking so that when FG003982
master pin (4, Figure 8) is removed track will not Figure 8
fall.
5. Straighten lock pin (3, Figure 8) and remove it from master
pin (4). Discard lock pin.
6. Remove master pin from master links.
7. Move unit backward until entire track is laying on ground.
NOTE: Do not drive unit off track.
FG003911
Figure 9
90 ~ 110
FG000345
Figure 10
FG000345
Figure 11
FG003912
Figure 12
FG003982
Figure 13
Parts List
2
8
7
5
3
4
6 5
8 7
FG004357
Figure 14
9
3
FG004358
Figure 15
2. Separate the pin (6, Figure 16) from the bearing (3).
3
FG004359
Figure 16
FG004360
Figure 17
3
FG004361
Figure 18
5. Use a press to separate the axle (4, Figure 19), O-ring (8)
and bearing (3).
8
3
FG004362
Figure 19
6. Remove bushing (5, Figure 20) with the press and special
tool.
10 5 2
FG004363
Figure 20
8
FG004364
Figure 21
3
FG004361
Figure 22
FG004365
Figure 23
Parts List
5
2 8
7
6
8 7
2 FG004392
Figure 24
2 FG004366
Figure 26
'(
Figure 27
2
6
7 FG004393
Figure 28
FG004396
Figure 29
2. Apply grease to the O-rings (7, Figure 30) and insert into
axle. 5
3. Align collar (2, Figure 30) and axle (3) pin holes and pin (5) 7
the collar. 3 2
FG004397
Figure 30
2
6
7 FG004393
Figure 31
6. Install the collar (2, Figure 32), O-ring (7, Figure 31), and
pin (5) on the remaining side.
7. Fill with new engine oil with approximately 450cc (15.2 oz).
5
8. Install plug (8, Figure 32) on the collar.
2 FG004366
Figure 32
FG000345
Figure 33
Parts List
8
3
1
7
5
11
12
10
13
14
'(
Figure 34
FG005127
Figure 35
FG004400
Figure 36
11
12
10
13
14
FG004404
Figure 37
3. Separate the roller (1, Figure 38) from the axle (2).
2
1
FG004406
Figure 38
4. Separate the floating seal (6, Figure 39) from the roller and
coller(1). 6
1
FG004409
Figure 39
5. Separate the O-ring (8) and thrust ring (3) from the axle(2).
3 8
FG004411
Figure 40
FG001502
Figure 41
5
4
FG004419
Figure 42
2. Insert floating seal (6, Figure 43) into the roller (1) and
coller. 6
NOTE: Apply clean engine oil to the joint side of the 1
floating seal. Apply grease to the floating seal
O-ring.
FG004409
Figure 43
3. Install the axle, washer (11, Figure 44) and bolt (12).
4. Insert the O-ring (8, Figure 44) to the cover.
Attach cover (10) and bolt (13) to the roller. 11
5. Fill with new engine oil with 600cc (20.3 oz). 14 12
6. Tighten plug (9, Figure 44). 10
13
9 FG004427
Figure 44
FR
11 ON
12 T
10
6
13
14
15
7
8
9
FG004444
Figure 45
Figure 46
Figure 47
Reference Reference
Description Description
Number Number
1 Bolt 8 Spring Pin
2 Lock Plate 9 Body
3 Lock Nut 10 Rod Packing
4 Bracket 11 Back up Rinf
5 Spring 12 Dust Seal
6 Sotpper 13 Rod
7 Tie Bar
CAUTION!
The track spring assembly is assembled with strong force
that more care should be taken for its disassembly.
CAUTION!
When supplying air, the operator should stand beside,
not behind, the rod for it may be sprung forth suddenly
with a blasting sound.
Figure 48
2. Use a flat driver to remove from the body (9) the dust seal
(12), the back up ring (11), and the rod packing (10), which
should be replaced with new ones because they cannot be
reused.
Figure 49
CAUTION!
The lock nut (3) can be removed easily by means of
heating, as it is attached with a special adhesive.
5. After removing the bolt (1), the lock plate (2), and the lock
nut (3), release the load of the press to separate the
bracket (4), the spring (5), the stopper (6), and the body
assemblies (7, 8, 9).
Figure 50
CAUTION!
When using a spanner, nuts should be tightened in a
zigzag pattern that force can be spread evenly.
Figure 51
6. Use a 10 drill to remove the spring pin (8) retaining the tie
bar (7) and the body (9).
7. Disassemble the tie bar (7) and the body (9) after oxygen
heating them, as they are attached with a special
adhesive.
8. Check and remove rust or damage in the body (9).
CAUTION!
Take care not to damage the inside of the body and screw
threads after the disassembly of the tie bar.
Figure 52
CAUTION!
When applying pressure, make sure that the tie bar is
set to the hole of the bracket properly, or its screw
thread may be damaged.
CAUTION!
When tightening the bolt, it should be torqued at
within 18.0 2.0 kg m.
Figure 53
CAUTION!
Remember that spring has a very high elasticity that it
might be sprung forth during assembly or
disassembly.
CAUTION!
Remember that spring has a very high elasticity that it
might be sprung forth during assembly or
disassembly.
9. Make sure that, after the assembly, the range of the right
angle made by the bracket floor and the external side of
the body should be within 3 mm.
CAUTION!
If the range is poor, eccentric driving and/or earlier
wear of the idler may occur.
CAUTION!
Safety precaution should be followed, as the track
spring ass'y is the system assembled with strong
force.
10. Wash out the inside of the body and apply grease in the
body evenly.
11. Insert the back up ring (3) and press outward.
12. Bend the rod packing and insert it into the back up ring.
CAUTION!
If air is not removed completely, air explosion due to
load may damage the rod packing.
Air Conditioner
Edition 1
Air Conditioner
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
Air Conditioner System ......................................... 6
Outline ............................................................................. 6
Internal and External Filters ............................................ 7
Air-Conditioning System Layout ...................................... 9
Air Conditioner/Heater Circuit Diagram ......................... 10
Air Conditioner/Heater Unit ........................................... 11
Relay - Blower ............................................................... 15
Relay - A/C .................................................................... 15
Duct Sensor................................................................... 15
Water Temp Sensor ...................................................... 16
Internal Air Temp Sensor .............................................. 16
Ambient Air Temperature Sensor.................................. 16
Sun Sensor.................................................................... 17
Control Panel................................................................. 17
Compressor................................................................... 25
Receiver Dryer .............................................................. 25
Troubleshooting .................................................. 26
Weight of R134a Gas Used In Machines ........... 29
Refrigerant System Repairs ............................... 30
Refrigerant Safe Handling Procedures.......................... 30
Repair and Replacement Procedure ............................. 31
Refrigerant Recovery .................................................... 33
Vacuuming Refrigerant System..................................... 33
Leakage Check ............................................................. 34
Refrigerant Charging ..................................................... 35
Inspecting System For Leakage.................................... 37
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Outline
A
C
FG000784
Figure 1
Modes
Outlets A A+B B B+C C
FG000422
Figure 2
Donaldson.
FG000440
Figure 3
FG000441
Figure 4
FG000342
Figure 5
10
11
2
5
6
5
7
4
1
8
9 FG003919
Figure 6
Reference Reference
Description Description
Number Number
1 Air Conditioner/heater Unit 7 Liquid Hose (1)
2 Condenser 8 Liquid Hose (2)
3 Compressor 9 Ambient Temperature Sensor
4 Receiver Dryer 10 Sun Sensor
5 Discharge Hose 11 Control Panel
6 Suction Hose
0.5RW
FUSIBLE LINK
LAMP SWITCH
A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A CN11-4 0.85LW 47C
DIODE 4
1.25B CN11-1 99 - +
M
107B CN8-12 0.5LW CN10-1 107A 0.85B 0.85B
BLOWER
99 CN9-10 1.25B
20 19 18 17 16 15 14 13 12 11 10
4 3 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
FG000781
Figure 7
Cold Box
Internal Air Inlet
Outlet
Vent Rear
Outlet
Vent
Front
Outlet
Foot
DEF Outlet
Outlet
External Air
VENT
COOL
DOOR
DOOR -INTAKE
-MIX
DEF Internal Air
WARM
Mode
Door
Vent Bi-level Foot Def/foot Def
Vent 100 60 0 0 0
Foot 0 40 100 80 60
Def 0 0 0 20 40
Main Components
Internal
Internal Air Sensor
Air Filter
Actuator Water Temp Evaporator
-Wind Direction Sensor FG001360
Control
Figure 9
CN10-20 CN10-2
FG001055
Figure 11
DRAIN
(CN10-1)
SOURCE GATE
(CN11-1) (CN10-6)
FG001056
Figure 12
Specifications
Rated voltage 24V
Rated current 20A
Figure 13
Relay - A/C
Power is supplied to the magnetic clutch of the compressor.
Specifications
L S1 (+)
Rated voltage 24V
Rated current 10A
B S2
(-)
FG001058
Figure 14
Duct Sensor
It is inserted in the core of the evaporator to prevent freezing of
the evaporator.
The sensor consist of negative characteristic thermistor that
resistant value increases and decreases when the temperature
rises and falls, respectively.
83.7
OUTPUT VOLTAGE(mV)
76.2
67.7
58.8
46.6
36.0
21.4
Control Panel
A/C OUTSIDE
AUTO A/C
AUTO MAX
TEMP
OFF
SEL MODE
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
Control Logic
Temp Control
FULL COOL FULL HOT
Actuator
Compressor
control External temperature 1. Function: Prevention of compressor in winter.
sensor
2. Control pattern
Starter Switch ON
Code Description
E0 Normal
E1 Internal Air Temp Sensor Short
E2 Internal Air Temp Sensor Open
E3 Ambient Air Temp Sensor Short
E4 Ambient Air Temp Sensor Open
E5 Duct Sensor Short
E6 Duct Sensor Open
E7 Sun Sensor Short
E8 Sun Sensor Open
E9 Water Temp Sensor Short
E10 Water Temp Sensor Open
E11 D.P.S OPEN
E12 Position Error of Wind Direction
Actuator.
E13 Position Error of Temp Control
Actuator.
0.5 0.5
FG001067
Figure 22
Receiver Dryer
The receiver dryer reserves refrigerant enough to ensure High/Low Pressure Switch
smooth freezing cycle responding immediately to the change of
level in the freezing cycle.
As liquid refrigerant from the condenser may contain refrigerant
gas with bubbles whose presence in the expansion valve
decreases the freezing power excessively, it separates liquid
and gas and sends liquid only to the expansion valve.
Water in refrigerant shall be eliminated with dryer and through
filter.
FG001366
Figure 24
kgf/cm2G
kgf/cm2G
kgf/cm2G
HDA6074L
Figure 26
4. Check high / low-pressure of refrigerant.
WARNING!
Always wear protective glasses and gloves when handling
refrigerant. If refrigerant comes in contact with the skin or
eyes, immediately flush with clean, running water and
consult a physician.
Select a clean and well ventilated area to work.
The refrigerant container is under high-pressure and should
be stored below 40C (104F). Be careful not to drop the
container from a high location.
The contents are under high-pressure and should not be
used with compressed air or near an open flame.
UNION NUT
TORQUE WRENCH
CORRECT WRONG
WRONG
WRONG
CORRECT
O - RING POSITION
HDA6066L
Figure 27
RECOVER REFRIGERANT
RUN SYSTEM
3. When the manifold gauge dial falls below 3.5 kg/cm2 (50
psi), slowly open the low-pressure valve.
4. Open both the high and low-pressure valves slowly until
the manifold gauge dials indicates 0 kg/cm2 (0 psi).
Reference 1
Description
Number
1 Handle
2 Hose Connection
2
3 Mounting Disk
3
A. Before mounting valve on the container, make sure
the handle is in the counterclockwise most position,
with the puncture pin retracted and the mounting disk HDA6070L
is in the raised position. Figure 32
B. Attach the manifold gauge center hose to the valve
assembly.
C. Turn the disk in the clockwise direction and securely
mount valve onto refrigerant container.
D. Turn the valve handle in the clockwise direction and
puncture the container seal with the pin.
E. Once the can has been punctured, turn the handle in
the counterclockwise direction so the refrigerant can
flow into the manifold gauge center hose. At this time,
do not open the low and high-pressure valves of the
manifold gauge.
F. Press the manifold gauge low side valve to eliminate
the trapped air in the hose.
Leakage Check
NOTE: Perform the leakage check after completing
vacuuming process.
1. After attaching the manifold gauge, open the high side
valve.
WARNING!
For accurate refrigerant leak detection, perform leak
detection procedure in a well ventilated area.
Refrigerant Charging
1. Perform the vacuuming procedure, vacuum holding and
leaking tests as described in the proceeding headings.
NOTE: First charge the refrigerant system with 100g
(3.5 ounces) of refrigerant with the engine off.
Then using the manifold gauges as a guide fully
charge the system with the engine running.
When exchanging refrigerant containers, press
the manifold gauge low side valve to eliminate
air from the charging hose.
Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low-pressure Side
3 High-pressure Side
4 From Receiver
5 Refrigerant Supply Container
WARNING!
When outside temperature is low, warm the
refrigerant supply container with warm
water not exceeding 40C (104F). Do not
allow water to come in contact with the
charging adapter valve handle.
When outside temperature is high, cool off
refrigerant supply container and condenser
to aid the refrigerant charging process.
Reference 4
HDA6073L
Description
Number Figure 35
1 Pressure
2 High-pressure
3 Low-pressure
4 Compressor Stop
Inspection Procedure
1. High-pressure Side
Compressor outlet condenser inlet receiver dryer
inlet air conditioner unit inlet.
2. Low-pressure side
Compressor inlet air conditioner unit outlet.
3. Compressor
Compressor shaft area, bolt hole area and magnetic clutch
area.
4. Receiver dryer
Pressure switch and plug area.
5. Connection valve area
Inspect all valve areas.
Verify all valves are capped to prevent leaking.
Check for foreign material inside of valve cap.
6. Interior of air-conditioning unit.
After stopping engine, insert detector probe into drain
hose. (Leave inserted for 10 seconds minimum.)
NOTE: When inspecting leakage from the air-
conditioning unit, perform the inspection in a
well ventilated area.
1Drive Coupling
(Main Pump)
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
FG000656
Figure 1
FG000657
Figure 2
Installation Procedure
1. Assemble the flange of the coupling (1, Figure 3) in the
engine flywheel with bolts (2, Figure 3). 1
NOTE: Apply lock tight to bolts (2).
NOTE: Set the flange that the label saying "2 mounted
long side" faces the pump. 2
Hydraulic System
Troubleshooting,
Testing and
Adjustment
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
CENTER JOINT
20
14 FR
ON
16
T
20 14 16 20
16 14
18 19
10
16 11
14
20
1 5
2
1
1
4
1 6
21 13
15
17
7
9 12
13
12 8
21
15
17
FG004981
Figure 1
General Notes
When referring to the schematic, refer to the following items:
As shown in the schematic, the main pump assembly
is driven by the engine. Mechanical energy is
converted to hydraulic power, generating the required
hydraulic flow which drives the system. Two main
pumps (a right side pump and a left side pump) make
up the main pump assembly.
Hydraulic output from the right side pump is
transmitted to the right side of the control valve.
Output from the left side pump is transmitted to the
valve spools on the left side of the control valve.
Hydraulic output from the pilot pump is used to
control the pump and to operate pilot and solenoid
valves.
The right half of the hydraulic control valve, supplied
by the right pump in the pump assembly, operates
valve spools for right travel, swing, boom up and arm
functions. The amount of oil flow to the actuators at
the output end of each of those circuits is regulated
through the movement of each individual valve spool.
The left half of the hydraulic control valve, fed by the
left pump in the pump assembly, has control spools
for left travel, bucket, boom and arm operation.
Two-stage operation is a feature of boom and arm
function. All of these circuits can be operated using
the output of only one half of the hydraulic pump
assembly (one pump or the other), or since both
halves of the control valve have a spool and available
circuit for these functions the output of both pumps
can be combined, allowing higher speed operation.
Boom up, arm crowd and dumping functions can
operate in any one of the two available power modes
the standard or general duty mode, the high speed/
rapid cycling mode.
Whenever the right travel or left travel control spools
are shifted, output from the main pump assembly
flows through the center joint to one or both of the
axial piston motors driving the side frame crawler
tracks. A pilot valve connected to the swash plate of
each travel motor changes motor capacity (and
output) in direct proportion to the position of the travel
switch selected by the operator.
Boom Up Circuit
When you pull the boom control lever backward, the right side
pilot valve generates secondary boom up pilot pressure that is BOOM
CYLINDER
transmitted to the BOOM1 and BOOM2 spools of the control
valve simultaneously. When secondary pilot pressure reaches 7
- 9 kg/cm2 (100 - 130 psi), boom control valve spools open and
oil from both pumps goes to the boom cylinder.
BOOM1 BOOM2
BOOM UP
PILOT
PUMP(L) PUMP(R)
ATS0750L
Figure 2
PUMP(L) PUMP(R)
ATS0760L
Figure 3
Overload relief valves set at 360 kg/cm2 (5,112 psi) have been
installed at the AM 1 and AMD 1 ports on the right side of the
control valve to protect the circuit and system components from
possible damage caused by shocks and/or overload pressure.
Additional protection - to prevent cavitation of the cylinder - is
provided by a makeup valve and reservoir return circuit, which
ensures that the volume of oil going to the cylinder will not
exceed the volume of oil coming out.
ARM DUMP
ARM2 ARM1
PILOT
PUMP(L) PUMP(R)
ATS0780L
Figure 5
BUCKET
BUCKET
CROWD BC
PILOT
PUMP(L) PUMP(R)
ATS0790L
Figure 6
PUMP(L) PUMP(R)
ATS0810L
Figure 8
TRAVEL(L) TRAVEL(R)
L.TRAVEL R.TRAVEL
FORWARD FORWARD
PILOT PILOT
PUMP(L) PUMP(R)
ATS0830L
Figure 10
TRAVEL(L) TRAVEL(R)
L.TRAVEL R.TRAVEL
BACKWARD BACKWARD
PILOT PILOT
PUMP(L) PUMP(R)
ATS0840L
Figure 11
Triage Summary
An excavator that fails to deliver designed performance should
be checked for the following:
Hydraulic flow, first, and.
Hydraulic pressure, afterwards, in a specified order of
priority through different points of the system.
To verify adequate available hydraulic flow, before any other
tests are performed through the circuit:
Check engine operation -
at 1,880 rpm with no load.
at 1,800 rpm stall load.
If engine rpm drops excessively with a load or fails to surpass
rated speed (1,900 rpm), performance problems may be due to
inadequate hydraulic flow caused by lagging rotational speed.
NOTE: Verify actual flow on the excavator against rated
performance, with a flow meter.
If engine tests meet specifications and adequate torque and
horsepower are available at the pump drive flex coupling, pull
out the electrical tray under the operator's seat to inspect the
self-diagnostic display.
If the EPOS trouble code display is clear, check hydraulic
functions in the following sequence:
Pilot pressure.
Negacon, negative control pressure.
Main relief pressure (front and rear pump)
Swing pressure.
Port relief pressure (individual control functions;
boom, arm, bucket, swing, and travel)
Power boost circuit.
Standard performance tests; cylinder speed,
hydraulic motor (travel and swing) speed, cylinder oil
tightness "permissible drift" test.
NOTE: System specification performance tests of
individual activator function are
determined by flow rate through the
IMPORTANT
It is suggested that the troubleshooter maintain the testing
sequence of the preceding list. Checks and adjustments
nearer the middle or the end of the list may depend on
adequate functioning of systems tested nearer the top of
the list.
WARNING!
This procedure should be done with two people. To reduce
the chance of accident or unintended start-up, one person
should remain at the operator's control stand while checks
and adjustments are made.
IMPORTANT
Top off the hydraulic fluid reservoir if there is any
measurable loss of hydraulic oil during test gauge and
adapter fitting installation.
WARNING!
This procedure should be done with two people. To reduce
the chance of accident or unintended start-up, one person
should remain at the operator's control stand while checks
and adjustments are made.
WARNING!
This procedure should be done with two people. To reduce
the chance of accident or unintended start-up, one person
should remain at the operator's control stand while checks
and adjustments are made.
VALVE FUNCTION
HAOB730L HAOB740L
WARNING!
This procedure should be done with two people. To reduce
the chance of accident or unintended start-up, one person
should remain at the operator's control stand while checks
and adjustments are made.
IMPORTANT
Pressure adjustments and checks cannot be made if pilot
pressure is outside the specified range. Refer to the pilot
pump adjustment procedure if required, then proceed with
any necessary adjustments to main relief pressure settings.
WARNING!
This procedure should be done with two people. To reduce
the chance of accident or unintended start-up, one person
should remain at the operator's control stand while checks
and adjustments are made.
IMPORTANT
Before starting this procedure or going onto make any
changes of adjustment settings:
Verify engine output to the rated speed
2,050 50 rpm.
Permanently mark setscrew positions at the
current regulator control setting.
2
2
1
1 ASS0320L
Figure 12
Pd
ATS0870L
Figure 14
The adjusting screw (1), affects the delivery rate (Q) of the
pump. Tightening the adjusting screw decreases the maximum
cut flow (as shown in Figure 15) while backing out the screw
increases cut flow delivery rate. Q
Pd
FG005205
Figure 15
Precautions/Initial Checks
1. Stop work. Release all weight or any type of load safely
before proceeding. Avoid risking injury or adding to
damage.
2. Turn off engine and disengage control functions until initial
tests are ready to be made..
WARNING!
Prevent possible injury and/or loss of operating control.
Stop work and park the excavator at the first indication of:
1. Equipment breakdown.
2. Inadequate control response.
3. Erratic performance.
Stop the machine, put the boom and arm in the inoperative
(overnight park) position and begin by making the fastest,
simplest checks first:
Check oil level.
Check for overheating, oil leaks, external oil cooler
clogging or broken fan belt. Consult service record for
prior repair/service work.
Drain some tank oil into a clean, clear container. Look
for metal shavings/grit, cloudiness/water or foam/air
bubbles in the oil.
Check for wobble through the engine/pump flex
coupling. Run engine with the pump input hydraulic
power control nut turned to the lowest power to check
the engine.
Investigate unusual operating noises or vibration.
Check for loose bolts, connections.
No rotation and:
Pressure at swing motor Swing brake not releasing. Check brake engagement and
inlet increases. disengagement; check release pressure.
Internal damage to gearbox drive Replace broken gears and drive train
train. assemblies.
Overload. Reduce load weight.
TROUBLESHOOTING
HYDRAULIC PROBLEMS
Problem Possible Cause Remedy
Attachment cylinders, swing Main pump(s) malfunction. Repair or replace.
and travel motors are all Low oil level in hydraulic system. Refill.
inoperable. Loud noises are
Main pump inlet (oil supply) piping Repair or replace.
heard from main pump
or hose damaged.
assembly.
Attachment cylinders, swing Pilot pump malfunction. Repair or replace.
and travel motors are all Pilot cutoff solenoid stuck. Repair or replace.
inoperable. No usual or loud
Pilot cutoff switch faulty. Repair or replace.
noises can be heard.
Engine/pump flex coupling Replace flex coupling.
damaged.
Sluggish performance of all Main pump(s) damaged or worn. Repair or replace.
hydraulic functions Main relief valve pressure off. Readjust pressure.
attachment, swing and
Low oil level in hydraulic system. Refill.
travel.
Hydraulic reservoir intake strainer Clean.
clogged.
Pump inlet (supply side) piping or Tighten connection.
hose allowing air into hydraulic
system.
TROUBLESHOOTING
CONTROL VALVE
Check control valve problems only after other hydraulic circuit
operational tests have been made. Refer to the
"Troubleshooting Baseline Recommendations" procedure.
Pump flow, pilot pressure, Negacon pressure, main relief
pressure, and port relief pressure should all be checked before
starting to work on the control valve. Make sure the hydraulic
TROUBLESHOOTING
JOYSTICK CONTROL VALVE
Problem Possible Cause Remedy
Secondary pressure does Low primary pressure. Check primary pressure.
not increase. Broken spring. Replace spring.
Spool sticking. Clean, repair or replace.
Excess spool to casing clearance. Replace spool casing.
Worn or loose handle subassembly. Repair or replace handle subassembly.
Secondary pressure too Dirt, other interference between Clean, repair or replace.
high. valve parts.
Return line pressure too high. Redirect return line.
Accumulator
Edition 1
Accumulator SP000028
Page 1
MEMO
SP000028 Accumulator
Page 2
Table of Contents
Accumulator
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 6
Specifications .................................................................. 8
Accumulator SP000028
Page 3
MEMO
SP000028 Accumulator
Page 4
SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
SP000028 Accumulator
Page 5
GENERAL DESCRIPTION
The accumulator is a gas-charged storage device designed to
hold a reserve quantity of hydraulic fluid under pressure. 1
Accumulators are used in hydraulic circuits in much the same
way that condensers (or capacitors) are used to collect, store 2
and maintain electrical charge in a circuit.
In a hydraulic circuit, minor variations or lags in pump output that
might otherwise cause unsteady or irregular operation are made
up from the supply of pressurized oil in the accumulator.
Reference 3
Description
Number
1 Screw Plug
2 Steel Pressure Vessel
3 Diaphragm 4
4 Fluid Valve
ARS1790L
Accumulator SP000028
Page 6
button on the bottom of the diaphragm
eventually seals off the lower oil passage. Just
after the needle on the gauge reaches its
highest point (when there is 0 bar (0 psi)
resistance from hydraulic system pressure)
pressure on the gauge will drop sharply to zero,
as the accumulator is completely emptied of oil
and the diaphragm button closes.
Record the highest gauge reading and compare to the "P1"
rated precharge pressure on the accumulator
manufacturer's data label. Repeat this test at least once a
year to verify proper functioning of the accumulator.
3. As hydraulic system pressure overcomes accumulator
precharge pressure, the flexible diaphragm begins to
retract upward.
4. When system oil is at highest working pressure and the
accumulator fills to maximum reserve capacity, the flexible
diaphragm is pushed up into the top of the upper chamber.
The highest working pressure is sometimes referred to as
the "P3" pressure and can also be referenced on the
manufacturer's data label on the exterior of the
accumulator.
5. If system oil pressure begins to fall off or is momentarily
checked or interrupted, the energy stored on the other side
of the diaphragm, in the form of compressed gas, pushes
oil back out of the lower chamber, maintaining oil pressure
of the circuit.
6. With minimal system pressure, an equilibrium point may be
reached in which accumulator precharge pressure and
hydraulic system oil pressure achieve a rough balance. In
this condition a minimal amount of oil is stored in the
accumulator.
SP000028 Accumulator
Page 7
Specifications
Model Serial Number System Charge Pressure Volume
10 kg/cm2 320 cc
DX300LC S/N 5001 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX340LC S/N 5001 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX420LC S/N 5001 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX480LC S/N 5001 and Up Pilot / Travel
(140 psi) (19.53 in3)
10 kg/cm2 320 cc
DX520LC S/N 5001 and Up Pilot / Travel
(140 psi) (19.53 in3)
Accumulator SP000028
Page 8
SP000181
CENTER JOINT (SWIVEL)SP000181
1Center Joint
(Swivel)
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Figure 1
Reference Reference
Description Description
Number Number
1 Body 6 Wear Ring
2 Shaft 7 Slipper Seal
3 Cover 8 O-ring(1AP 120)
4 Spacer 9 O-ring(1BP 100)
5 Shim 10 O-ring(1BG 120)
CAUTION!
It is recommended to use a hoist or a similar device for it is
heavy.
CAUTION!
Remove active oil and wash it out before starting
disassembly.
CAUTION!
It should be disassembled after its active oil is cool enough
after it is removed from the system for its active oil is very
hot.
1. Set PF3/4 eye bolts on the cover drain port and use a hoist
to move it to a workplace.
2. Remove active oil remaining on each port with air.
3. Use a 19 mm spanner to loosen spacer bolts and remove
the cover and O-rings (1BG120).
Figure 2
CAUTION!
Care should be taken not to make a flaw on the surface
of the shaft when disassembling the body of the shaft
assembly.
Figure 3
Figure 4
CAUTION!
Care should be taken not to damage the inside of the
body because it is likely to be damaged when
disassembling the slipper seal. It may be
disassembled more easily with a driver whose tip is
bent as shown in the figure below.
Figure 5
7. Remove the PT and PF plugs sealing the shaft.
Internal sealing PF 3/4: 12 mm wrench.
External sealing PT3/8: 8 mm Wrench.
Figure 6
CAUTION!
The inside of the body should be air washed and rust-
proof treated after washing it, as its material is subject
to rust.
CAUTION!
Apply active oil to every functional (moving) part before
assembly to reduce any assembly friction as much as
possible.
Figure 7
3. Assemble the sliper seal, the wear ring, and the O-ring into
the body.
4. Assemble the 1AP - 120 O-ring the outside of the body.
CAUTION!
After assembling the sliper seal, a manual test should
be performed to ensure that every part is assembled
for its position properly.
Figure 8
CAUTION!
Applying active oil to the surface of the shaft enables
the assembly without any damage to the sliper seal.
5. Fix the position of the shaft and press the body carefully
into shaft with both being parallel each other.
6. Use a plastic (or rubber) hammer to tap the body until it is
inserted completely.
CAUTION!
Tap the body in a zigzag pattern that it does not tilt to
one side.
Figure 9
7. Engage the shim, the spacer, and the spacer bolts on the
top of the shaft.
8. Use a torque wrench to tighten spacer bolts at 5 ~ 6 kg m
Figure 10
CAUTION!
After the completion of the assembly, a start-up and a
rotation torque tests should be performed for the Figure 11
sliper seal to seat in its place properly.
Cylinders
Edition 1
Cylinders SP000030
Page 1
MEMO
SP000030 Cylinders
Page 2
Table of Contents
Cylinders
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 6
Theory of Operation ........................................................ 6
Parts List ......................................................................... 8
Special Tools and Materials ............................... 10
Piston Nut...................................................................... 10
Piston Jig....................................................................... 12
Steel Bushing Jig........................................................... 14
Dust Wiper Jig ............................................................... 16
Slipper Seal Jig ............................................................. 18
Slipper Seal Straightening Jig ....................................... 20
Disassembly ....................................................... 22
Reassembly ........................................................ 27
Cylinders SP000030
Page 3
MEMO
SP000030 Cylinders
Page 4
SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
SP000030 Cylinders
Page 5
GENERAL DESCRIPTION
Two essentially similar types of hydraulic cylinders are used on
the excavator. The cylinder that is used to operate the excavator
boom or bucket is equipped with a rod stopper, which acts as a
cushion only when the cylinder rod is fully retracted (and the
bucket is pulled close to the arm). This type of cylinder is shown
in the lower drawing.
Arm cylinders have a cushion or stopper for operation in both
directions. This type of cylinder is shown in the upper drawing.
Theory of Operation
1 Piston
2 Oil Path A 1
3 Oil Path B D
F1 = P x D2
4
F2 = P x (D2-R2) Figure 2
4
Cylinders SP000030
Page 6
Because the volume of oil needed to lengthen the cylinder rod
(Q1) is greater than the volume of oil required to retract the
cylinder rod, it takes more time to extend a cylinder than it does
to retract it. 1
Q1 = S x (D2)
4
Q2 = S x (D2-R2)
4
Q1 > Q2 FG001459
Figure 3
SP000030 Cylinders
Page 7
Parts List
The following parts list is a partial listing only; for full and
complete parts list information, refer to the Hydraulic Equipment
Component Parts List.
Cross section in Figure 4 shows an arm cylinder.
Cross section in Figure 5 shows a boom cylinder.
The bucket and boom cylinders are identical and differ only in
the attached pipes.
20 19 18 21,22 23 24 26
35 4 11,12 9,10 8 6 27 7 5 15 13,14 1 3 16 17
25 2 35
32, 33, 34
4 35 11, 12 9, 10 8 6 7 15 13, 14 5 3 1
16 17 20 19 18 21,22 23
24 2 35
FG005227
Figure 5
Cylinders SP000030
Page 8
Reference Reference
Description Description
Number Number
1 Tube Assembly 19 Wear Ring
2 Bushing 20 Ring
3 Rod Assembly 21 O-ring
4 Bushing 22 Backup Ring
5 Rod Cover 23 Piston Nut
6 DD-Bushing 24 Set Screw
7 Retaining Ring 25 Socket Head Bolt
8 Buffer Seal 26 Pipe Band Assembly
9 U-Packing 27 Hex Socket Bolt
10 Backup Ring 28 Check Valve
11 Dust Wiper 29 Spring
12 Retaining Ring 30 Spring Support
13 O-ring 31 Hex Socket Plug
14 Backup Ring 32 Spring Washer
15 O-ring 33 Hex Bolt
16 Cushion Ring 34 Pipe Assembly
17 Piston 35 Grease Nipple
18 Slipper Seal
SP000030 Cylinders
Page 9
SPECIAL TOOLS AND
MATERIALS
Piston Nut
( )
15
-0.1
-0.2
C
(C3~C5)
D +0.1
+0.2
A
35
B
8 Through Hole
5
0.
R
R(R15 ~ R20)
4-
350
ARS4730L
Figure 6
Material SM45C (AISI 1045)
Rockwell Harden from 22 - 27
Oil Quench
Cylinders SP000030
Page 10
MODEL CYLINDER A B C D MODEL (CYLINDER)
142.0 mm 102.0 mm 12.0 mm 5.0 mm
BOOM
(5.59 in) (4.02 in) (0.47 in) (0.20 in)
147.0 mm 107.0 mm 12.0 mm 5.0 mm
DX300LC ARM S/ARM
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
140.0 mm 98.0 mm 12.0 mm 5.0 mm
BUCKET S/BUCKET
(5.52 in) (3.86 in) (0.47 in) (0.20 in)
145.0 mm 105.0 mm 12.0 mm 5.0 mm
BOOM OPT BOOM
(5.71 in) (4.13 in) (0.47 in) (0.20 in)
147.0 mm 107.0 mm 12.0 mm 5.0 mm
DX340LC ARM OPT ARM
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
145.0 mm 105.0 mm 12.0 mm 5.0 mm
BUCKET OPT BUCKET
(5.71 in) (4.13 in) (0.47 in) (0.20 in)
147.0 mm 107.0 mm 12.0 mm 5.0 mm
BOOM
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
147.0 mm 107.0 mm 12.0 mm 5.0 mm
DX420LC ARM
(5.79 in) (4.21 in) (0.47 in) (0.20 in)
155.0 mm 115.0 mm 12.0 mm 5.0 mm
BUCKET
(6.10 in) (4.53 in) (0.47 in) (0.20 in)
SP000030 Cylinders
Page 11
Piston Jig
( )
15
2-"B"
)
F/2
8 Through Hole
R(
"
"D
"A"
"
C"
R(R15~20) 35
R5
4-
30
ARS4740L
Figure 7
Material SM45C (AISI 1045)
Rockwell Harden from 22 - 27
Oil Quench
Cylinders SP000030
Page 12
MODEL CYLINDER A ( 0.1) B C D MODEL (CYLINDER)
110.0 mm 13.0 mm 76.0 mm 140.0 mm
BOOM
(4.33 in) (0.51 in) (2.99 in) (5.51 in)
120.0 mm 13.0 mm 85.0 mm 150.0 mm
DX300LC ARM S/ARM
(4.72 in) (0.513 in) (3.35 in) (5.91 in)
110.0 mm 13.0 mm 76.0 mm 140.0 mm
BUCKET S/BUCKET
(4.33 in) (0.51 in) (2.99 in) (5.51 in)
120.0 mm 13.0 mm 85.0 mm 150.0 mm
BOOM OPT BOOM
(4.72 in) (0.51 in) (3.35 in) (5.91 in)
130.0 mm 13.0 mm 93.0 mm 165.0 mm
DX340LC ARM OPT ARM
(5.12 in) (0.513 in) (3.66 in) (6.50 in)
120.0 mm 13.0 mm 85.0 mm 150.0 mm
BUCKET OPT BUCKET
(4.72 in) (0.51 in) (3.35 in) (5.91 in)
130.0 mm 13.0 mm 93.0 mm 165.0 mm
BOOM
(5.12 in) (0.51 in) (3.66 in) (6.50 in)
130.0 mm 13.0 mm 93.0 mm 165.0 mm
DX420LC ARM
(5.12 in) (0.513 in) (3.66 in) (6.50 in)
130.0 mm 13.0 mm 93.0 mm 165.0 mm
BUCKET
(5.12 in) (0.51 in) (3.66 in) (6.50 in)
SP000030 Cylinders
Page 13
Steel Bushing Jig
(5)
"A" - 20
"B" + 40
"B"
"A"
(20)
15 F E
ARS4750L
Figure 8
Material: SM45C which is done thermal refining <QT> Hrc 22 - 28
Undefined Chamfer C/R = 0.5 Max.
1 Place: Finally work to used DNMG Tip <Nose R0.4>
Cylinders SP000030
Page 14
MODEL
MODEL CYLINDER A-0.05 B ( 0.1) E F+0.05 Part
-0.15 0 (CYLINDER)
90.0 mm 105.0 mm 40.0 mm 7.0 mm
BOOM
(3.54 in) (4.13 in) (1.58 in) (0.28 in)
90.0 mm 105.0 mm 40.0 mm 6.5 mm
DX300LC ARM S/ARM
(3.54 in) (4.13 in) (1.58 in) (0.26 in)
90.0 mm 105.0 mm 40.0 mm 7.0 mm
BUCKET S/BUCKET
(3.54 in) (4.13 in) (1.58 in) (0.28 in)
100.0 mm 115.0 mm 45.0 mm 7.5 mm
BOOM OPT BOOM
(3.94 in) (4.53 in) (1.77 in) (0.30 in)
100.0 mm 115.0 mm 45.0 mm 7.5 mm
DX340LC ARM OPT ARM
(3.94 in) (4.53 in) (1.77 in) (0.30 in)
100.0 mm 115.0 mm 45.0 mm 7.5 mm
BUCKET OPT BUCKET
(3.94 in) (4.53 in) (1.77 in) (0.30 in)
110.0 mm 130.0 mm 70.0 mm 11.0 mm
BOOM
(4.33 in) (5.12 in) (2.76 in) (0.43 in)
110.0 mm 130.0 mm 70.0 mm 11.0 mm
DX420LC ARM
(4.33 in) (5.12 in) (2.76 in) (0.43 in)
110.0 mm 130.0 mm 70.0 mm 11.0 mm
BUCKET
(4.33 in) (5.12 in) (2.76 in) (0.43 in)
SP000030 Cylinders
Page 15
Dust Wiper Jig
1.5
3-C
R0.2
1
DIA. (B+40)
DIA. (A-20)
DIA. A
DIA. B
15 C D
ARS4760L
Figure 9
Material: SM45C which is done thermal refining <QT> Hrc 22 - 28
Undefined Chamfer C/R = 0.5 Max.
Cylinders SP000030
Page 16
MODEL CYLINDER A-0.2
-0.3 B -0.2
-0.3 C 0-0.1 D MODEL (CYLINDER)
95.0 mm 109.0 mm 6.0 mm 7.0 mm
BOOM
(3.74 in) (4.29 in) (0.24 in) (2.28 in)
105.0 mm 121.0 mm 6.0 mm 7.0 mm
DX300LC ARM S/ARM
(4.13 in) (4.76 in) (0.24 in) (2.28 in)
90.0 mm 104.0 mm 6.0 mm 7.0 mm
BUCKET S/BUCKET
(3.54 in) (4.10 in) (0.24 in) (2.28 in)
100.0 mm 114.0 mm 6.0 mm 7.0 mm
BOOM OPT BOOM
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
115.0 mm 131.0 mm 6.0 mm 7.0 mm
DX340LC ARM OPT ARM
(4.53 in) (5.16 in) (0.24 in) (2.28 in)
100.0 mm 114.0 mm 6.0 mm 7.0 mm
BUCKET OPT BUCKET
(3.94 in) (4.49 in) (0.24 in) (2.28 in)
115.0 mm 131.0 mm 6.0 mm 7.0 mm
BOOM
(4.53 in) (5.16 in) (0.24 in) (2.28 in)
120.0 mm 136.0 mm 6.0 mm 7.0 mm
DX420LC ARM
(4.72 in) (5.35 in) (0.24 in) (2.28 in)
110.0 mm 126.0 mm 6.0 mm 7.0 mm
BUCKET
(4.33 in) (4.96 in) (0.24 in) (2.28 in)
SP000030 Cylinders
Page 17
Slipper Seal Jig
0
R1
R1
(A+2)
A
(A-14)
10
B
(B+40)
ARS4770L
Figure 10
Cylinders SP000030
Page 18
MODEL CYLINDER A+0.2
+0.1 B+0.2
+0.1
MODEL (CYLINDER)
140.0 mm 28.5 mm
BOOM
(5.51 in) (1.12 in)
150.0 mm 28.5 mm
DX300LC ARM S/ARM
(5.91 in) (1.12 in)
140.0 mm 28.5 mm
BUCKET S/BUCKET
(5.51 in) (1.12 in)
150.0 mm 28.5 mm
BOOM OPT BOOM
(5.91 in) (1.12 in)
170.0 mm 34.5 mm
DX340LC ARM OPT ARM
(6.69 in) (1.36 in)
150.0 mm 28.5 mm
BUCKET OPT BUCKET
(5.91 in) (1.12 in)
165.0 mm 34.5 mm
BOOM OPT BOOM
(6.50 in) (1.36 in)
180.0 mm 41.5 mm
DX420LC ARM OPT ARM
(7.09 in) (1.63 in)
160.0 mm 34.5 mm
BUCKET OPT BUCKET
(6.30 in) (1.36 in)
SP000030 Cylinders
Page 19
Slipper Seal Straightening Jig
1
2-C
R
2-5
(A+15)
A
1
2-R
100
25
50
ARS4780L
Figure 11
Cylinders SP000030
Page 20
MODEL CYLINDER A+0.2
+0.1
MODEL (CYLINDER)
140.0 mm
BOOM
(5.51 in)
150.0 mm
DX300LC ARM S/ARM
(5.91 in)
140.0 mm
BUCKET S/BUCKET
(5.51 in)
150.0 mm
BOOM OPT BOOM
(5.91 in)
170.0 mm
DX340LC ARM OPT ARM
(6.69 in)
150.0 mm
BUCKET OPT BUCKET
(5.91 in)
165.0 mm
BOOM OPT BOOM
(6.50 in)
180.0 mm
DX420LC ARM OPT ARM
(7.09 in)
160.0 mm
BUCKET OPT BUCKET
(6.30 in)
SP000030 Cylinders
Page 21
DISASSEMBLY
CAUTION!
Vent air from the hydraulic system before disconnecting
cylinder piping connections. Use the lever on the reservoir,
while the engine is running. Discharge the hydraulic
accumulator and vent residual tank pressure after the
engine is shut off. Pour clean replacement fluid back into
the system if excessive fluid is lost.
Figure 12
Figure 13
Figure 14
Cylinders SP000030
Page 22
4. Tap two bolts into cover of cylinder head, 180 apart.
Tighten them in a staggered, even sequence, to back off
piston rod end cover from edge of cylinder wall. Look for
adequate clearance between cover and end of cylinder
wall before using a plastic or other soft-faced hammer for
final disassembly.
Figure 15
Figure 16
Figure 17
Figure 18
SP000030 Cylinders
Page 23
8. Remove set screw using socket wrench.
HAOF340L
Figure 19
Figure 20
Figure 21
11. Use a plastic hammer to evenly pull off rod cover (9) from
end of piston rod. Be careful not to damage rod bushing (6)
and dust wiper, U-packing and other seals.
Figure 22
Cylinders SP000030
Page 24
12. Use a dull, rounded tip tool to pry off O-ring (11) and
backup ring (12).
HAOF37OL
Figure 23
Figure 24
14. Remove O-ring (20) and backup ring (21) from cylinder
head.
HAOF38OS
Figure 25
HAOF39OL
Figure 26
SP000030 Cylinders
Page 25
16. Disassemble retaining ring (3) and dust wiper (2). Separate
retaining ring (8) and rod bushing (6).
Figure 27
Figure 28
Cylinders SP000030
Page 26
REASSEMBLY
IMPORTANT
Replace any part that shows evidence of damage or
excessive wear. Replacement of all O-rings and flexible
seals is strongly recommended. Before starting the cylinder
reassembly procedure, all parts should be thoroughly
cleaned and dried, and/or prelubricated with clean
hydraulic fluid. Prepare the work area beforehand to
maintain cleanliness during the reassembly procedure.
Figure 29
Figure 30
SP000030 Cylinders
Page 27
3. Prelubricate O-rings and seals before reassembly (Figure
31).
Figure 31
Figure 32
Figure 33
Figure 34
Cylinders SP000030
Page 28
7. Use specially fabricate or factory sourced tool to tighten
piston nut (22).
Figure 35
8. Assemble wear ring (18), slide ring (17) and set screw (23)
to piston assembly.
Reference
Description
Number
1 Set Screw
Figure 36
Figure 37
Figure 38
SP000030 Cylinders
Page 29
Cylinders SP000030
Page 30
SP000261
SWING MOTOR SP000261
Swing Motor
Edition 1
Swing Motor
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 6
Parts List ......................................................................... 6
Specifications .................................................................. 8
Torques ........................................................................... 8
Theory of Operation ........................................................ 9
Makeup Check Valve .................................................... 12
Operation of Time Delay Valve ..................................... 12
Operation of Swing Reactionless Valve ........................ 12
Tools and Materials ............................................ 13
Tools.............................................................................. 13
Troubleshooting, Testing and Adjustment .......... 14
General Precautions...................................................... 14
How to Check Faults of Hydraulic Motor ....................... 14
Troubleshooting............................................................. 14
Disassembly ....................................................... 16
General Cautions .......................................................... 16
Disassembly of drive shaft subassembly ...................... 16
Disassembly of the cylinder block subassembly ........... 19
Disassembly of the rear cover subassembly................. 20
Cleaning and Inspection (Wear Limits and
Tolerances)........................................................ 23
Reassembly ........................................................ 23
General Cautions .......................................................... 23
Reassembly of drive shaft subassembly ....................... 23
Assembly of Cylinder Block Assembly Subassembly.... 26
Assembly of Rear Cover Assembly Subassembly ........ 30
Air Pressure Test........................................................... 34
Oil Leakage Check ........................................................ 34
Installation of test bench................................................ 35
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Parts List
21
20
25
33 42
24
23
9
34
38
36 10 41
37
35 11
26 12
27 43
29
30 22 28
13
14
18
8
19
6
17 5
39
1
31
15
32
16
15
16 4
15
3
16
40
15
2
16
7
FG005164
Figure 1
Torques
No. Tools Measures B Torque
30 Relief Valve M33 36 mm 1700 - 1900 kgcm
(123 - 137 ft lb)
33 Plug PT 1/4 6 mm 2,090 kgcm
(150 ft lb)
32 Wrench Bolt PF 1/4 5 mm 691 kgcm
(50 ft lb)
24 Wrench Bolt M14 12 mm 2,090 kgcm
(150 ft lb)
25 Wrench Bolt M14 12 mm 2,090 kgcm
(150 ft lb)
Structure
The hydraulic motor consists of the following five parts:
Rotary part generating rotary power.
Relief valve.
Parking brake.
Makeup check valve.
Time delay valve.
Swing reactionless valve.
Circuit Diagram
Figure 2
Y Cylinder A Piston
W1 W1
R1 N1
f1 P
F1
O
Drive Shaft
Y
High pressure Low pressure
FG005170
Figure 3
Figure 4
Tools
Tools B Length Tools to Be Used
Hex L Wrench 5 mm Wrench bolt (32)
6 mm Plug (33)
12 mm Wrench bolt (24, 25)
17 mm Plug (28)
Socket Wrench 36 mm Relief valve assembly (33)
Spanner
Snap Ring Pliers (For Orifice And Snap Ringp (4)
Axis)
Bar Hammer Needle bearing (22), Pin (6, 21)
Torque Wrench Measure:
Oil Seal Assembly Jig Oil seal (2)
Bearing Induction Heating Device Roller bearing (3)
B B
ARS3980L
Figure 9
General Precautions
1. Observe any abnormalities and any possible causes that
have noting to do with the motor before starting work.
2. Make sure that no foreign substance is involved when
disassembling the machine, which is the most frequent
cause of its wear.
3. Treat carefully and pay attention to avoid any damage
against it that is machined precisely.
Troubleshooting
Problem Possible Cause Remedy
Abnormal operation of driving devices.
Motor pressure does not Oil bypassing in relief valve (30) Replace or repair relief valve.
increase. Check spring broken. Replace check spring.
Oil channel inside the rear cover Replace rear cover
cracked.
Abnormal wear on check surface. Replace check.
Pressure increases but Friction and/or separation plates Replace friction and/or separation plates.
hydraulic motor does not stuck.
rotate. Slideway stuck. Replace stuck slideway.
Number of rotations is below specification.
Insufficient rotation. Lack of incoming oil. Check hydraulic circuits up to motor.
Too high oil temperature. Low oil temperature.
Too much leakage. Replace or repair faulty parts.
Low-pressure. Low set pressure in relief valve. Adjust pressure.
Brake released but weak Sticking or abnormal wear of Replace or repair slideway.
driving force. slideways.
Hard to control brake.
General Cautions
1. Prepare for a clean place for disassembly. Place a rubber
sheet on place to prevent any damage to parts.
2. Wash out dust and foreign substance in motor and
deceleration assembly.
3. Take care not to damage connecting parts and ways of O-
ring, oil seal, seal surface, gear, pin, and surface of
bearings.
4. Numbers in parentheses indicate those on sectional plans
of motor.
FG000682
Figure 10
Figure 11
Figure 12
FG000687
Figure 13
FG000688
Figure 14
FG000689
Figure 15
Figure 17
6. Remove snap ring (4) from body (1) using snap ring pliers
jig.
7. Turn body over, and separate shaft (5) assembly using
steel bar.
FG000693
Figure 18
Figure 19
FG000696
Figure 20
FG000697
Figure 21
9. Remove friction plate (15), plate (16), ball guide (12), ball
guide seat (11) and spring (10) from cylinder block (9).
FG000698
Figure 22
FG000700
Figure 24
FG000701
Figure 25
11. Remove two relief valve assemblies (30) from rear cover
(23) with torque wrench.
FG000706
Figure 27
FG000707
Figure 28
12. Remove check valve assemblies from rear cover (23) with
L wrench, and disassemble it in order of plug (28), spring
(27), and poppet (26).
FG000708
Figure 29
13. Remove plug (35) from rear cover (23) with L wrench and
disassemble it in order of backup ring (37), O-ring (36), O-
ring (38) and anti-inversion valve assembly (34).
FG000710
Figure 31
FG000711
Figure 32
FG000712
Figure 33
REASSEMBLY
General Cautions
1. Wash and clean each part. Then dry them with
compressed air. The friction plate, however, should not be
washed with treated oil.
2. Each connecting parts should be tightened according to its
assigned torque.
3. Only use a plastic soft-faced hammer.
FG000715
Figure 35
FG000716
Figure 36
FG000717
Figure 37
FG000719
Figure 38
Figure 39
FG000717
Figure 40
Figure 41
5. Secure shaft with snap ring (4) using snap ring pliers.
FG000722
Figure 42
Figure 43
FG000724
Figure 44
Figure 45
FG000726
Figure 46
FG000727
Figure 47
FG000728
Figure 48
FG000729
Figure 49
FG000759
Figure 50
FG000730
Figure 51
FG000731
Figure 52
FG000696
Figure 53
FG000732
Figure 54
Figure 55
FG000704
Figure 57
FG000687
Figure 58
FG000736
Figure 59
FG000738
Figure 61
Figure 62
2. Insert poppet (26), spring (27), and plug (28) in rear cover
(23). Tighten plug with L wrench. (Left and right
symmetrically.)
FG000708
Figure 63
FG000745
Figure 65
FG000711
Figure 66
FG000710
Figure 67
FG000746
Figure 68
FG000706
Figure 69
Figure 70
6. Coat valve plate (20) with grease and attach it to rear cover
(23).
FG000701
Figure 71
7. Put the rear cover ass'y on the body (1) and tighten its
wrench bolts (24, 25) with impact and then torch wrench.
Figure 73
8. Install time delay valve assembly onto rear cover (23) with
wrench bolts (32).
FG000682
Figure 74
Figure 75
FG000754
Figure 76
FG005165
Figure 77
FG005166
Figure 78
FG005169
Figure 79
Figure 80
Travel Motor
(With Gearbox)
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Specifications
Outline Dimensions
Figure 1
Structure
Figure 2
Reference Reference
Description Description
Number Number
40-1 Socket 40-8 Shim
40-2 Valve 40-9 Adjusting Spring
40-3 Valve Seat 40-10 O-ring, IB P7
40-4 Connecting Piston 40-11 Back-up Ring, T2 P7
40-5 Plug 40-12 O-ring, IB G25
40-6 Pilot Bod 40-13 Back-up Ring, T2 G25
40-7 Piston
Inlet Outlet
Direction of Rotation
Port Port
VA VB Right (clockwise)
VB VA Left (counterclockwise)
Motor
High pressure oil delivered from hydraulic pump is routed to inlet
port of brake valve (42) and through the rear cover (2) and valve
plate (8), to cylinder block (3). The oil flow and direction of shaft
rotation are indicated in Table 1: Direction of Rotation.
As shown in (A, Figure 5), high pressure oil is supplied to the
pistons which are on one side of the line Y-Y that connects
upper and lower dead points and produces force Fl.
Fl = P x A
(P pressure, A: area of piston section).
The shoe plate (11) with inclined angle of a divides this force F1
into thrust force F2 and radial force F31 ~ F34 (or F35) (B, Figure 5 Main Ports
Figure 5). This radial force is applied to axis Y-Y as turning force
and generate drive torque of T.
T = r1F31 + r2F32 + r3F33 + r4F34
NOTE: In case high pressure oil is applied to five pieces of
pistons, r5F35 should be added.
This drive torque is transmitted via cylinder block (3) to driving
shaft (9).
Negative Brake
Negative brake is released when high pleasure oil, selected by
the brake valve (42, Figure 6) that is connected directly to the
rear cover (2), Is applied to the brake piston (6).
Otherwise the braking torque is always applied.
This braking torque is generated by friction between separator
plates (7), inserted into the case (1), and friction plates (5).
NOTE: The separator plates are splined on the outer
circumference and engage case (1). The friction
plates are splined on the inner diameter and engage
cylinder block (3).
Figure 6
When no hydraulic pressure is applied to the brake piston (6), it
is pushed by the brake springs (29). The piston pushes friction
plates (5) and separator plates (7) towards case (1) and
generates frictional force which stops rotation of cylinder block
(3) and shaft (9).
Figure 7
Figure 8
Others
Seal Tape
Kerosene
Grease
Hydraulic Oil
Compressed Air
Waists etc.
General Instructions
1. Select clean disassembling place. Place a rubber pad on
the work bench to prevent parts from being damaged.
2. Clean dirt and foreign materials from reduction gear and
motor.
3. Be careful not to damage the contact surface of O-ring, oil
seal, and seal class and the contact or sliding surface of
gear, pin, and bearing class.
4. Numbers in () indicate part numbers in reduction gear and
motor drawing.
5. Piping side of motor indicates rear side and output side
indicates front side.
6. Before applying Loctite, completely remove oil from mating
surfaces using Loctite #587 and uniting them.
7. When tightening bolts, apply Loctite #262 to bolt threads
and tighten to rated torque using a torque wrench. (Apply
when assembling reduction gear only.)
8. Use only a plastic hammer.
9. After cleaning each part, blow dry with moisture free air.
But do not clean friction plates with cleaning oil.
Disassembling Procedure
1. Removing accessory valves.
Before disassembling motor, remove accessory valves.
A. Remove brake valve (42, Figure 9).
B. Remove pilot valve (41).
C. Remove check valve (17).
D. Remove overload valve (40).
E. Remove coupling (10)
NOTE: According to disassembling purpose, select
valves to be removed. Figure 9
Motor can not be disassemble without removing
brake valve.
CAUTION!
Be aware of piston popping out.
Figure 11
CAUTION!
Be aware of piston popping out.
Figure 13 Removing Shoe Plate
O. Remove shaft (9).
P. Remove retaining ring (19) and oil seal (26).
Q. If bearings need to be replaced, remove inner races
and outer races using bearing puller. Install new
bearings during reassembly.
IMPORTANT
Under outer race of rear bearing (31), are shims (33).
Reuse them as they are if none of the major
components mentioned in the following notes are
replaced.
General Instructions
1. Wash each part thoroughly with kerosene, and blow dry
using compressed air.
2. Assemble sliding parts after coating them with clean
hydraulic oil.
Reassembly
1. Coat outer surface of oil seal (26, Figure 15) and inner face
of case (1, Figure 15) with grease. Using jig, press oil seal
(26, Figure 15) into case (1).
2. Secure oil seal (26, Figure 16) into position with retaining
ring (19, Figure 16).
3. Place outer race of bearing (30) on case (1) (this is a loose
fit), and press the inner race on shaft (9) (this is a tight fit).
NOTE: It is easier to install inner race if it is heated to
100C. Never over heat.
4. Coat contact surface to oil seal (26) with grease to prevent
damage and install shaft (9) into case (1).
5. Install control piston (20) into case (1).
6. Using match marks made during disassembly, install shoe
plate (11) and pivots (22) into the case (1).
7. Coat three spherical recesses in shoe plate (11) with
ample grease and assemble it in case (1).
Figure 16
10. Install all the separator plates (7, Figure 18) and friction
plate (5) alternately between case (1) and cylinder block
(3). Separator plates (7) are installed first and last.
11. Install D-rings (15,16) on brake piston (6). Insert brake
piston (6) into case (1) using inserting jig after.
NOTE: Two kinds of D-rings are used on brake piston
(6). The larger one (16) is first inserted into the
groove, then the smaller one (15) is installed. It
is impossible to see how the smaller ring goes
into the groove. Therefore, never push it forcibly
into the groove. Otherwise, it may be scraped
off by the edge of case (1).
12. Lay down rear cover (2, Figure 19) to mount valve plate
(8). Align match marks made during disassembly and also
place brake springs (29) with ample grease to be attached
to rear cover (2) while this assembling. Also set O-ring (38) Figure 18
on rear cover (2). Then, insert rear cover (2) to case (1)
and fasten cap screws (32).
13. Install coupling (10) on shaft (9).
NOTE: Tightening torque of cap screw (32) is 33.0 kgm
with rust preventive on the threads.
Maintenance of Parts
The followings are the general maintenance standards.
However, it is important to determine which parts should be
replaced, depending on the characteristics before
disassembling, damages and discoloration of exterior view, the
purpose of disassembling, the expected remaining service life,
etc.
Maintenance Standard
Figure 20
Fastening Torque
Use torque wrench when tightening the following cap screws,
plugs and valves. Lubricating with rust preventive oil.
General instructions
The followings are the general instructions to be followed when
some troubles occur with hydraulic motors.
1. Judge the nature of abnormality before troubleshooting,
and ascertain if the same symptom has occurred before or
not. Review if the motor itself is actually causing the
problem.
2. In many cases, the wear is caused by dusts. Take great
care to prevent dusty when disassembling and
assembling.
3. All the parts especially those of moving parts should be
carefully handled, and be careful not to score or scratch
the sliding surfaces.
4. Be careful not to score the seating surface for O-ring, etc.
Replace O-rings with the new ones, once disassembled.
Specifications
Outline Dimensions
Figure 21
Specifications
Structure
Figure 22
Operation
1. The reduction unit slows down the rotating speed of motor
and converts motor torque to stronger rotating force. This
reduction unit utilizes a two stage, planetary reduction
system. Planetary reduction system consists of sun gear,
planetary gears, (planetary) carriers, and ring gear. When
the sun gear (a) is driven through input shaft, planetary
pinions (b), rotating on their center, also move, meshing
with fixed ring gear (a), around sun gear (5). This
movement is transferred to carrier (k) and deliver the
torque. This mechanism is called a planetary gear
mechanism.
Figure 24
Tools
Prepare following tools and instruments before disassembling or
assembling.
Description Remarks
Torque Wrench 0 ~ 0.5 kgm (0 ~ 4.9 Nm)
Hex. Socket Wrench Width across flats 8mm and 14mm
Work Stand
CAUTION!
While oil is still hot, inside of the unit may be
pressurized. Take care of the hot oil gushing out of the
unit when loosening the plug.
CAUTION!
Take great care not to pinch your hand between parts
while disassembling or let parts fall on your foot while
lifting them.
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Figure 34
Figure 35
Figure 36
Figure 37
Figure 38
Assembling
Figure 39
General Notes
1. Clean every part with kerosene and dry them with
compressed air. Surfaces to be coated with Loctite must
be degreased with solvent.
2. Check every part for any abnormalities.
3. Each cap screw should be coated with Loctite #242
applied on its threads.
4. Apply gear oil lightly on each part before assembling.
5. Be careful not to pinch your hand between parts while
assembling nor let parts fall on your foot while lifting them.
Figure 40
Figure 41
Figure 42
3. Install spring pins (7) into carrier 1 (2) and carrier pins 1
(3).
Figure 43
Figure 44
Figure 45
Figure 46
2. Install three M20 eye bolts equally apart from each other in
housing (18). Using the eye bolts, position housing (18) on
ring gear (17), aligning match marks.
3. After applying Loctite #242 on threads of M18x100 cap
screws (25), tighten them with torque wrench to 41kgm.
4. Install floating seal (23) on housing (18).
NOTE: Clean the groove for floating seals (23) to
eliminate oil, dust, paint or other foreign
material.
NOTE: Apply gear oil lightly on sliding surfaces of
Figure 47
floating seals (27) before assembling. Keep O-
rings and mounting surfaces dry and free of oil.
NOTE: Make sure floating seal (23) O-are not twisted
and that floating seal is correctly installed i.e.
parallel to each other between housing (18) and
motor case after assembled as shown in Figure
48.
Figure 48
Figure 50
Figure 51
Figure 52
Figure 53
Figure 54
Figure 55
Figure 56
Installing Cover
NOTE: Gear oil can be added before installing cover (1) if
you can measure proper volume of oil.
1. Apply Loctite #515 on mating surfaces of cover (1) and ring
gear (17). Install cover (1) on ring gear (17).
2. Apply Loctite #242 on threads of 18 - M10x25 cap screws
(24) and tighten them with to a torque of 8 kgm.
Maintenance Standards
1. The followings are general maintenance standards.
However, it is important to determine which parts should
be replaced, depending on the characteristics shown
before disassembling, damage or discoloration, the
purpose of disassembling, the expected remaining service
life etc.
Figure 58
Fastening Torque
Use a torque wrench when tightening the following cap screws
and plugs.
Lubrication
After installing the travel motor and gearbox assembly, position
the drain port at its lowest position and check if lubrication oil
comes out when loosening the level plug. If not oil is present at
the level plug, add oil.
Rotating Inspection
Place the unit on a test stand and rotate it with no load and
check if there are any abnormal noises or oil leaks.
NOTE: This inspection can be done while mounted on the
track frame before attaching track.
Specification
Outline Dimensions
Figure 59
Number Description
13 O-ring
14 Socket Head Cap Screw
15 Plug
16 O-ring
17 O-ring
18 O-ring
Structure
Figure 60
Reference Reference
Description Description
Number Number
1 Body 7 Cover
2 Spool Assembly 8 Restricto
3 Spring Seat 9 Spring
4 Spring 10 Plug
5 O-ring 11 O-ring
6 O-ring 12 Socket Head Cap Screw
Figure 61 Holding
Figure 62
Figure 63 Stopping
Figure 64 Counterbalancing
Tools
Disassembling Procedure
1. Remove valve from hydraulic motor.
2. Detach O-rings (I6 and 17) from gasket surface.
3. Remove countersunk head cap screw (12) and cover (7).
4. Pull out O-rings (5 and 6), spring (4) and spring seat (3).
5. Pull out spool (2) from body (1). It is impossible to
disassemble this spool any further.
6. Remove plug (10) from cover (7), spring (9) and restrictor
(8).
Instructions on Reassembling
1. Perform the reassembling work on clean place.
2. Be careful to install the parts at the same position as
mounted before.
3. Remedy the Indents and the like, if made during
disassembling, by oil stone etc.
4. Coat each part by hydraulic oil, and you can perform
reassembly more easily.
5. Replace O-rings with new ones, as a rule.
Fastening Torque
Main Pump
Edition 1
Main Pump
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
ectional View ........................................................ 6
A8VO200LA1KH1/63 ...................................................... 6
General Repair Guidelines ................................... 8
Seal Kits and Sub-assemblies ............................ 10
Sealing the Drive Shaft ....................................... 14
Gear Pump Sealing ............................................ 16
Remove the Control Housing ............................. 18
Control Module ................................................... 22
Control Module LR ........................................................ 22
Control Module H .......................................................... 23
Removing the Controller ..................................... 24
Valve Plate With Valves ..................................... 26
Remove the Rotary Groups ................................ 27
Remove the Intermediate Wheel ........................ 30
Remove Auxiliary Drive ...................................... 32
Inspection ........................................................... 35
Re-fitting the Rotary Group................................. 40
Pump Assembly.................................................. 42
Hydraulic Component - Measurement "D".......... 45
Measuring Device - Hydraulic Component 452 269...... 45
Mounting Position.......................................................... 46
Measuring Procedure .................................................... 48
Installation of Control Housing............................ 49
Assembly of Intermediate Wheel ........................ 52
Installation of Gear Pump ................................... 53
Installation of Cover / Auxiliary Drive .................. 54
Assembly Guidelines for Tightening Torques ..... 55
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
A8VO200LA1KH1/63
ASS0010L
Figure 1
ASS1140L
Figure 3
ASS0030L
Figure 4
ASS0040L
Figure 5
ASS0050L
Figure 6
ASS0060L
Figure 7
ASS0070L
Figure 8
ASS0080L
Figure 9
ASS0090L
Figure 10
ASS0100L
Figure 11
ASS0110L
Figure 12
ASS0120L
Figure 13
ASS0130L
Figure 14
ASS0140L
Figure 15
ASS0150L
Figure 16
ASS0160L
Figure 17
ASS0170L
Figure 18
ASS0180L
Figure 19
ASS0190L
Figure 20
ASS0200L
Figure 21
ASS0210L
Figure 22
ASS0220L
Figure 23
ASS0230L
Figure 24
ASS0240L
Figure 25
ASS0250L
Figure 26
1 ASS0260L
Figure 27
ASS0270L
Figure 28
ASS0280L
Figure 29
ASS0290L
Figure 30
ASS0300L
Figure 31
ASS0310L
Figure 32
2
2
1
1 ASS0320L
Figure 33
Number Description
1 Setting Screw: Qmax
2 Setting Screw: Hydraulic Stroke Limitation
3 Setting Screw: Power Characteristic (Begin of Regulation)
X
ASS0330L
Figure 34
Control Module LR
ASS0340L
Figure 35
ASS0350L
Figure 36
ASS0360L
Figure 37
ASS0370L
Figure 38
(1)
ASS0380L
Figure 39
1. Remove cover.
NOTE: Do not change the setting of adjustment screw
(1, Figure 39).
ASS0390L
Figure 40
ASS0400L
Figure 41
ASS0410L
Figure 42
ASS0420L
Figure 43
ASS0430L
Figure 44
ASS0440L
Figure 45
ASS0450L
Figure 46
ASS0460L
Figure 47
ASS0470L
Figure 48
ASS0480L
Figure 49
2
Rotary Group 2
Rotary Group 1
ASS0490L
Figure 50
2
1
ASS0500L
Figure 51
A Adjustment of measurement D
*
1. Holding device
Drive shaft 2
Drive shaft 1
1. Holding device
*
A
Adjustment of measurement D
ASS0520L
Figure 53
2. Install sleeve. I
NOTE: Press out bolt with a hydraulic press.
ASS0530L
Figure 54
ASS0540L
Figure 55
ASS0550L
Figure 56
ASS0560L
Figure 57
ASS0570L
Figure 58
ASS0580L
Figure 59
ASS0590L
Figure 60
ASS0600L
Figure 61
ASS0610L
Figure 62
ASS0620L
Figure 63
ASS0630L
Figure 64
ASS0640L
Figure 65
ASS0650L
Figure 66
2. Visually check:
To ensure that bearing seats are free of scores.
ASS0660L
Figure 67
3. Visually check:
Check to see that bearing bores are free of scores and that
there is no evidence of wear.
ASS0670L
Figure 68
ASS0680L
Figure 69
ASS0690L
Figure 70
6. Piston:
Check to ensure that they are free of scores and that there
is no pitting.
ASS0700L
Figure 71
7. Central pin:
Check to ensure that it is free of scores and that there is no
pitting.
ASS071L
Figure 72
8. Retaining plate:
Check to ensure that it is free of scores and that there is no
evidence of wear.
ASS0720L
Figure 73
ASS0730L
Figure 74
10. Check:
Control land (1, Figure 75), internal control drilling (2,
Figure 75) and pin cups (3, Figure 75).
ASS0740L
Figure 75
11. Check:
That sliding surfaces (1, Figure 76) are free of scores.
Seal (2, Figure 76).
ASS0750L
Figure 76
2
1
1
ASS0760L
Figure 77
*
*
*
*
ASS0770L
Figure 78
ASS0780L
Figure 79
ASS0790L
Figure 80
3. Insert spring plate (1, Figure 81) and cup springs (2, Figure
81) into their correct position (and orientation) using grease
to hold them into place.
ASS0800L
Figure 81
ASS0810L
Figure 82
ASS0820L
Figure 83
ASS0830L
Figure 84
ASS0840L
Figure 85
ASS0850L
Figure 86
ASS0860L
Figure 87
Stop
D
A
A
D
Stop
ASS0870L
Figure 88
Assembly Guideline
Retaining force:
After rotary group has been installed into housing, it has to be
pressed in until the end stop is reached. Allow housing to cool
down from its assembly temperature (approximately 80C) to
room temperature.
ASS0880L
Figure 89
ASS0900L
Figure 90
ASS0890L
Figure 91
ASS0910L
Figure 92
ASS0920L
Figure 93
Figure 94
Figure 95
ASS0950L
Figure 96
ASS0960L
Figure 97
Figure 98
Figure 99
ASS0990L
Figure 100
* ASS1000L
Figure 101
ASS1010L
Figure 102
ASS1020L
Figure 103
Pressure Pressure
side side
Suction side
ASS1030L
Figure 104
ASS1050L
Figure 106
2
ASS1060L
Figure 107
ASS1070L
Figure 108
ASS1080L
Figure 109
ASS1090L
Figure 110
ASS1100L
Figure 111
ASS1110L
Figure 112
G
Seal
ASS1120L
Figure 113
1 Control Valve
(KVMG-400-DA)
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Figure 4
Figure 6 Boom Up
Figure 8
Figure 9 Dump
Figure 11
Figure 12
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
4. Pressure up operation
When pressure at pilot port (Pi) is increased, piston (H)
moves to the pressure setting position of plug (I) so that
the force of spring increases, thus increasing pressure in
the neutral oil passage (HP).
Figure 21
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
Figure 33
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
6 Poppet
7 Spring Figure 34
8 Plug
9 O-ring
10 Backup Ring
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
Figure 35
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
Figure 36
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
6 Poppet
7 Spring Figure 37
8 Plug
9 O-ring
10 Backup Ring
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
Figure 38
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
Figure 39
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
Figure 40
Reference
Description
Number
1 Spool
2 Spring Seat
3 Spring
4 Spring
5 Spool End
Figure 41
Reference
Description
Number
1 Spool
2 Sleeve
3 Sleeve
4 Piston
5 O-ring
6 Backup Ring
7 O-ring Figure 42
8 Backup Ring
Reference
Description
Number
1 Spool
2 Spool End
Figure 43
Reference
Description
Number
1 Poppet
2 Poppet
3 Spring
4 Plug
Figure 44
Reference
Description
Number
1 Plug
2 O-ring
3 O-ring
4 O-ring
Figure 45
Reference
Description
Number
1 Plug
2 O-ring
3 O-ring
4 Backup Ring
Figure 46
Figure 47
Item Specification
Serial No. 1001 thru 1050 1051 and Up
Hi: 34.3 0.5 MPa Hi: 34.3 0.5 MPa
Relief Valve Pressure
Low: 31.4 0.5 MPa Low: 31.4 0.3 MPa
Flow 250 liter/min. 150 liter/min.
Reference
Description
Number
1 O-ring
2 O-ring
3 O-ring
4 Backup Ring
5 O-ring
6 Backup Ring
7 O-ring Figure 48
Item Specification
Relief Valve
35.3 0.5 MPa
Pressure
Flow 20 liter/min.
Reference
Description
Number
1 Plug
2 Spring
3 Poppet
4 Sleeve
5 O-ring
6 O-ring
Figure 49
Specifications
Component Name Specification
Rated Flow 400 liter/min.
500 liter.min at Neutral
Max. Pressure 31.9 MPa
Allowable Back Pressure Peak Pressure: Below 1.5 MPa
Normal Pressure: Below 0.5 MPa
Allowable Working Temperature Range -20 ~ 90C
General
Problem Possible Cause Remedy
Spool does not stroke. Hydraulic oil excessively hot. Remove blockage in oil piping.
Lock nut and adjuster deformed. Reset pressure and tighten lock
nut in rated torque.
Oil leaks Relief valve seat parts damaged. Replace relief valve.
Hydraulic System
Problem Possible Cause Remedy
Hydraulic system is poor or Hydraulic pump failed. Check pressure or replace pump.
none of the controls function
Relief valve failed. Replace pump.
IMPORTANT
If pressure of main relief valve is higher than the specified
pressure for it, change main relief valve assembly setting
without adjusting over load relief valve.
1. Shift the control valve spool and read the pressure gauge
from the stroke end of the cylinder.
2. Loosen lock nut (3) and turn adjusting plug clockwise to
raise pressure. One turn varies pressure by approximately
21.2 MPa.
3. Tighten lock nut (3) after pressure has been adjusted. Lock
nut (3) should be torqued to 2.80 - 3.2 kgm (20 - 23 ft lb).
4. Recheck the pressure setting again.
CAUTION!
When disassembling assembly, when pressure is not
fully released, or bucket is not lowered to ground, it is
very dangerous. A poppet in an antidrift valve may
spring out and drop the bucket at the same time.
Always lower bucket to ground and fully release
pressure before disassembling.
WARNING!
When removing spool, be careful not to damage it.
Attach label to each spool in order to install it in the
correct position when reassembling.
3. Remove socket head bolts (63) and short cap (13 and 74).
Remove O-ring from valve housing.
4. Remove spool end (further part number - 5, width across
flats: 22 mm) of spool (3, 4, 6, 7, 9 10 and 11), spring seat
(further part number - 2) and spring (further part number - 3
and 4).
5. Remove spool end (5-5, width across flats: 22 mm) of
spool (5), spring seat (5-2) and spring (5-3,4). Remove
plug (5-8: groove width; 3 mm), O-ring (5-9) and backup
ring (5-10).
6. Remove spool end (8-5, width across flats: 22 mm) of
spool (8), spring seat (8-2) and spring (8-3,4). Remove
plug (8-8: groove width; 3 mm), spring (8-7) and poppet (8-
6).
7. Disassembly of spool
IMPORTANT
Work with spool gripped in vise with wood (see Figure
50) not to scratch outside diameter of spool.
Because Loctite is applied to threaded portion of spool
end, heat outside surface of spool with industrial drier
to release Loctite.
Heat spool until spool end is easily loosened, and Figure 50
remove immediately after heating it to 200 - 250C.
If it is over heated, change spring to new one.
WARNING!
Removing antidrift valve seat, when pressure is not
fully released, or bucket is not lowered to ground, is
very dangerous. A part in the valve may spring out and
drop the bucket at the same time. Always lower bucket
to ground and fully release pressure before
disassembling.
IMPORTANT
The filter in plug assembly (47-7) is pressed into place
and can not be removed. If filter replacement is
necessary, replace it with a new plug assembly.
WARNING!
At this time, be careful not to drop spring into
passage. If valve is operated with spring in passage, a
broken piece may penetrated in main spool sliding
surface and a serious accident may occur by a
runaway or not being able to stop.
Disassembly Of Flange
1. Remove flange from spare port. Remove socket head bolt
(77, width across flats: 10 mm) and flange (76) and O-ring
(78).
2. Remove flange from boom two. Remove socket head bolt
(64, width across flats: 8 mm) and flange (56) and O-ring
(57).
Reference
Size Quantity
Number
60 6 mm 5
61 10 mm 17
62 12 mm 6
58 24 mm 1
52 27 mm
59 8 mm
Figure 51
Figure 52
Figure 53
Cleaning
Clean all parts thoroughly using a suitable cleaning fluid and dry
them with moisture free compressed air. Put them on a clean
paper or a vinyl surface for inspection.
Inspection
Inspect all parts for scratches, notches and the other defects.
1. Inspect load check seat surface of valve housing for
scratches, scores, dirt, notches and corrosion. Remove
small scratches with oilstone.
2. Inspect exterior surface of spool for scratches and notches.
Remove small scratches with oilstone.
3. Inspect all grooves and passages of sliding parts for
foreign materials.
4. Replace any springs that are damaged, heavy deformed or
worn.
5. If relief valve malfunctions, inspect it by using relief valve
procedure (see page).
6. Replace all O-rings and backup rings with new ones.
7. After disassembling cap or plug, check whether there are
paint chips around valve body hole or plug. If paint chips
penetrate into valve, they can cause malfunction or leaks
to occur.
Subassembly
Before reassembling valve housing, subassemble parts as
needed.
IMPORTANT
Be careful not to get Loctite into spool by over
applying it.
Be careful that spool operation does become
deteriorated by over torquing spool end.
Subspool (20)
1. Assemble backup ring (20-8) and O-ring (20-7) in sleeve
(20-3). Assemble backup ring (20-6) and O-ring (20-5) in
sleeve (20-2).
2. Assemble piston (20-4) in sleeve (20-3) with O-ring.
3. Assemble piston in sleeve (20-2).
IMPORTANT
Be careful not to get Loctite into spool by over
applying it.
Be careful that spool operation does become
deteriorated by over torquing spool end.
IMPORTANT
Insert spring into poppet. Large end of spring should
be facing the poppet. If spring is not inserted properly,
it can break.
IMPORTANT
When fastening flange, spring (33) should be inserted
into flange. If it is not properly installed, the spring can
be broken. When tightening socket head bolts, they
should be tightened evenly.
IMPORTANT
When fastening flange, spring (33) should be inserted
into flange. If it is not properly installed, the spring can
be broken. When tightening socket head bolts, they
should be tightened evenly.
Reassembly of Flange
1. Assemble flange for spare port. Install O-ring (78) on
flange (76), and fasten flange with socket head bolts (77).
Torque is 10.50 - 11.52 kgm (76 - 83 ft lb).
2. Assemble flange for boom two. Install O-ring (57) on valve
housing, and fasten flange (56) with socket head bolt (64).
The good surface of flange should be facing the O-ring
side. Torque is 5.91 - 6.53 kgm (43 - 47 ft lb).
IMPORTANT
When installing body assembly (47), spring (33) should
be completely installed in spring position of body
assembly.
IMPORTANT
Insert spool in hole perpendicularly. Make sure that
spool is in correct position. If it is not in correct
position, a malfunction can occur.
IMPORTANT
When assembling, be careful not to drop O-ring from
mating surface.
IMPORTANT
After reassembly is completed, recheck tightening
torque of all components. If they are not properly
tightened, an oil leak can occur. The torque values are
based on the threads being lubricated.
Figure 54
Figure 55
Figure 56
START-UP PROCEDURES
1. Before operating machine, make sure that oil passages
and hydraulic oil are clean.
2. Hydraulic oil of which annealing point is 82-113C should
be used in the hydraulic system.
3. Relief valve pressure should not be raised above specified
pressure setting.
4. The difference between main relief valve setting pressure
and over load relief valve setting pressure should not be
over 2.0 MPa.
5. Before operating machine, the hydraulic system should be
fully warmed up. If machine is operated with cold hydraulic
oil and valve, be careful of the following, to prevent spool
sticking due to heat shock.
NOTE: Do not operate main relief valve or over load
relief valve suddenly and continuously. Cycle oil
through all actuators and warmed up cold
hydraulic oil in the lines and components
uniformly.
NOTE: Slight or compound work should not be
suddenly operated at cold weather because
heat is developed partly at all the orifices.
Remote Control
Valve (Work
Lever / Joystick)
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Function
1. Neutral Position
When the lever is in neutral mode, the spool is pushed
upward by return spring. The force of balancing spring,
which determines the secondary discharge pressure, is not
transmitted to the spool. The input port is closed and the
pressure of the output port is the same as the pressure of
the tank port T.
2. Control Switch
Pressing of the push rod starts to press the balance spring,
whose force is transferred to the spool to connect the P
and T ports, transferring the pilot pressure. Output
pressure acts on the bottom of the spool and press the
spool upwards until it is balanced with the force of the
balance spring.
In short, the second pressure (output pressure) changes in
proportion to the pressing force of the balance spring.
28
24
18
25A
16 23
17
35
12 18
22 16
32 17
25 35
8 20 12
7
6
33 8
5 7
21
30
6
4 33
5
19
27 9
4
26 1
9
3 4
2 1
29
37 : 24 ~ 28
3
FG004596
Figure 1
Performance
Figure 2
Torques
FG000804
Figure 3
FG000805
Figure 4
3. Remove hex nut (23) and swash plate (22) from case.
FG000806
Figure 5
FG000807
Figure 6
FG000808
Figure 7
FG000810
Figure 8
FG000811
Figure 9
FG000812
Figure 10
FG000814
Figure 12
FG000815
Figure 13
FG000816
Figure 14
REASSEMBLY
1. Install four plugs (2) into case (1).
FG000815
Figure 16
FG000817
Figure 17
FG000814
Figure 18
FG000818
Figure 20
FG000819
Figure 21
FG000812
Figure 22
FG000820
Figure 23
5. Install spool kit assembly into case (1). (The same way is
used for four parts.)
FG000821
Figure 24
6. Assemble plug kit insert rod seal (18), O-ring (17), and
push rod (12) into plug (16) in proper order.
FG000822
Figure 25
FG000810
Figure 26
FG000811
Figure 27
FG000811
Figure 28
FG000823
Figure 29
FG000808
Figure 30
FG000807
Figure 31
10. Install wash plate (22) and hex nut (23) into case (1).
FG000806
Figure 32
FG000824
Figure 33
12. Install boot (20) and bushing (29) into case (1).
FG000825
Figure 34
FG000805
Figure 35
14. Put lead wire in bushing (29), tie it, and arrange boot.
FG000826
Figure 36
FG000827
Figure 37
FG001097
Figure 38
FG000828
Figure 39
FG000829
Figure 40
START-UP PROCEDURES
1. Start engine and set throttle at "LOW IDLE."
2. Set safety lever on "UNLOCK" position.
HAOB290L
Figure 41
ARO0470L
Figure 42
Travel Control
Valve (With
Damper)
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Theory of Operation
The damper valve is divided into two areas of operation. There
is the pressure reducing valve (a) and the damper mechanism
(b). The following hydraulic circuit is an example of a remotely
located control valve.
5
6
4
2
ARS1810L
Figure 1
Reference Reference
Description Description
Number Number
1 Remote Control Valve 4 Control Valve
2 Pilot Pump 5 Hydraulic Motor
3 Main Pump 6 Hydraulic Cylinder
40 160
SECONDARY PRESSURE (kg/cm2)
112.6
251.5
Operating Torque 91.8
46.4
7.51
Secondary Pressure
Figure 2
HB4M033L-1
Figure 3
HB4M032L-1
Figure 4
27 31 30 29 28 33
32 25,26
24
23
3
22
16 14,15
21 36
38 17
13 18
12 19
11 20
9
6
5
7
4 10
3 8
37 1 35 34 2
P T
1 2 3 4
FG003925
Figure 5
Specifications
Travel Control Valve Specification
Pilot Control
Type
(With Damper)
Torques
Part Reference
Bolt Size Tool Tightening Torque
Number
88 kgcm
26 M6 5 mm L-Wrench
(6 ft lb)
100 kgcm
30 M8 4 mm L-Wrench
(7 ft lb)
440 kgcm
32 M10 17 mm Spanner
(32 ft lb)
440 kgcm
37 M10 8 mm L-Wrench
(32 ft lb)
WARNING!
PERFORMING INSPECTION
OR MAINTENANCE
FG003015
If engine must be running while performing Figure 6
maintenance, always use extreme caution. Always
have one person in the cab at all times. Never leave the
cab with engine running.
FG003016
Figure 7
ARS1870P
Figure 8
FG000985
Figure 9
3. Remove cam shaft (29) and cover (25) from cam (27).
FG000986
Figure 10
4. Remove hex nut (32) and swash plate (31) from cam.
FG000987
Figure 11
FG000988
Figure 12
FG000989
Figure 13
FG000990
Figure 14
FG000991
Figure 15
FG000992
Figure 16
FG000993
Figure 17
FG000994
Figure 18
FG000995
Figure 19
FG000996
Figure 20
FG000997
Figure 21
FG000998
Figure 22
FG000996
Figure 23
FG000997
Figure 24
FG000998
Figure 25
FG000995
Figure 26
FG000999
Figure 27
FG001000
Figure 28
FG000994
Figure 29
FG000992
Figure 30
FG000993
Figure 31
FG000991
Figure 32
7. Assemble rod seal (23), dust seal (24), and O-ring (22) into
plug (21).
FG001001
Figure 33
8. Assemble seal (16), piston (38), steel ball (17), plate (19),
spring (18), and retaining ring (20) into push rod (14).
FG001003
Figure 35
FG001004
Figure 36
FG001005
Figure 37
FG000990
Figure 38
FG001006
Figure 39
12. Assemble cover (28) onto each body (1 and 2) and install
hex socket head bolt (26) using torque wrench.
FG001007
Figure 40
FG000989
Figure 41
FG000987
Figure 42
14. Position cam (27) on cover (25), and insert cam shaft (29)
using hammer.
FG000986
Figure 43
15. Install set screw (30) in cam (27) and tighten it using torque
wrench.
FG000985
Figure 44
FG001009
Figure 45
ARS2250P
Figure 46
FG003016
Figure 47
2. Install pedal brackets (3) and levers (4, Figure 48) on pedal
valve and install four bolts and washers (2).
3. Install rubber boots (1, Figure 48). 1
3
3
2
2
ARS2951L
Figure 48
FG003016
Figure 49
HAOB290L
Figure 50
3. Slowly push and pull both travel lever about five times
without a load to vent air from pilot lines.
HAOB903L
Figure 51
1Solenoid Valve
Assembly
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Figure 1
Reference
Description Sizes Quantity Remarks
Number
1 Block Body 95x120x240 1 1-A1079-05-0
2 Solenoid valve TF-S34-00-VDL24VDC 6 C1, C2, C3, C4, C5
3 Check Valve FD-DCP-0-A 1 C6
4 Pilot Shift Valve FD-PSS1-0005 1 C7
5 Plug PF 1/4" 3 P5, P6, H0
6 Plug PT 1/4" 1
7 Plug PT 1/8" 14
Reference
Function Operations Remarks
Number
Provides pressure and oil coming from the pilot pump
C1 Pilot cut-off for the pilot pressure supply solenoid valve to drive
each work system.
Breaker Supplies pilot pressure for the breaker valve assembly
C2
operation and the breaker pressure supply solenoid valve.
Sets low travel speed and high travel speed, of shifts
speed between both depending on the state of the
C3 High travel speed
solenoid valve operation or a signal detected in the e-
EPOS controller.
Main pressure Increases the pressure set for the main relief valve
C4
increase temporally to increase the excavation power.
Operating the C5 solenoid valve starts the Swing
Work modes
C5 Priority valve of the main control valve to improve
control
swing operation.
Figure 2
Reference Torques
Components Screw Sizes Tools
Number (kg/cm)
2 Solenoid valve UNF7/8 - 14" 200 25 Hex torque
wrench/1", socket
2-1 Coil Lock Nut UNF1/2 -20" 60 2 Hex torque wrench/19
mm, socket
3 Check Valve UNF7/8 - 14" 400 2
4 Pilot Shift Valve UNF7/8 - 14" 200 25 Hex torque wrench/1",
socket
5 PT 1/4" Plug PF 1/4 19" 250 25 Torque wrench/
19 mm, socket
6 PT 1/8" Plug Bolt PT 1/4 19" 500 Torque wrench/
6 mm, wrench socket
7 PT 1/8" Plug Bolt PT 1/8 - 28" 280 Torque wrench/
5 mm, wrench socket
Figure 3
2Breaker EPPR
Valve (Opt)
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Figure 4
Reference Reference
Description Description
Number Number
1 Solenoid 5 Pin
2 Valve casing 6 Spring
3 Sleeve 7 O-ring
4 Spool 8 O-ring
Maintenance
Used Torques
Bolt Sizes Names
(kgf.cm)
M 35 Hex bolt 450 50
M 10 Hex bolt 200 20
NPTF 1/16 Plug 90
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Fan Motor
(Vane Type)
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Figure 1
Reference Reference
Description Description
Number Number
1 End Cap (UNC) 13 Retaining Ring
2 Rotor Insert Assembly 14 Retaining Ring
3 Spring Vane 15 Shaft Seal
4 Pin-Vane Holdout 16 Sq. Section seal
5 Vane 17 Dowel Pin
6 Cam Ring 012 18 Sq. Section seal
7 Port Plate Pressure 19 Needle Bearing
8 O-ring 20 Screw
9 Housing 21 Ball
10 Ball Bearing 22 Adaptor Valve
11 Key 23 Screw
12 Shaft
General
This manual covers installation, operation, maintenance and
overhaul instructions for the single vane type hydraulic motor.
Description
It has been designed especially for severe duty applications
which require high pressure, up to 320 bar (4,600 PSI) and high
operating speed (up to 6,000 rpm).
The 12 vanes pattented cartridge allows very low noise level
whatever the speed, low torque ripple, and high efficiencies.
Single vane motor consists of five basic components :
the housing (housing and shaft seal)
the pressure plate (plate, ball, adaptor and screw)
the cartridge (camring, rotor, vanes, springs and pins)
the end cap (cap and needle bearing)
the shaft assembly (shaft, ball bearing, retaining ring
and key)
The design of the motors allows to change the cartridge, to
renew the motor or to change the displacement to suit altered
requirements for speed or torque.
Applications
The motors are designed primarily for coaxial drives which do
not impose axial or side loading on the shaft.
The motor has a stiff taper or cylindrical shaft and a high load
capacity double ball bearing, and allows direct mounting on
shaft (fan, belt drive, chain drive).
For uni-directional application, the motor may be fitted with an
internal valve which allows smooth dynamic braking, with a very
simple hydraulic circuit, without risk of motor cavitation.
These uni-directional motors may be equipped with an internal
drain.
Figure 2
Performance Data
Loads on Shaft
Max. axial load : Fa max. = 6000 N
Max. radial load : Fr max. = 5500 N
Lifetime Under Load
Figure 3
16.666
L10h (Hour) = x L10
N (RPM)
Figure 4
Mounting Flange
2 bolt special mounting, designed to make the bearing to be as
close as possible to the shaft load.
Misalignment
Axial or radial loads on shaft may be caused by misalignment of
motor and drive axles.
The mounting pad or adaptor into which the motor is installed
must be concentric with the receptor shaft within 0.15 mm (0.006
inch) TIR. This concentricity is particularly important if the motor
shaft is rigidly connected to the receptor without any flexible
coupling.
The angular alignment of the two axles must be less than 0.1.
Splined Shafts
The mating female spline should be free to float and find its own
center.
The angular alignment of two spline axes must be less than
0.05 per 25.4 radius.
The coupling spline must be lubricated with a lithium
molydisulfide grease or a similar lubricant.
The coupling must be hardened to a hardness between 27 and
45 R.C.
The female spline must conform to the Class 1 fit as described in
SAE-J498b (1971).
This is described as a Flat Root Side Fit.
Taper Shafts
The shaft and the internal ball bearing of these motors are
designed to support high axial and radial loads.
This shaft is 125/1000 taper, with M16x150 threaded end to
install a bolt and a pin.
PIPE CONNECTION
Pipe
All fluid lines, either pipe, tubing or hose, must be of adequate
size and strength to assure free flow to and from the motor. An
undersized inlet line will restrict the fluid flow to the motor and
prevent proper operation by creating turbulences and aeration.
If rigid pipe or tubing is used, the workmanship must be accurate
in order to eliminate strain on the motor housing or the fluid
connectors.
Sharp bends in lines should be eliminated whenever possible.
All system piping must be cleaned with solvent or an equivalent
cleaning agent before connecting to the motor.
Do not use galvanized pipe. Galvanized coating may flake off
after continued use.
External Drain
The externally drained motors must have a drain line connected
to the center housing drain connection of sufficient size to
prevent back pressure in excess of 3.5 bar (50 PSI), returning
direct to the reservoir below the surface of the oil as far away as
possible from the suction pipe of the pump.
It is preferable to install the center housing with the drain hole up
to facilitate the purge of the motor.
If the motor is mounted shaft up, the drain line must have a bend
above the motor to purge it and to be sure that the shaft seal is
lubricated (see drawing).
Figure 6
Fluid Cleanliness
The fluid must be cleaned before and during operation to
maintain contamination level of NAS 1638 class 8 (or ISO 18/14)
or better. Filters with 25 micron (or better, 10 100) nominal
ratings may be adequate but do not guarantee the required
cleanliness levels.
The maximum acceptable contents of water are :
0.10% for mineral base fluids, 0.05% for synthetic fluids,
crankcase oils, biodegradable fluids.
If the amount of water is higher, then it should be drained off the
circuit.
General
Internal parts of the motor are lubricated by the operating fluid
itself ; therefore, preventive maintenance is limited to keeping
the fluid in the system clean.
The system filters should be replaced frequently. When
possible, dirt should not be allowed to accumulate on the motor
or around the shaft seal. Check frequently that all
fittings and bolts are tight.
For the motor part numbers, refer to section drawing page 6.
Disassembly
1. Drain all the fluid from the motor, and thoroughly clean the
external surface.
Prepare a clean, lint free surface on which to place the
internal parts for inspection and repair. Remove the four
housing screws (20) and carefully remove the end cap (1).
Figure 7
Figure 8
CAUTION!
the cartridge and the pressure plate may go out from
the housing together, sticked by oil.
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
3. Install seal (16) on the pressure plate spigot (7). Install seal
(8) in the housing (9).
Figure 14
Figure 15
5. Install the two dowel pins (17) and two 10-24 UNC-2B
screws on the cam ring. By using the screws, insert the
cartridge into the housing, dowel pins facing the
corresponding hole on the pressure plate. Be sure the
cartridge is well seated on the pressure plate by pushing
with fingers on the vanes and the cam ring : they should
not be lower than the cam ring surface.
Figure 16
Figure 17
7. Insert the end cap in the housing, the locating hole facing
the dowel pin on the cam ring. As the cap is well inserted ,
less than 1 mm (0.04 inch) between cap and housing,
rotate the end cap to the specified porting combination.
Figure 18
Figure 19
Priming
It is important to purge the air off the circuit and the motor.
Manually, fill the motor housing with fluid, and connect the motor
to the circuit.
Start rotation in a jogging manner until a prime is picked up, and
increase the speed to 500 to 1000 rpm.
Check that there is no leakage or air suction at the flanges (inlet,
outlet, drain), neither at the shaft seal.
If the motor does not prime properly in the first minute, or
pressure can not be obtained, it should be shut down and
condition corrected.
Cold Starting
The motor should be started at low pressure and low speed until
the fluid warms up, before running at high pressure or speed.
Shaft Replacement
Disassemble the motor.
Place the housing on a clean surface, shaft up. Remove the
retaining ring (13) and extract the shaft (12) from the housing, by
pulling it straightly not to scare the shaft seal lips (15).
Visually inspect the shaft seal : if the lips are damaged, replace
the seal.
Grease the seal and the shaft seal area. Manually, insert the
shaft into the housing, and install the retaining ring.
Reassemble the motor.
Figure 20
COUPING DIMENSIONS
Figure 21
(4.3)*
(1.8)*
M
2.5
133.6
68
B
SHAFT CODE1
M DATAIL "D"
SAE"BB"-J 744(with M16?j
(SCALE 1/1)
TAPER 125/1000
22.2
6.35
6.30
38.1 23.1
D 160
KEYED
@ 2-14
C.W.
+0.13
C.C.W.
-0.13
64
3.2 4
-0.05
+0
85.9
135
0.25
25.4
?154
92
C.W. A B
C.C.W. B A
FG004904
Figure 22
Gear Pump
(Fan Cooling
Drive)
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Figure 1
Figure 2
3. Coat the sharp edges of the drive shaft with adhesive tape
and smear a clean grease on the shaft end extension to
avoid any damaging lip of the shaft seal when removing
the mounting flange.
Figure 3
Figure 4
Figure 5
Figure 6
6. Remove the shaft seal taking care not to give any damage
on the surface of shaft hole.(only when it is needed to
replace shaft seal)
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
11. Check that the pump rotate freely when the drive shaft is
turned by hand. If not a pressure plate seal may be
pinched.
Figure 20
Figure 21
Figure 22
3. Coat the sharp edges of the drive shaft with adhesive tape
and smear a clean grease on the shaft end extension to
avoid any damaging lip of the shaft seal when removing
the mounting flange.
Figure 23
Figure 24
Figure 25
6. Remove the shaft seal taking care not to give any damage
on the surface of shaft hole.
(only when it is needed to replace shaft seal)
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
Figure 36
Figure 37
Figure 38
10. Locate mounting flange while taking care not to give any
damage on the shaft seal by edge of shaft.
And tap around the mounting flange with rubber mallet.
Figure 39
Figure 40
Figure 41
Fan Cooling
Flow In-Out
Change Valve
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Figure 1
Reference Reference
Description Description
Number Number
10 Relief Valve 70 Seal Kit
20 Seal Kit 80 Check Valve : Make up
30 Coil 90 Check Valve
40 Nut 100 Seal Kit
50 O-ring 110 Socket Bolt
60 Solenoid Valve 120 Body
1Hydraulic
Schematic
(DX420LC)
Edition 1
Hydraulic Schematic
(DX420LC)
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 7
DX420LC .............................................................. 8
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
1. PUMP
2. PILOT FILTER
C/V PA 3. SOLENOID VALVE (CUT OFF)
4. ACCUMULATOR
SH
Dr Pi Pi N Am Am N Pi Pi Dr OPTION APPLIED PART 5. SOLENOID VALVE(PACKAGE)
6. JOYSTICK VALVE(L)
ONE-WAY ; JOYSTICK BOTTON 24 25 26 7. JOYSTICK VALVE(R)
B FORWARD
A FORWARD
Au
Dr
PG 8. PEDAL VALVE
ONE-WAY ; JOYSTICK BOTTON or PEDAL 24 25 29 30 26 9. SHUTTLE VALVE
S 10. CONTROL VALVE
q2 min.
q2 min.
ONE/TWO-WAY 24 25 26 27 28 29 30 26
T 11. BOOM CYLINDER
BACKWARD B
BACKWARD A
q1
q1
max.
max.
ROTATING ; JOYSTICK SWITCH 31 32 33 34 D 12. ARM CYLINDER
GB GA 13. BUCKET CYLINDER
1 2 Pi Dr 4 3
14 ROTATING ; PEDAL 31 32 34 35 14. SWING DEVICE
Dr Bm Bm Dr 15. TRAVEL DEVICE
B RIGHT Mu LEFT A
15 TRAVEL MOTOR (L) 16 TRAVEL MOTOR (R) 15 QUICK COUPLER 36 16. CENTER JOINT
17. RESTRICTION VALVE
18. RESTRICTION VALVE
19. OIL COOLER
20. FULL FLOW FILTER
21. AIR BREATHER
22. HYDRAULIC TANK
a A B
DR2 DR3 DR4 Valve;control
23. LOCK VALVE
V2 T E 24. PROPORTIONAL VALVE
34
DR1
23
25. HIGH PRESS. RETURN FILTER
11 11 10 12
Pi1 of Pump C2 P 26. ONE/TWO-WAY SELECT V/V 1
Pi2 of Pump from #32
ps2
T2 T1 T3
ps1 27. ONE/TWO-WAY SELECT V/V 2
O 28. STOP VALVE
Pi1 E
P 29. OPT. PEDAL VALVE 1
T 30. SHUTTLE VALVE for OPT.
C2 C2 pc1 T 31. PTO
E E 36
32. ADDITIONAL GEAR PUMP
A5 b
33. SOL. V/V for ROTATING
34. ROTATING VALVE
Pi1 Pi1 pb9 ARM2 ARM1 B5
2 2 4 2
35. OPT. PEDAL VALVE 2
T T P 36. QUICK CLAMP VALVE
V2 V2 pb5
pa9 39. SOL. VLAVE E3C
1 1 3 1
23 23
pc2
pa5
A8 T
pc3
8
B8
B4 T P
35 T P T P
29
13 pb8 BOOM1 BOOM2 pb4
pa4 L.H
pa8 B3
B7
A3
A7
BKT SWING OPT. PEDAL 1
L.TRAVEL R.TRAVEL
OPT. PEDAL 1
pb3
27 2 1 2 1 4 3 2 1
pb7 CW CCW FORWARD FORWARD
pa7
pa3 28 BACKWARD BACKWARD
B6 A2 T
OPT R.H
A6 pb2
TR(L) 26
P4
pb6 33
pa2
B1
pa6 P1
A1
TR(R) from JOYSTICK(L) SWITCH
pb1
25
pa1
VALVE(LEFT) VALVE(RIGHT) 6 7
pr PA PT T P T P
P2 P3 PH PP P1
PH of Sol. v/v 2 2
19k
SWING MOTOR SH 19k 1 3 1 3
4 4
SWING ARM BOOM BUCKET
1 3 2 4 2 4 1 3
19 LEFT DUMP DOWN CROWD
17 UP DUMP
RIGHT CROWD
24
A1 A2 A3 A4 A5 A6 A7 A8 30
18 9
A9 A10
ps1
B1 S1 B2 B3 B5 B6 B7 B8 B9 S2 B10
Pi1
Hammer Operating
B4
21 A1 A2 PH pc3 pa3 pb3 pb5 pb8 pa7 pa8 pb7 pb2
Psv a4
Safety Cut-off
Swing Priority
pa2
Pressure up
from PRESS. SWITCH ON #30
4
high speed
SOL. V/V P3 pa5
500k
a2 500k Travel 5
a1
20 (FRONT) SENSOR SENSOR (REAR) pc1 pc2 Pi
P2 HO TR2 PH SP
1
10u T
P1 ACC
22 G1 Opt. Pedal
P Hammer Select
177u Operating A B
Pi1 Pi2
ps1 ps2 A
T T
2 P1
P4 P5 P3
40k 3
ENGINE SHUTTLE VALVE S1
B1
a3
1. PUMP
2. PILOT FILTER
C/V PA 3. SOLENOID VALVE (CUT OFF)
4. ACCUMULATOR
SH
Dr Pi Pi N Am Am N Pi Pi Dr OPTION APPLIED PART 5. SOLENOID VALVE(PACKAGE)
6. JOYSTICK VALVE(L)
ONE-WAY ; JOYSTICK BOTTON 24 25 26 7. JOYSTICK VALVE(R)
B FORWARD
A FORWARD
Au
Dr
PG 8. PEDAL VALVE
ONE-WAY ; JOYSTICK BOTTON or PEDAL 24 25 29 30 26 9. SHUTTLE VALVE
S 10. CONTROL VALVE
q2 min.
q2 min.
ONE/TWO-WAY 24 25 26 27 28 29 30 26
T 11. BOOM CYLINDER
BACKWARD B
BACKWARD A
q1
q1
max.
max.
pa4 L.H
pa8 B3
B7
A3
A7
BKT SWING OPT. PEDAL 1
L.TRAVEL R.TRAVEL
OPT. PEDAL 1
pb3 27 2 1 2 1 4 3 2 1
pb7 CW CCW FORWARD FORWARD
pa7
pa3 28 BACKWARD BACKWARD
B6 A2 T
OPT R.H
A6 pb2
TR(L) 26
P4
pb6 33
pa2
B1
pa6 P1
A1
TR(R) from JOYSTICK(L) SWITCH
pb1
25
pa1
VALVE(LEFT) VALVE(RIGHT) 6 7
pr PA PT T P T P
P2 P3 PH PP P1
PH of Sol. v/v 2 2
19k
SWING MOTOR SH 19k 1 3 1 3
4 4
SWING ARM BOOM BUCKET
1 3 2 4 2 4 1 3
19 LEFT DUMP DOWN CROWD
17 UP DUMP
RIGHT CROWD
24
A1 A2 A3 A4 A5 A6 A7 A8 30
18 9
A9 A10
ps1
B1 S1 B2 B3 B5 B6 B7 B8 B9 S2 B10
Pi1
Hammer Operating
B4
21 A1 A2 PH pc3 pa3 pb3 pb5 pb8 pa7 pa8 pb7 pb2
Psv a4
Safety Cut-off
Swing Priority
pa2
from PRESS. SWITCH ON #30
Pressure up
4
high speed
a1 a2
20 (FRONT) SENSOR SENSOR (REAR) pc1 pc2 Pi
P2 HO TR2 PH SP
1
10u T
P1 ACC
22 G1 Opt. Pedal
P Hammer Select
177u Operating A B
Pi1 Pi2
ps1 ps2 A
T T
2 P1
P4 P5 P3
40k 3
ENGINE SHUTTLE VALVE S1
B1
a3
FG001424
Figure 1
13
Dr Pi Pi N Am Am N Pi Pi Dr
to X1(A2) of pump
to X1(A1) of pump
(through A of EPPR valve)
ps2 T4 T2 T3 ps1
B FORWARD
A FORWARD
T1
Au
Dr
q2 min.
q2 min.
Pi1 of Arm Lock v/v
(opt.) pa10 pa11
BACKWARD B
BACKWARD A
q1
q1
max.
max.
11 DR1'
11 BC BC GB DR1 GA
1 2 Pi Dr 4 3
ARM LOCK pc1
Dr Bm Bm Dr
B RIGHT B5 Mu LEFT A
15 TRAVEL MOTOR (L) 16 TRAVEL MOTOR (R) 15
B9
A9
A5
pb9 ARM2 ARM1
C2 C2 pb5
360k@20L REGEN.
E E
pa9 pa5
Pi1 B8 V2 T
Pi1 DR1 B4
11 T 11 T 10 23
V2 V2 Pi2 of Pump Pi1 of Pump
A8 ps2 ps1 A4
pb8
BUCKET T2 T1 T3 OPTION
26 pb4
26 pa8
360k@20L
DR2'
250k@20L
C2 C2 pc1
DR2 pa4
38 E E
pc2 BOOM LOCK A5 A3
B3
A P A7
Pi1 Pi1 pb9 ARM2 ARM1 B5
T T pb3 P
BV2 V2 B7 pb5
B 250kg/cm 2
pa9 BOOM2
23 23 pb7 BOOM1 pa3
pc2 B2
T
P3 of 05 pa5
pa7
A8 360k@20L pc3
A2
B8
B6 SWING
pb2
B4
A6
13 pb8 TRAVEL
BOOM1 BOOM2 pb4 DR3
pb6
Valve;control a A B FP pa4
pa2
pa8 B3 pc6
36 B7
pa6 B1
A3
A7
BKT
T/STRAIGHT SWING
pb3 A1
pb7 TRAVEL
P pb1
pa3
pa7
from #34 pi4 pa1
Pi B2
80kg/cm 22 B6 A2 pr1
OPT
A6 MAIN RELIEF2 pb2
TR(L) 22
350Kg/cm @150L/min(PH => )
2
pb6
LEFT 22
320Kg/cm @150L/min(PH
25Kg/cm
25Kg/cm
< ) 22
P4 RIGHT
T pa2
PH PA PP PT
P2 P3 P1 B1 P1
100kg/cm 22 pa6 10
b 19k 19k
A1
from #37 from #37
TR(R)
pb1
25
pa1
A B
T VALVE(LEFT) VALVE(RIGHT)
A3 A3
P2 P3 pr PH PA PP PT P1
35
PH of Sol. v/v
19k 27
SWING MOTOR SH 19k
from #05
to #24
P1 ps1
CC C 17 to #36 P
40k@24L
from 17
JOYSTICK(L) SWITCH 19 23 34
Pcr=2.0k
X1
21 24
ps2
19
18 Pcr=2.0k ps1 R3 R1
10u 18 01
10u X1 2
0.5k
0.5k 0.05k
0.05k
11 4
Pi1
21
Cut-off
A1 Psv a4 A2
Safety Cut-off
Safety Cut-off
from PRESS. SWITCH ON #30
A1 4
500k A1
500k
a2
10u 20
+__ 0.2k ENGINE a1 Opt.
Opt. Pedal
Safety
10u 1.5k +
1.5k 0.2k (FRONT) SENSOR SENSOR (REAR) Hammer
Hammer Pedal
Operating
Operating P2
1 Select
Select P2
1.5k
1.5k 1.5k
1.5k DV11
DV11 ACC
ACC P2
10u T
280HP/2000rpm
280HP/2000rpm S
S P1 ACC
177u
177u 140kgm/1300rpm
140kgm/1300rpm TT TT
22 G1
P
177u Pi1 Pi2
ps1 A2 ps2 A
A2
22 2 P1
20 P4
40k 3
ENGINE P1
P1
P1
B1 P1
M3
M3 a3 P
P
P0
P0
Dr1 B3 Dr3 ps1
ps1 A3
X1
X1 from SELECT
from SWITCH
SELECT SWITCH
31
R4
R4 R2
R2 32 Hammer
Hammer Select
Select
5
to #34 P
Shear Select
Shear Select
Figure 2
W
ONE-WAYC2; JOYSTICK BOTTON W
24 25 26 8. PEDAL VALVE
7. JOYSTICK VALVE(R)
Au 9. CONNECTOR
Dr
PG 8. PEDAL10. VALVE
CONTROL VALVE
ONE-WAY ; JOYSTICK BOTTON or PEDAL T 165kg/cm 2 24 25B 29 30 26 9. SHUTTLE
S 11. BOOM VALVE
CYLINDER
S 10. T 12.
CONTROL ARMVALVE
CYLINDER
pa9 of c/v Pi1 E
ONE/TWO-WAY 24 25 26 27 28 29 30 26 D 13. BUCKET CYLINDER
pa11 MB T 11. BOOM CYLINDER
14. SWING DEVICE
DR1' ROTATING ; JOYSTICK SWITCH 31 32 33 34 P D 12. ARM 15.
CYLINDER
TRAVEL DEVICE
BC GB DR1 GA LEFT 13. BUCKET CYLINDER
16. CENTER JOINT
pc1 14 ROTATING
12 ; PEDAL 31 32 34 35 14. SWING17. DEVICE
RESTRICTION VALVE
15. TRAVELRESTRICTION
18. DEVICE VALVE
B RIGHT B5 Mu LEFT A 19. OIL COOLER
QUICK COUPLER 36 16. CENTER JOINT
20. FULL FLOW FILTER
L.H R.H Forward 17. RESTRICTION VALVE
21. AIR BREATHER
VA
18. RESTRICTION VALVE
REG
A5 22. HYDRAULIC TANK
ARM1 23. GEAR PUMP
19. OIL COOLER
30 VB
pb5 29 Backward
20. FULL24. FAN DRIVE SUPPLY VAKVE
FLOW FILTER
25. FAN DRIVE MOTOR
21. AIR BREATHER
pa5 D 26. LOCK VALVE
MA
15 22. HYDRAULIC TANK VALVE
27. PROPORTIONAL
a A B
Valve;control
23. LOCK28.VALVE
HIGH PRESS. RETURN FILTER
29. ONE/TWO-WAY
24. PROPORTIONAL VALVE SELECT V/V 1
V2 T E MB
P34 30. ONE/TWO-WAY SELECT V/V 2
B4
23
25. HIGH31.
PRESS. RETURN FILTER
12 O
C2 P
RIGHT
26. ONE/TWO-WAY SELECT
P 32. OPT. PEDAL VALVE 1
V/V 1
A4 from #32
OPTION 220kg/cm 2 27. ONE/TWO-WAY
T 33. SHUTTLE SELECT
VALVE forV/V
OPT.2
O 28. STOP34.VALVE
ADDITIONAL GEAR PUMP
pb4 P 29. OPT. 35.
Pi1 E PEDAL
SOL. VALVE 1
V/V/ for ROTATING
T 30. SHUTTLE VALVE for OPT.
36. ROTATING VALVE
31. PTO 37. OPT. PEDAL VALVE 2
Forward
pc1 T VB
pa4 38. QUICK CLAMP VALVE
REG
36
32. ADDITIONAL GEAR PUMP
39. SOL. V/V for 2-PUMP
A5 A3 28 VA b
33. SOL. 40.
V/VPATTERN
for ROTATING
Backward CHANGE VALVE
B3 421350 34. ROTATING VALVE
CENTER
B5
JOINT 2 2 4 2
35. OPT. PEDAL VALVE 2
pb3 P
421350 MA
36. QUICK CLAMP VALVE
pb5
BOOM2 B LEFT Mu RIGHT A 39. SOL. VLAVE E3C
1 2 1 2 3 4 1 2
pa3
B2 GA GB
22
pa5 270Kg/cm
A2 T
pc3 1 1 3 1
SWING 8
pb2 35 29
B4 T P T P T P
Dr
pb4 DR3
37 8 32
T P T P T P
Am
Am
pa4 L.H
pa2
B3 pc6
B1
14
A3 OPT. PEDAL 1 OPT. PEDAL 1
PG 13k 27 L.TRAVEL R.TRAVEL
pb3 A1 2 2 1 3 2
TRAVEL CW CCW
1
FORWARD
4
FORWARD
1
pb1
pa3 SH 28 BACKWARD BACKWARD
pa1 OPT. PEDAL 1 OPT. PEDAL 1
pi4 A B pb6 L.TRAVEL
pa6 pb1 pa1 R.TRAVEL
B2
2 1 2 1 4 3 2 1
A2 pr1 T
CW CCW FORWARD FORWARD
R.H
pb2 BACKWARD BACKWARD
26 #35 B
P4 RIGHT 33
#35 A
pb6 pa6 pb1 pa1
pa2
P1
B1
P1
A1
from JOYSTICK(L) SWITCH
25 T P T P
pb1
pa1
2 2
1 3 1 3
6 7
pa10 4 4
A SWING
T P ARM T BOOM
P BUCKET
1 3 2 4 22 44 3 1
T 2 DOWN
DOWN UP
UP 2
LEFT DUMP DUMP
1 3 RIGHT CROWD 1 CROWD
3
A1 C1
A1 C1
4 B1 D1
B1 D1 40 4
SWING ARM BOOM BUCKET
39 1 3 2 4 2 4 1 3
11
ISO
ISO A2 C2 C2 BHL
LEFT DUMP DOWN B2 D2 CROWD BHL
A2
B2 D2
RIGHT CROWD UP DUMP
P
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10
A1 A2 A3 A4 A5 A6 A7 A8 30
9
A9 A10
B1 B2 B3 B5 B6 B7 B8 B9 S1 B10
11 4 B1 S1 B2 B3 B5 B4B6
B4
B7 B8 B9 S2 B10
Operating
Hammer Operating
pa4 pb4
Hammer Operating
B4
pa5
pb2 pb3 pa2 pa5 pb7 pa8 pa7 pb8
PH PH pc3 pc6 pa3 pb5 pb8 pa7 pa8 pb7 pb2
Cut-off
Priority
Safety Cut-off
Swing Priority
Safety Cut-off
Swing Priority
pa2
up
Pressure up
up
speed
high speed
4
speed
pa5
SOL. V/V P3 pa9 pb5 pa3 33
Pressure
5
Pressure
Hammer
Travel
Travel
Safety
Travel
pc1 pc2 Pi
Swing
high
high
P2 HO TR2 PH SP
ACC
ACC P2
P2 TR2
TR2 PH
PH HO
HO SP
SP
T
P1 ACC
A
A
TT LH-HI
LH-HI
(CLOSE)
RH-HI
RH-HI
(CLOSE) (OPEN)
G1 Opt. Pedal (OPEN)
P Hammer Select
Operating A B B
B
A
T T
P1 TT
P4 P5 P3
P1 3 SHUTTLE VALVE S1
P1
P0 P6
P6 P5
P5 P3
P3 P4
P4
P0
from JOYSTICK(R) BOTTON
P1 P1
Hammer Select C/V pa7
C/V pa7
5 #35 P1
#35 P1
from SELECT SWITCH
P1
P1 from JOYSTICK(R) SWITCH
from JOYSTICK(R)
from JOYSTICK(R) BOTTON
BOTTON
Hammer Select Shear Select
Hammer Select
Select from JOYSTICK(R)
from JOYSTICK(R) SWITCH
SWITCH
Hammer Shear Select
Shear Select
Shear Select
DX300LC
DX420LC
FG001415
FG005206
Electrical
System
Edition 1
Electrical System
Safety Precautions ............................................... 7
Applicable Models ................................................ 7
Introduction ........................................................... 9
Electrical Supply System .................................... 10
Engine Starting Circuit ........................................ 12
Start Operation .............................................................. 12
After Start ...................................................................... 14
Engine Preheating System ................................. 16
Engine Stop ........................................................ 18
Charging System ................................................ 20
Monitoring System .............................................. 21
Instrument Panel ........................................................... 22
Monitoring System Schematic....................................... 24
Operation ............................................................ 26
Instruments.................................................................... 26
Warning and Indicator Lights .............................. 28
Indication of Warning Lights .......................................... 28
Indication of Multifunction Gauge and Letter Information
Area29
Initial Operation .................................................. 31
Mode Selector Switch ......................................... 31
Graphic Information Area Display....................... 32
Overview ....................................................................... 32
Main Menus for the Graphic Display Area..................... 33
Menu Selector Buttons .................................................. 33
Menu Selector Buttons .................................................. 33
Main Menu .......................................................... 34
Language ...................................................................... 34
Set Clock ....................................................................... 35
Filter/Oil Info .................................................................. 35
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Symbol Color
W White
G Green
Or Orange
B Black
L Blue
Lg Light green
R Red
Gr Gray
P Pink
Y Yellow
Br Brown
V Violet
6
3
8
4 2
B A
BR
E
- + - +
12V 150AH 12V 150AH
R(I) B(B+) P(R)
STARTER SWITCH CONNECTION
1
PST TML B BR R1 R2 C ACC
OFF SG
ON 7
START
R
F
E
FG001476
Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode
Start Operation
When the starter switch is turned to the "START" position, the
"S" and "E" terminals of the starter controller (7) are connected.
At this time the contacts in the starter relay (8) are closed by the
current flow from the battery (1) fusible link (3) fuse box (6)
"B" terminal of starter switch (5) "C" terminal of starter
switch (5) "30" terminal of starter relay (12) - "87a" terminal
"C" terminal of starter relay (8) - "D" terminal "S" terminal of
starter controller (7) - "E" terminal ground.
When the contact point "B" and "PP" of starter relay (8) are
connected, the pinion gear of the starter (9) is pushed forward
and makes contact with the ring gear of the flywheel and the
internal contacts of the starter are connected. The current flows
from the battery (1) "A" terminal of the battery relay (2) "B"
terminal of the battery relay (2, Figure 2) "30" terminal of the
starter (9). The starter motor is rotated and the engine is started.
If the instrument panel has the password function activated ,
input number should match the set number, otherwise the start
circuit closes and the engine does not start.
85 86 ACC
C
B 5
R2 BR
12
R1
3
CN1-15
6
4
B A
CN2-1
BR
13 E
11
R(I) B(B+) P(R) 2
STARTER SWITCH CONNECTION
PST TML B BR R1 R2 C ACC
OFF SG
- + - +
ON 10
START R
F 1
E
FG004533
Figure 2 STARTER CIRCUIT (1) - WHILE STARTING
Reference Reference
Description Description
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
3 Fusible Link 10 Alternator
4 Circuit Breaker 11 Diode
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 e-EPOS Controller
7 Starter Controller
7 8 9
N S D PP 50
P C B 30
B E
11
A
87a
30
87
85 86 ACC
C
B 5
R2 BR
12
R1
3
CN1-15
6
4
B A
CN2-1
BR
13 E
11
R(I) B(B+)
STARTER SWITCH CONNECTION
P(R) 2
PST TML B BR R1 R2 C ACC
OFF SG
- + - +
ON 10
START R
F 1
E
FG004666
Figure 3 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START
Reference Reference
Description Description
Number Number
1 Battery 8 Starter Relay
2 Battery Relay 9 Starter
3 Fusible Link 10 Alternator
4 Circuit Breaker 11 Diode
5 Starter Switch 12 Starter Relay 2
6 Fuse Box 13 e-EPOS Controller
7 Starter Controller
6
9 4
CN6-1,2 2
ACC C B A
PREHEAT CN7-4,5,6
L5 B 5
R2 BR
R1 BR E
10
CN4-4,5,6
CN2-1
- + - +
11 C B 1
- +
7 200A
STARTER SWITCH CONNECTION
1-33,34,35 8 TML
1-39 PST B BR R1 R2 C ACC
(1) (2)
1-16 D OFF
H + -
1-04 ON
START
12
FG001478
Figure 4 ENGINE PREHEAT CIRCUIT
Reference Reference
Description Description
Number Number
1 Battery 7 Preheat Relay
2 Battery Relay 8 Air Heater
3 Fusible Link 9 Preheat Indicator Light
4 Circuit Breaker 10 Diode
5 Starter Switch 11 e-EPOS Controller
6 Fuse Box 12 Engine Controller
In the event that the engine can be shut down using the starter
switch (5), an emergency stop switch (10) is provided to shut O I
down engine. To activate the emergancy stop switch, move it to
the "I" (EMERGENCY STOP) position.
The emergency stop switch (10) is in its "O" (OFF) position
during normal operation. The switch must be moved and held in
the "I" (EMERGENCY STOP) position until the engine stops.
When released it will automatically move back to the "O" (OFF)
position.
FG001344
Figure 5 ENGINE EMERGENCY STOP
SWITCH
8
6
0.5G
3
ACC C
10 B 5
R2
1-19 2 3 BR
4 2
R1 B A
1-45
1-39 BR
E
7
9
- + - +
1
FG001473
Figure 6 ENGINE STOP CIRCUIT
Reference Reference
Description Description
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 7 Diode
3 Fusible Link 8 Engine Controller
4 Circuit Breaker 9 Injector Solenoid
5 Starter Switch 10 Emergency Stop Switch
ACC C
B
R2
5
BR
0.5G
R1
6
3
8
4 2
B A
BR
E
- + - +
R(I) B(B+) P(R) 12V 150AH 12V 150AH
STARTER SWITCH CONNECTION
1
PST TML B BR R1 R2 C ACC
OFF SG
ON 7
START
R
F
E
FG001474
Figure 7 CHARGING CIRCUIT
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode
1
+ 2
-
5 7
8
4 R
CHECK
3 9
E F
C H C H
10
E/G SPEED 1700 RPM
6
POWER
AUTO
1 2 3 4
ESC
11
5 6 7 8
13
12
FG000547
Figure 8
Reference Reference
Description Description
Number Number
1 Instrument Panel 8 Warning Buzzer
2 Battery Pump Discharge Pressure
9
3 Light Switch Sensor
4 Return Filter Switch Hydraulic Oil Temperature
10
Sensor
5 Pilot Filter Switch
11 Fuel Sensor
6 e-EPOS Controller
12 Air Cleaner Indicator
7 Alternator
13 Engine Controller
7 8 9 10 11 12
5 CHECK
1
3
E F
4
2
C H C H
19
6 5 4 3 2 1 8 7 6 5 4 3 2 1
13
12 11 10 9 8 7 16 15 14 13 12 11 10 9
POWER
AUTO
1 2 3 4 (CN7) (CN6)
ESC
20
14 5 6 7 8
16 18
FG000548
Figure 9
When the engine starter switch is turned to the "I" (ON) position,
all gauge bands, switch/button indicator lights and indicator/
warning lights will turn "ON" and the alarm buzzer will sound
about two seconds.
During this functional check, a LOGO will appear on the multi
function gauge in the graphic information area.
19
CN6-1
3
CN6-3
ILL.
CN6-2 +
CN6-12 -
L1
L2 CN6-11
2
17
L3 4
L4 R2 B 16
B
CN6-9
L5
CN6-10 BR
L6 14
E
1-35
CN3-7
1-34 1
2
CN3-8 8
1-33
3
1-53
4 CN3-9
1-52
20
1-51
5 CN3-10 7
6
1-29 (Preheat)
14
CN5-2
R(I) CN2-14
13
FG001472
Figure 10
Instruments
Sensor Specification
Function Display
Input Terminal Input Specification
Blue
Coolant ECU-CAN
61C 102C
Temperature Communication
41C 107C
C H
White Red
FG000550
Blue
50 l/min 615 mA
220 308
130 180
280 50 l/min 519 mA
(Output
100 150 50 l/min 482 mA
Terminal)
Flow 80
100 l/min 409 mA
Adjusting 50 CN1-19
50 (Default Set)
CN1-20
50 220 l/min 335 mA
(None)
FG005199 308 l/min 300 mA
N = 162 f / 60
ECU-CAN N = Engine speed (rpm)
Tachometer E/G SPEED 1700 RPM Communication
f = Frequency of engine
speed sensor (Hz)
FG000049
FG000050
Main pump
discharge CN3-1
pressure FRONT PUMP 320 BAR
CN3-2
(front pump)
V = 0.00816 x P + 1.0
FG000051
V: Sensor output voltage (V)
P: Displayed pressure (Bar)
Main pump
discharge CN3-3
pressure REAR PUMP 313 BAR
CN3-4
(rear pump)
FG000052
It lights in case of no
charge [voltage of
Normally, it lights
"R(I)" terminal is
when starting engine
Charge CN2 - 14 below 12 1V] or
and is out after engine
overcharge [voltage
starts.
of "R(I)" terminal is
HAOA610L above 33(V)].
FG000045
Preheating period
depends on coolant
It lights during temperature.
preheating ("CN5-2"
terminal voltage is No preheating at
Preheating CN5-2 below 2V) and turns above 10C
"OFF" after 10 sec preheating at
completion of 5C
HAOA639L preheating.
20 sec preheating at
below 0C
HB4O2003
Input
Description Symbol Operation Remarks
Terminal
FG000056
FG000057
FG000053
FG000554
FG001470
FG001471
e-EPOS Output
Output Check
(Operation Electromagnetic
Operation Mode Proportional Pressure Swing Priority 7-Segment
mode display
LED) Reducing Valve (E.P.P.R Solenoid Valve Display
Valve) Current (mA)
No-load: 150 20mA
Power Mode ON Load: Variable output - 9x
Power (Max. current: 400 20mA)
Mode No-load: 400 20mA
Standard Mode OFF Load: Variable output - 7x
(Max. current: 600 60mA)
Work Trenching Mode OFF - ON x2
Mode Digging Mode ON - OFF x0
Overview
Many kinds of condition of machine are displayed on the letter
information display department. The information display
department is divided into two menus. One is main menu for
user and the other is special menu for specialist. These menus
can be moved from normal display mode by the combination of
selector buttons.
CHECK
5
E F
C H C H
POWER 4
AUTO
1 2 3 4
ESC
3
5 6 7 8
2
FG000557
Figure 11
Language
MAIN MENU
Put the cursor on Language in the main menu and put the Enter
1. Language
Button ( , 3 on Figure 11) and the language select view
appears. 2. Set Clock
The default language is Korean, but it will memorize and use the
3. Filter / Oil Info
newly set language. 4. Adjust Display
Use the Up Arrow Button ( , 1 on Figure 11) or Down Arrow
5. Set Password
Button ( , 2 on Figure 11) to move cursor to a language to be : UP : DOWN : SELECT
selected on the Language Select display and press the Enter FG000072
Button ( , 3 on Figure 11) and the selected language is Figure 13
indicated in the right bottom of the screen.
: UP : DOWN : SELECT
FG000783
Figure 14
SET CLOCK
0 6 :0 5
2004 06/29
: + : : MOVE
FG000076
Figure 16
Filter/Oil Info
MAIN MENU
This mode displays total operating hours of filters and oils.
1. Language
After changing the filter and oil, reset the operating hour and 2. Set Clock
then the operating hours until the next service interval can be
easily checked. 3. Filter / Oil Info
4. Adjust Display
5. Set Password
: UP : DOWN : SELECT
FG000077
Figure 17
1. Fuel Filter
Hrs : 0025
: UP : DOWN : RESET
FG000078
Figure 18
Adjust Display
MAIN MENU
Pressing the Enter Button ( , 3 on Figure 11) in the main
1. Language
menu after putting cursor on Adjust Display brings Adjust
Display. 2. Set Clock
Screen brightness can be adjusted using the Up Arrow Button
3. Filter / Oil Info
( , 1 on Figure 11) or the Down Arrow Button ( , 2 on Figure 4. Adjust Display
11). 5. Set Password
The default brightness is set to 50%. : UP : DOWN : SELECT
FG000080
Figure 20
Adjust Display
50%
+
LCD TEST
LCD TEST
LCD TEST
: + :
FG000081
Figure 21
Entering/Accessing Menus
1 4
When normal mode screen is displayed, if the enter button ( ,
3) and escape button (ESC, 4) are pressed simultaneously for
POWER
more than 3 seconds, normal mode screen (Figure 24) will be AUTO
changed to special menu screen (Figure 25). 1 2 3 4
ESC
5 6 7 8
2 3
FG001402
Figure 23
Submenu Selections
: UP : DOWN Page:3/3
FG003928
Figure 28
Menu Select
DIGITAL OUTPUT STATE
1. Relief Press. Up S/V :
2. High Speed S/V :
3. Swing Priority S/V :
4. Reverse Fan S/V :
5. Starter Relay :
6. Afterheat Relay : N.A
: UP : DOWN Page:1/1
FG004979
Figure 30
Failure Information
1. Entering Sub-menus: When a cursor is located in "Failure SPECIAL MENU
Info" of special menu screen press enter button ( , 3 on 1. Machine Info
Figure 23) and "Failure Info" screen is displayed.
2. Exiting Sub-menus: If escape button (ESC, 4 on Figure 23) 2. Failure Info
is pressed for more than 1 second, this information screen
will be returned to previous screen. 3. Operating Hrs
: UP : DOWN : SELECT
FG000563
Figure 31
* Real-time Failure:
Current status of failure is displayed. FA I L U R E I N F O
* Failure Log:
Memorized record of past failure is displayed.
1. Realtime Fail
* Delete Fail Log: 2. Failure Log
This mode is used to delete all of the
memorized record of past failure.
3. Delete Fail Log
: UP : DOWN : SELECT
FG000564
Figure 32
: Yes ESC: No
FG000568
Figure 36
D E LETE D !!!
: Yes ESC: No
FG000569
Figure 37
: Yes ESC: No
FG000570
Figure 38
FMI 0 Above normal range (DATA VALID but ABOVE NORMAL OPERATIONAL RANGE)
FMI 1 Below normal range (DATA VALID but BELOW NORMAL OPERATIONAL RANGE)
FMI 2 Incorrect signal (DATA ERRATIC, INTERMITTENT OR INCORRECT)
FMI 3 Voltage above normal (VOLTAGE ABOVE NORMAL OR SHORTED TO HIGH SOURCE)
FMI 4 Voltage below normal (VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE)
FMI 5 Current below normal (CURRENT BELOW NORMAL OR OPEN CIRCUIT)
FMI 6 Current above normal (CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT)
FMI 8 Abnormal signal (ABNORMAL FREQUENCY OR PULSE WIDTH OR PERIOD)
FMI 11 Failure mode not identifiable (ROOT CAUSE NOT KNOWN - Malfunction)
FMI 31 NOT AVAILABLE OR CONDITION EXISTS
Reset Hours
: UP : DOWN : SELECT
FG000572
Figure 40
: UP : DOWN : SELECT
FG000573
Figure 41
1. Power Mode 2. Trenching Mode 3. Auto Idle 4. Travel Speed 1st, 2nd
OPERATING HOURS
6. Coolant Temp. [ C]
40 : 00003 Hr
41 - 60 : 00005 Hr
61 - 85 : 00000 Hr
86 - 95 : 00000 Hr
96 - 105 : 00007 Hr
106 : 00001 Hr
: UP : DOWN Page:3/3
FG000575
Figure 43
: UP : DOWN : Yes
FG000578
Figure 44
ENTER PASSWD
: Yes ESC: No
FG000576
Figure 46
DELETED!!!
: Yes ESC: No
FG000577
Figure 47
: Yes ESC: No
FG001086
Figure 48
16
6 6
7 7 11 12 14
8
8
13
15
E/G
4 4 5
3
9 10
Work Mode
Auto Idle
Machine Info
2
CHECK
E F
C H C H
23 1
POWER
2
AUTO
3 4
ESC
5 6 7 8
R UP
WE
PO
1
17 21 19 18 22 20
FG000795
Figure 49
6 6
E/G
5
4 4
3
10
2
1
POWER
AUTO
1 2 3 4
ESC
17 5 6 7 8
23 22
FG000796
Figure 50
Reference Reference
Description Description
Number Number
Instrument Panel (Power Mode 10 Electromagnetic Proportional
1
Selector Switch) Pressure Reducing Valve (Mode
2 e-EPOS Controller Control)
3 Engine Controller (ECU) 17 Engine Control Dial
4 Main Pump 22 Aux Mode Switch
5 Aux Pump 23 Aux Mode Resistor
6 Control Valve
1. Power Mode
This mode should be selected for high speed work. In this
mode the engine output is most efficiently utilized due to
the discharged oil volume being controlled based on the
equivalent horsepower curve at various loaded pressures.
The e-EPOS controller compares the target engine speed
with the actual engine speed and controls the signal to the
E.P.P.R. (Electromagnetic Proportional Pressure
Reducing) valve which in turn varies the pump output
quantity.
If the load increases, the engine speed will fall below the
rated speed. When this occurs, the controller senses this ARO0260L
decrease and immediately reduces the pump discharge Figure 51
volume to maintain the engine speed at the rated level.
On the other hand, if the load is decreased the controller
increases the discharge volume of the pump to maintain
the engine speed at the rated level.
By repeating these control operations, the engine speed is
maintained at the rated speed so that maximum power can
be generated.
In Power Mode, the e-EPOS controller receives engine
speed signals from the engine control dial and the engine
controller (ECU) and converts it to an operating signal
current and is then transferred to the pump's E.P.P.R
valve. At this time the E.P.P.R. valve converts the electric
signal to the corresponding control pressure and sends it
to the two pumps, adjusting the pump discharge volume to
the desired level.
B D
FG000580
Figure 52
Reference Reference
Description Description
Number Number
A Engine Horsepower (hp) D Pump Discharge Pressure (kg/
B Engine Speed (rpm) cm2)
C Pump Discharge Volume (lpm)
A C
B D
FG000581
Figure 53
Reference Reference
Description Description
Number Number
A Engine Horsepower (hp) D Pump Discharge Pressure (kg/
B Engine Speed (rpm) cm2)
C Pump Discharge Volume (lpm)
1
15A
CN6-1
CN6-2
26
4 26 15A 26 10A
CN6-9
25
CN6-10
CN1-1
CN7-4 CN4-4 CN1-2
CN7-5 CN4-5 CAN
CN7-6 CN4-6
CN1-8 24
CN1-9 11
3
23
1-35
1-34 22
1-33 CN1-10 1 10
5
P/V-(A)
1-53 2
1-52 CN1-21 3
VEHICLE 6
1-51 4
CONN
(CONN.1) 1-03
1-09
17
+(5V) CN3-15 1
1-14 CW LOW
SIG CN3-16 2
1-15
GND CN3-17 3
HIGH
1-01
1-07
1-12
15A 26
1-13
1-39 BR B 10A 26
28
AMP 070 16P AMP 040 12P AMP 040 20P AMP 070 18P AMP MIC 21P
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
18 35 6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 17
12 11 10 9 8 7 16 15 14 13 12 11 10 9
36 53
7 11 54 71
(CN7) (CN6)
1 6 72 89
FG000582
Figure 54
6 6
12
E/G
5
3 4 4
2
1
POWER
AUTO
1 2 3 4
ESC
17 5 6 7 8
FG000797
Figure 55
Reference Reference
Description Description
Number Number
Instrument Panel (Trenching 5 Aux Pump
1
Mode Selector Switch) 6 Control Valve
2 e-EPOS Controller 12 Solenoid Valve
3 Engine Controller 17 Engine Control Dial
4 Main Pump
1. Digging Mode
This mode is used for general digging work, loading work
and ground leveling work requiring quick stops. The
current to the solenoid valve for swing priority is shut off.
2. Trenching Mode
This mode is used for heavy duty ditch digging work or for
loading work requiring big swing angles. The voltage is
assigned to the swing priority control valve activating the
swing control valve restricting the flow of oil to the boom
and the arm.
ARO0270L
Figure 56
04@
BM5,0
BM5,1
26
4 26 04@
BM5,8 25
BM5,0/
BM0,0
BM6,3 BM3,3 BM0,1
BM6,4 BM3,4 B@M
BM6,5 BM3,5
24
12
'B4(
BM0,02
BM0,7
BM0,8
01 00 0/ 8 7 6 1/ 08 07 06 05 04 03 02 01 00 07 06 05 04 03 02 01 00 0/ 8 10 1/ 08 07 06 05 04 03 02 01 00
05 04 03 02 01 00 0/ 8
'BM1( 'BM0(
'BM4( 'BM3( 'BM2(
@LO/3/17O
5 4 3 2 1 0 7 6 5 4 3 2 1 0
01 00 0/ 8 7 6 05 04 03 02 01 00 0/ 8
'BM6( 'BM5(
FG000583
Figure 57
Reference Reference
Description Description
Number Number
1 Instrument Panel 24 Battery
2 e-EPOS Controller 25 Battery Relay
12 Solenoid Valve (Swing Priority) 26 Fuse
4
(Drive Signal) (Command Signal)
17
FG004980
Figure 58
Reference Reference
Description Description
Number Number
3 Engine Controller 17 Engine Control Dial
4 e-EPOS Controller
CCW ( 10 ) ( 10 ) CW
MECHANICAL MECHANICAL
STOP STOP
(V)
5
4.0V
4
3 2.5V
2
2 1.0V
1
0 SETUP
1ST 2nd 7th 12th 13th
CCW CW
STOP STOP
FG000866
Figure 59
Reference Reference
Description Description
Number Number
1 Knob 2 Potentiometer (Variable
Resistor)
1
04@
BM5,0
BM5,1
26
4 26 04@
BM5,8 25
BM5,0/
BM0,0
BM6,3 BM3,3 BM0,1
BM6,4 BM3,4 B@M
BM6,5 BM3,5
BM0,7 24
BM0,8 28
3
0,24
0,23
0,22
0,42
0,41
UDGHBKD 0,40
29
BNMM Ox
BM1,04
'BNMM-0( 0,/2
17
0,/8
Ow *'4U( BM2,04 0
0,03 BM1,05 BV KNV
RHF BM2,05 1
0,04
FMC BM2,06 2
0,/0
30 GHFG
0,/6
26 04@
0,01
0,02
AQ A 0/@
0,28
27 26
@LO/6/05O @LO/3/01O @LO/3/1/O @LO/6/07O @LOLHB10O
7 6 5 4 3 2 1 0 0/ 8 7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0 5 4 3 2 1 0 0/ 8 7 6 5 4 3 2 1 0
01 00 0/ 8 7 6 1/ 08 07 06 05 04 03 02 01 00 07 06 05 04 03 02 01 00 0/ 8 10 1/ 08 07 06 05 04 03 02 01 00
05 04 03 02 01 00 0/ 8
'BM1( 'BM0(
'BM4( 'BM3( 'BM2(
07 24 5 4 3 2 1 0 7 6 5 4 3 2 1 0
01 06
01 00 0/ 8 7 6 05 04 03 02 01 00 0/ 8
25 42
6 00 43 60
'BM6( 'BM5(
0 5 61 78
DBTBNM-0'78,OHM(
FG000585
Figure 60
E/G
4
3
1
POWER
AUTO
1 2 3 4
ESC
5 6 7 8
5 5
FG000798
Figure 61
Reference Reference
Description Description
Number Number
1 Instrument Panel (Auto Idle 3 Engine Controller
Switch) 4 Engine Control Dial
2 e-EPOS Controller 5 Pressure Switch
6 6
E/G
4 4 5
3
31
7
(Pump control signal)
2
1
(E/G overheating signal)
CHECK
E F
POWER
AUTO
1 2 3 4
ESC
5 6 7 8
FG000802
Figure 62
Reference Reference
Description Description
Number Number
1 Instrument Panel 6 Control Valve
2 e-EPOS Controller 7 E.P.P.R. Valve (Electromagnetic
3 Engine Controller Proportional Pressure Reducing
Valve)
4 Main Pump
31 Warning Buzzer
5 Aux Pump
Operation
16
6 6
11
E/G
4 4 5
3
2 1
CHECK
E F
C H C H
UP
WER POWER
PO AUTO
1 2 3 4
20
ESC
5 6 7 8
18
FG000800
Figure 63
Reference Reference
Description Description
Number Number
1 Instrument Panel 11 Solenoid Valve (Boost)
2 e-EPOS Controller 16 Main Relief Valve
3 Engine Controller Breaker/Boost/Shear Selector
18
4 Main Pump Switch
5 Aux Pump Power Boost Switch (Top of
20
Right Work Lever)
6 Control Valve
1
15A
CN6-1
CN6-2
26
2 26 15A 26 20A
CN6-9 25
CN6-10
CN1-1 18
CN7-4 CN4-4 CN1-2
CN7-5 CN4-5 CAN
CN7-6 CN4-6 PST SHEAR PRESS BREAKER
UP
TML 1 0 2
9
24
11 10
3
(C4) 14
CN1-11
13
11
6
CN2-2 (POWER MAX)
16
15
CN1-8 12
CN1-9
6 3
(Center)
(POWER MAX / BREAKER)
20
AMP 070 16P AMP 040 12P AMP 040 20P AMP 070 18P AMP MIC 21P
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
AMP 040 28P
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
(CN7) (CN6)
FG000586
Figure 64
Reference Reference
Description Description
Number Number
1 Instrument Panel 20 Power Boost Switch (Top of
2 e-EPOS Controller Right Work Lever)
11 Solenoid Valve (Pressure Up) 24 Battery
18 Breaker/Boost/Shear Selector 25 Battery Relay
Switch 26 Fuse
6 6
13
E/G 8
15
4 4 5
3
17 2 19
FG000799
Figure 65
Reference Reference
Description Description
Number Number
2 e-EPOS Controller 8 Pump Pressure Sensor
3 Engine Controller 13 Solenoid Valve (High speed)
4 Main Pump 15 Travel Motor
5 Aux Pump 17 Engine Control Dial
6 Control Valve Selector Switch For Automatic
19
7 Pressure Switch (Py Port) Travel
15A
26
2 26 15A 26 15A
25
8 CN1-1
+ CN1-2
SIG CN3-1
CN3-2
- 13
(C3) 24
+ CN1-12
SIG CN3-3
CN3-4
- 19
9 3
0
2
CN2-4 I
II
0
I 5
CN2-5 6 II
7 8
17
CN1-8 +(5V) CN3-15 1
CW LOW
CN1-9 SIG CN3-16 2
GND CN3-17 3
HIGH
AMP 070 16P AMP 040 12P AMP 040 20P AMP 070 18P AMP MIC 21P
8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 10 9 21 20 19 18 17 16 15 14 13 12 11
16 15 14 13 12 11 10 9
(CN2) (CN1)
(CN5) (CN4) (CN3)
AMP 040 28P
6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
(CN7) (CN6)
FG000587
Figure 66
Reference Reference
Description Description
Number Number
2 e-EPOS Controller Selector Switch For Automatic
19
8 Pressure Sensor (Front Pump) Travel
9 Pressure Sensor (Rear Pump) 24 Battery
13 Solenoid Valve (High speed) 25 Battery Relay
17 Engine Control Dial 26 Fuse
e-EPOS Controller
The system operation status and malfunction codes can be
checked through the display on top of the e-EPOS controller box
the rear cover behind the operator's seat.
1 2
4 3
FG000588
Figure 67
Reference Reference
Description Description
Number Number
1 Upper Digit Power Monitor (Stays "ON"
2 Lower Digit 4 While Power Is In Normal
Range)
Engine Speed Monitor LED
3 (Flash Interval Increases With
Engine Speed.)
1. Power Monitor
This LED is turned "OFF" when the input voltage to the
e-EPOS controller is below 18.5 1 V or above 32.5 1 V.
Stays "ON" while in normal range.
2. Engine Speed Monitor
This LED light flashes according to the engine speed. The
flashing interval is proportional to the engine speed.
Display Readout
Mode Selection Operation Status
Upper Digit Lower Digit
Normal Operation
Power Mode
Power Mode
HAOH340L
Power Mode
Normal Operation
Standard Mode
Standard Mode
HAOH350L
Normal Operation
Digging
Digging Mode
HAOH370L
Work Mode
Normal Operation
Trenching
Trenching Mode
HAOH380L
4. Communication Monitor
What are shown in the 7-SEGMENT LED are same as
those in the Error Codes.
Outline
A
C
FG000784
Figure 68
Modes
FG000422
Figure 69
Donaldson.
FG000440
Figure 70
FG000441
Figure 71
FG000342
Figure 72
10
11
2
5
6
5
7
4
1
8
9 FG003919
Figure 73
Reference Reference
Description Description
Number Number
1 Air Conditioner/heater Unit 7 Liquid Hose (1)
2 Condenser 8 Liquid Hose (2)
3 Compressor 9 Ambient Temperature Sensor
4 Receiver Dryer 10 Sun Sensor
5 Discharge Hose 11 Control Panel
6 Suction Hose
0.5RW
FUSIBLE LINK
LAMP SWITCH
A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A CN11-4 0.85LW 47C
DIODE 4
1.25B CN11-1 99 - +
M
107B CN8-12 0.5LW CN10-1 107A 0.85B 0.85B
BLOWER
99 CN9-10 1.25B
20 19 18 17 16 15 14 13 12 11 10
4 3 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
FG000781
Figure 74
Cold Box
Internal Air Inlet
Outlet
Vent Rear
Outlet
Vent
Front
Outlet
Foot
DEF Outlet
Outlet
External Air
VENT
COOL
DOOR
DOOR -INTAKE
-MIX
DEF Internal Air
WARM
Mode
Door
Vent Bi-level Foot Def/foot Def
Vent 100 60 0 0 0
Foot 0 40 100 80 60
Def 0 0 0 20 40
Main Components
Internal
Internal Air Sensor
Air Filter
Actuator Water Temp Evaporator
-Wind Direction Sensor FG001360
Control
Figure 76
CN10-20 CN10-2
FG001055
Figure 78
DRAIN
(CN10-1)
SOURCE GATE
(CN11-1) (CN10-6)
FG001056
Figure 79
Specifications
Rated voltage 24V
Rated current 20A
Figure 80
Relay - A/C
Power is supplied to the magnetic clutch of the compressor.
Specifications
L S1 (+)
Rated voltage 24V
Rated current 10A
B S2
(-)
FG001058
Figure 81
Duct Sensor
It is inserted in the core of the evaporator to prevent freezing of
the evaporator.
The sensor consist of negative characteristic thermistor that
resistant value increases and decreases when the temperature
rises and falls, respectively.
83.7
OUTPUT VOLTAGE(mV)
76.2
67.7
58.8
46.6
36.0
21.4
Control Panel
A/C OUTSIDE
AUTO A/C
AUTO MAX
TEMP
OFF
SEL MODE
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
Control Logic
Temp Control
FULL COOL FULL HOT
Actuator
Starter Switch ON
Code Description
E0 Normal
E1 Internal Air Temp Sensor Short
E2 Internal Air Temp Sensor Open
E3 Ambient Air Temp Sensor Short
E4 Ambient Air Temp Sensor Open
E5 Duct Sensor Short
E6 Duct Sensor Open
E7 Sun Sensor Short
E8 Sun Sensor Open
E9 Water Temp Sensor Short
E10 Water Temp Sensor Open
E11 D.P.S OPEN
E12 Position Error of Wind Direction
Actuator.
E13 Position Error of Temp Control
Actuator.
0.5 0.5
FG001067
Figure 89
Receiver Dryer
The receiver dryer reserves refrigerant enough to ensure High/Low Pressure Switch
smooth freezing cycle responding immediately to the change of
level in the freezing cycle.
As liquid refrigerant from the condenser may contain refrigerant
gas with bubbles whose presence in the expansion valve
decreases the freezing power excessively, it separates liquid
and gas and sends liquid only to the expansion valve.
Water in refrigerant shall be eliminated with dryer and through
filter.
FG001366
Figure 91
kgf/cm2G
kgf/cm2G
kgf/cm2G
19
4
BR B
14 17
$/ 16
$/ B
BR
NC $/ E
COM
NO
26
$/ A
21
25 15
$/
$/
$/ $"/
*
$/
22
U
7
$/
23
$/
$/
7 $/
$/
$/
'(
Figure 93
Reference Reference
Description Description
Number Number
4 Start Switch 21 Engine Controller
7 Hydraulic Oil Temperature 22 Coolant Temperature Sensor
Sensor Cooling Fan Speed Control
23
14 e-EPOS Controller Valve
15 Battery 24 Work interrupt switch
16 Battery Relay Cooling Fan Reverse Rotation
25
17 Circuit Braker Switch
19 Fuse Box Cooling Fan Reverse Rotation
26
Solenoid
Wiper Circuit
5 6 7
- 2 3 5 (Continuous mode) 3
+
M
8 (Intermittent 1 mode) 4
4 4
10 (Intermittent 2 mode) 5
5 6 11 (Washer mode) 6
1 7 8
12 - + 1
P
1
6 9 13 2
9 2 8
AMP MIC 13P
CN12 CN13 KET 8P
3
AMP MIC 13P 1
1 2 3 4 5 6 4 3 2 1 4 5 6
1 2
7 8 9 10 11 12 13 9 8 7 6 5
FG000589
Figure 94
Reference Reference
Description Description
Number Number
1 Battery 6 Wiper Controller
2 Battery Relay 7 Wiper Switch Panel
3 Fusible Link 8 Window Washer
4 Fuse Box 9 Wiper Cutoff Switch
5 Wiper Motor 10 Light Switch
Continuous operation
- Operation of wiper motor
Pressing the successive operation switch on the wiper switch
panel (7) changes the voltage of the "5" terminal of the wiper
controller (6) from HIGH (about 5.5 0.5V) to LOW (0+0.5V) and
also current flows via the "3" terminal of the wiper controller (6)
the "2" and "4" terminals of the wiper motor (5) the "4"
terminal of the wiper controller (6) to run the wiper motor (5)
continuously.
- Stop of wiper motor
Pressing again the successive operation switch on the wiper
switch panel (7) changes the voltage of the "5" terminal of the
wiper controller (6) from LOW (0+0.5V) to HIGH (about
5.5 0.5V). As the "5" and "6" terminals of the wiper motor are
connected still that power is supplied to the "6" terminal of the
wiper controller (6),
However, the controller (6) runs the wiper motor continuously
and then rotates the motor reversely by " letting current flow via
the "4" terminal of the wiper controller (6) the "2" and "4"
terminals of the wiper motor (5) the "3" terminal of he wiper
controller (6) when the "1" and "6" terminals of he wiper motor
(5) are connected and thus power voltage is supplied to the "7"
terminal of the wiper controller (6).
The Wiper motor (5) stops reverse revolution when the contact
of a cam switch connected to the "6" terminal of the wiper motor
(5) moves to an insulation area of the cam plate to disconnect
the "5" and "6" terminals of the wiper motor (5).
When the wiper motor (5) stops, arm and blade connected to it
move to the stop positions of the right pole in the cabin.
Intermittent operation
- Intermittent 1st (3-second)
Pressing once the Intermittent switch in the switch panel (7)
changes voltage of the "8" terminal in the wiper controller (6)
from HIGH (about 5.5 0.5V) to LOW (0+0.5V) and current flows
through the "3" terminal in the wiper controller (6) the "2" and
"4" terminals in the wiper motor (5) the "4" terminal in the
wiper controller (6) to start the cycle that wiper stops 3 seconds
after every operation.
- Intermittent 2nd (6-second)
Pressing twice the Intermittent switch in the switch panel (7)
changes voltage of the "10" terminal in the wiper controller (6)
from HIGH (about 5.5 0.5V) to LOW (0+0.5V) and current flows
through the "3" terminal in the wiper controller (6) the "2" and
"4" terminals in the wiper motor (5) the "4" terminal in the
wiper controller (6) to start the cycle that wiper stops 6 seconds
after every operation.
7
13 87a
30
87
*15 85 86
*16
*9 6
87a
30 87a
*14 87
87
30
85 86
85 86
12
*8
87a
87
30 *5
0 0
85 86 3 I 2 2 I 3
II II
0
I 5 5
0
I
4
6 II II 6
7 8 8 7
20A
15A
10 30A
CN6-1 15A
CN6-2 15A
CN6-9 11
L6 CN6-10 3
CN2-6
CN7-4 CN4-4
2
CN7-5 CN4-5 CAN
CN7-6 CN4-6 CN1-1
CN1-2
CN1-8
1
CN1-9
FG000590
Figure 95
Kind of Light
The lighting system is consists of headlights, work lights, cabin
lights (optional), relays and switches.
Operation
Connected Terminal
Switch Position Activated Relay Lit Light
of switch
1 "2-3" Terminal - Illumination Light of Switch
"2-3" Terminal - Illumination Light of Switch
Headlight Relay Headlight (2 Ea.)
Light Switch
2 Work Light (2 Ea.)
"5-6" Terminal
Work Relay Indicator Light of Work Light
(L6)
Front Cabin Light (2 Ea.) or
1 "2-3" Terminal Front Cabin Light Relay
Front Cabin Light (4 Ea.)
Cabin Light Front Cabin Light (2 Ea.) or
"2-3" Terminal Front Cabin Light Relay
Switch Front Cabin Light (4 Ea.)
2
Rear Cabin Light Relay / Rear Cabin Light (2 Ea.) and
"5-6" Terminal
Rear Work Light Relay Rear Work Light (1 Ea.)
ANTENNA
7 8 10
MODULE
2 15
3 Vcc(+5V) 9
11 3 16 (LH) (RH)
15A 1 MICOM
4 13
+ - + -
5 Vcc(+5V)
7
3 14
10A 1 DC/DC 17
CONVERTER 1 2 5 2
6 10
10A 87a 3
30 11
87 4
86 85
4
9 10 11 12 13 14 15 16 17 18
1 2 3 4
1 1 2 3 4 5 6 7 8
FG000591
Figure 96
Reference Reference
Description Description
Number Number
1 Battery 7 Audio Control Panel
2 Battery Relay 8 Stereo
3 Fuse Box 9 Speaker
4 Fusible Link 10 Antenna Module
5 Converter 11 Light Switch
6 Stereo Relay
Connected Terminal of
Switch Measured values Operations
switch
PWR 4.36 0.2V Stereo ON, OFF
1.24 0.2V Volume up
"3-4"
0+0.2V Volume down
SCAN 2.49 0.2V Frequency selection
1Electrical
Schematic
(DX420LC)
Edition 1
Electrical Schematic
(DX420LC)
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
General Description .............................................. 7
DX420LC .............................................................. 8
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
WIPER
CONTROLLER WIPER AUDIO
SWITCH PANEL CONTROL PANEL
6-LAMP ASS'Y (OPT) ROTATING BEACON (OPT) LOWER WIPER (OPT) (543-00106 )
(543-00095) (543-00096)
STARTER SWITCH CONNECTION WORKING LAMP 50B
(534-00064 )x2 87a - 155B 2 5 (CONT) 0.5LR 3
0.85LW 3 155A 159A 159B
+
129B 0.85RG 129C 30 2RY TELESCOPIC BEACON M
TML B BR R1 R2 C ACC 1.25RG 0.85RG 51B 8 (INT-1) 4 CONT. POWER
PST 0.85RG 2RG 51A 87 33C LOWER WIPER RELAY 160A 0.5LY 160B
(RR) 0.85Or 0.85LR 156A 4 0.85LB 4 156B
OFF 0.85B 0.85B (RH) (2544-9033) 161A 10 (INT-2) 0.5LG 5 161B INT SEEK ANTENNA
0.85B 0.5B 85 86 0.5RG ROTATING
0.85B WASHER VOL.
ON (REAR) BEACON SWITCH L 36B 0.85R 36A 87a 0.85G 37B 1 0 162A 11 (WASHER) 0.5L 6 162B
REAR WORKING LAMP 87a 0.85RG 129D 55C 30 38B 2 38A
1.25RG (549-00101/K1002406D3) 87
START (534-00085 ) 30 125E 1.25RL 51C 88B 3 I WINDOW WASHER MODULE
87 (RL) 0.85RG ROTATING BEACON 124B 157B 1 0.85WL 7 157A CAR STEREO
129A 0.85B 1 0 (K1000789) (K1002641 )
WORKING LAMP RELAY (534-00062) 86 88E 0.5B 7 8 54L
+
2 0.85RG STOP RUN B 88H 0.85Br 85 5 (541-00010 )
86 128B (LH) 0.85B (2544-9033 )
158B 0.85WB 6 158A 35C 12 0.85RB - + 0.85L 1 34E
0.5B 85 0.5RG 1.25B CABIN LAMP 33B 0.85Or 33A 3 I 0.5WR P SPEAKER
127B 0.85RG M 190A 63C 6 35A 34C 2 121B 121A 15
(534-00085 )x2 LOWER WIPER SW 0.5WG (2541-9020 )x2
0.85B 0.5B 7 8 0.5WR Vcc(+5V)
NOTE. (FR) 0.85B 52D S 37A 0.85G (549-00101/K1002406D5) 0.85WR 0.5RB 0.5L
HEAD LAMP 87a -
3 123B 0.5W 123A 16 (LH) (RH)
30 1.25R WIPER MOTOR 35B 34D 54D MICOM
1. DIODE PART NO. CABIN LAMP RELAY 2 (534-00085 )x2 53B 54K E 0.85B 0.85BR 0.85BR 0.5WR 1
DIODE 5
127C 0.85RG 0.85RW 1.25RW 53A 87 (538-00011)
(2544-9033 ) 34B 1 0.85L 0.85L 4 169A 0.5BL 169B 13
DIODE 1 . : 548-00003A CABIN LAMP SWITCH (RH) 2 1
(FMR) 0.85B 0.85B 0.5B 85 86 0.5RG
0.5RW 54C + - + -
DIODE 2 ~ 9 : 2548-1027 (549-00103/K1002406D13 ) LAMP SWITCH (549-00103/K1002406D11) LOWER WIPER MOTOR 130B 13 0.5WR 2
190B CN14 MOLEX 4P Vcc(+5V) 117B 118B 119B 120B
2B 125B 55B (538-00012 ) 0.85B 0.85Lg 9 138A 99 2 8
0 0 0.85B 0.5B 7
DA1~DA3, DA6 : K1000815 87a 2 2 52B LOWER WIPER CUT SW 117A 0.5GrR
(FRONT) 30 125D 2RL 0.5WR 126A 3 I 0.5RL 53C 0.85WR 54A 3 I 0.85R 138B AMP MIC 13P
0.85RW HEAD LAMP RELAY (549-00077) CN12 CN13 KET 8P 118A 17 0.5BY
DA4, DA5 : K1000814 127D 0.85RG 87 II II WIPER CUT SW 17B 14
2RG 127A (LH) (2544-9033 ) 0.5BR
125C 0.85B 0 (549-00086 ) 119A 2 0.5GrL
(FML) 85 86 126B 0 0.85BR 0.85L 16C 5
0.85B 0.5B 5 52C
I 5 0.5RL I 0.5R 120A 10 0.5BW
128A 6 55A 0.5WR 0.5WR
0.5RG II 0.5RG 0.5RG 6 II FUEL PUMP (OPT) 87a 0.5LW 3 65C
16B 30 11 0.5B
127E 0.85RG 7 8 0.5WR 0.5B 7 8 54G 0.5WR 0.85L
0.5B CIGAR LIGHTER 87 65A 0.85LW 4 65B
CABIN LAMP RELAY 1 FUEL PUMP FUEL PUMP SW
(FL) 0.85B 54F (545-00001) 99
(2544-9033 ) SEAT HEATER (OPT) 1.25R
(401-00238) (549-00093 ) 0.5BR 0.5BR 88C 86 85 0.5B 0.85B
2B 2RL 1.25B 64B 1.25WL 64A 1 2 63B 1.25WR
CABIN LAMP P 99
2RY
(534-00085 )x2 1 0
2 143B 1.25RB 1.25B DC/DC 3 17A 0.85BR
1.25B 3 0.85WR 15B 1 STEREO RELAY
144B 1.25R 144A I CONVERTER 1
2 16A 0.85L (2544-9033 )
7 8 54Q (2531-1003 )
0.5B SEAT AIR SUSPENSION (OPT) 1.25RB 1.25RB
62B STARTER CONTROLLER STARTER RELAY
SEAT HEATER
1.25R (2543-9015 ) (2544-1022)
0.85WR
0.85BR
AIR SUSPENSION
0.5RW
(545-000 )
0.85L
SEAT HEATER SWITCH (401-00 ) 1.25W N
TERMINAL NO LCD GAUGE PANEL 2RY 14C S 0.85BW D PP 3Y
CN2 (549-00101/K1002406D1) 143C 2 132A 0.85R
(539-00076 ) 1.25B 1.25RB DC/DC 14B 14A 5A
P 0.85RG 0.85LR 1
CONVERTER 2 132B +
131B 3 12V POWER 0.85BL C B 3W
DIODE 3
(2531-1003 ) 18B
KET 118 9P DIAGNOSTIC CONN. 14P 99 SOCKET 12C 4C
CN6-3 3 54B 0.5WR 0.5WR 0.5WR - E B P
4 3 2 1 ILL. (527-00006) 0.85B
CN6-1 1 28B 0.85R 0.85R 0.85BL
0.5R 0.85B 13B 12B
1.25WG
9 8 7 6 5 3 2 1 CN6-2 2 28C 0.5R 2RL 2RL
PILOT BUZZER 0.5RW 0.85LR STARTER RELAY 2
(CN13) 7 6 5 4
(2516-1116 ) (2544-9033 )
11 10 9 8 L1 1.25RB 87a 0.85BL
+
14 13 12
0.5R 28G TRAVEL/SWING ALARM ASS'Y (OPT) FUEL HEATER (OPT) 0.85BY 30
MOLEX 4P L2 CN6-12 12 29B 0.5WB 29A - 87 12A
11B
L3 + 31B 0.85RY 0.85RY 0.5LR 86 85 0.5GB
CN6-11 11 130D 0.5RW ALARM BUZZER 87a
1.25WR
1 2 3 4 (CN15) - 0.85B 30 20C 2RG 0.5RG 13C
0.85WR
89A
0.85RG
0.85BR
0.85RY
1.25R
0.85R
(516-00011 ) 0
1.25W
0.85LR
L4 2.5R 59A 87
2RG
0.85L
2RL
2RY
(CN14) 3 2 87a 30B 1 0
0.5P I 0.5W 2 0.5GB
CN6-9 9 99 0.5B 30 59B 85 86
L5 104C II 32B 0.85RG 0.5RY 39A 3 I 125A 50A 20A 28A 52A 63A 124A 179A 62A 131A 34A 88A 15A 3Y
ECU CONNECTOR CN6-10 10 99 0.5B 31A 87 0.5B 20B 3W STARTER
0 39B 0.5B 7 8
L6 9 10 11 12 13 14 1 2 3 4 5 6 7 8 6A 1.25WR (65.26201-7049)
I 5 0.5W 0.5W 85 86 0.5RG
122B 122A 6 54K 5B C 24V 6KW
0.85B 0.85V II 32C 32A FUEL HEATER 30A 20A 20A 15A 15A 15A 10A 10A 10A 10A 10A 10A 10A 10A
1.25WR
30C FUEL HEATER 1.25WR 2WR
0.85LR
0.85BY
12 17 18 35
36 53
OVER LOAD WARNING (OPT) 4bar
7 8 0.5WR RELAY
(2544-9033 )
SWITCH
4G
17 18 2E
4D
15
2B
16
11A
54M ALARM RELAY (549-00101/K1002406D2) 15R 98A B
7 11 54 71 SWING PRESS SW (2544-9033 )
ALARM SWITCH 5W 5W ACC C
1 6 72 89 (549-00010 ) 0.5B 2.5B FUSE BOX 2 FUSE BOX 1
OVER LOAD (549-00103/K1002406D14) 5W 5W 13A
ONLY SWING (OPT) FUEL HEATER (K1001263A) (K1001263A)
WARNING SWITCH B
(549-00102/K1002406D4) 4F 2D 4E 10A 6B BR 0.85Br
ECU CON.1 (89-PIN) 1 0 0.5RG 15 16 2WR 17 18 2C 2WR R2
2 140B 0.5BrY 57B 0.85RY 7A
VEHICLE CONN. A
0.5B 3 I 0.5RW 0.5RW HORN 1 10A 10A 10A 10A 10A 10A 10A 10A 30A 20A 20A 15A 15A 15A
H.F 0.85B HORN RELAY R1
8 0.5WR 0.5WR (516-00014 ) (2544-9033 )
0.5B 7 54P 0.5WR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 STARTER SWITCH
WARNING LAMP 87a 60B
1.25RB
0.85RY
(K1001654 )
0.5RW
0.5WR
0 30 56B 0.85RB 56A 66A 30A 93A 166A 40A 130A 83A 42A 133A 143A 21A 19A
0.5GB
0.5BG
L1 : CHARGE 28D 0.85R CN5-4 140A 141A 3 2 21B 57C 0.85RY 57A 87
+ I 0.5RL 0.85RY 60R
L2 : ENG OIL PRESS HORN 2 FUSIBLE LINK
0.85WR
0.85RB
0.85LB
0.85RG
0.85RL
0.5GBr
II
0.85Y
0.5RW
1.25BrR
PRESSURE SENSOR
2RW
139B 0.85BrW CN3-5 139A CN2-6 L.F 0.85B 85 86 56C 0.5RB (2527-1023A)
1.25RB
51D
1.25RL
L3 : W/T OVER HEAT SIG 0.5RG (516-00015 ) 0.5G 58A 0.5Br
2LR
(OWD) 0
L4 : E/G WARNING 145A 0.85W CN3-6 145B 141B CN2-4 0.5BrB (MANUAL) 0.5BrB 5 21L
(2547-9045 ) - I 0.5RL 0.85LB 2WR 2WR 2R
2WR
L5 : PREHEAT 22B CN2-5 0.5BrW (AUTO) 0.5BrW 22A 6 II
CONTROLLER 0.85RG 0.85RG 0.85Br 2A 1B
L6 : WORK LAMP 28E 0.85R 8 54H
+ (543-00108 ) 0.5B 7 0.5WR 7B 0.5G
ECU CON.3 (16-PIN) ECU CON.2 ( PIN) 0.5G 0.5GBr 0.85RY
PRESSURE SENSOR(A) 74B 0.85GR CN3-1 74A 3W
CYLINDER CONN. ENGINE CONN. LCD DISPLAY PANEL SIG 0.85Y 2RW
(FRONT PUMP) HIGH SPEED SWITCH
WATER TEMPERATURE 75A 0.85W CN3-2 75B DIODE 2 BATTERY RELAY
(2547-9045 ) - 10B CN2-1 0.5BG KEY SW 'START' (549-00103/K1002406D12) 0.5BG 0.5BG 0.5BG CIRCUIT BREAKER
FUEL LEVEL (2544-9024 ) 2R
(2527-9004 )
DIODE ARRAY 89B CN1-15 0.5GB START RELAY 0.5GB 0.5GB 0.5GB 8A 1A
28F 0.85R B
+ Py A
GRAPHIC DISPLAY PRESSURE SENSOR(B) 1.25BrR 8W 8W 8W
76B 0.85GY CN3-3 76A 104A CN2-15 0.85P 104B 0.85B AUTO IDLE (1)
(REAR PUMP) SIG
5 6 7 8 3 4 / TRAVEL SW 0.5RW 0.5RW 0.5RW 4B 3B 3A
(2547-9045 ) 77A 0.85WL CN3-4 77B 19bar
- (2549-9112 ) 1.25BrW
21C CN1-1 0.85RL 0.5WR 0.5WR 1.25BrW 8C BR
CN7-4 4 80A 0.5Y 0.5Y CN4-4 80B 21D CN1-2 0.85RL 1.25RL 1.25RL 1.25RL 1.25RL
1 2 3 4 1 2
E
CN7-5 5 81A 0.5YB 0.5YB CN4-5 81B 9D CN2-14 0.5RW ALT 'I' 0.5RW 0.5RW 0.5RW 9D 3 1 6C 0.5WR 1.25B
CAN A 8B
DA1 ~ DA3 DA4 ~ DA6 CN7-6 6 82A SHIELD SHIELD CN4-6 82B NC 0.85RL 0.5B 2 HOUR
40B 60R
COM 0.85Y
CN1-8 0.85B SOL-VALVE ASS'Y 0.85YG 41A NO HOUR METER
99 OFF
(426-00262 ) 10W (2528-9040 ) DIODE 1 60B 60R
99 CN1-9 0.85B 0.5B E DR B+ 0.5WR
CN7 CN6 0.85YG 41B PILOT CUT-OFF SWITCH
(C1)
AMP 040 12P+16P 41C (549-00089 ) ON 83B
3 PILOT 9B
DA4-1
1 CUT OFF
0.85B 99 ROOM LAMP
ECU - + - +
(539-000 )
0.85YL 0.85YL 61C (C2) QUICK CLAMP(OPT) (534-00079 )
2RW 0.5RW 0.5RW 12V 150AH 12V 150AH
4 61B 15R
ENGINE CYLINDER INJECTOR DA4-2 BREAKER 0.5Br 0.5Br
2
0.85B 99 () 1 BATTERY
AMP 040 12P
1.25BrR
0.5WR AIRCON UNIT
0.85BG
0.85RL
0.5GBr
CN4
0.85W
0.5Br
2-07 DIODE 6 (549-00092 )
2RW
FUEL HIGH PRESSURE 21E
0.5G
3-04 0.85RL 0.85RL (920-00127 ) 0.85W 18A 4A 9A
CN1
(C4)
PUMP 2-05 CYL. 3 0.5RW P(R) B(B+) R(I)
3-12 5 21H RELIEF SOL-VALVE 1.25LR CN11-2 42C 153B 98B
(0 445 020 011) DA1-1 LED 1~12 130C
PRESS UP CN9-6 C B
23C CN1-11 0.85GrW 23B 1 0.85GrW 23A 0.85B 0.5LR CN10-8 42D
3 2-09 54E CN9-11 0.5WR - +
3-03 0.85RL 0.85RL 21G CN10-18 46B
OIL PRESSURE P& (C5)
200A
4 2-33 CYL. 2 ILL 42B CN9-5 1.25LR
SENSOR 3-06 7 21K SWING
t DA1-3 0.5BW SG
AMP 070 18P
15L 15B
BOOST PRESSURE P& 4 2-28
60B CN2-2 0.5BrW (POWER MAX) 0.5BrW 168B CN8-10 0.5LG CN10-16 168A 0.85BG F
SENSOR 3-10 E
(LDF 6T)
t 1 2-21
71B CN2-10 0.5GY (BREAKER) 0.5GY
BREAKER SHEAR SELECT SW A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A 100A 100B
3-15 CYL. 6 PREHEAT RELAY
(0 281 002 576) 0.5RG CN4-3 137A GND 150E CN2-8 0.5RL (1-WAY) 0.5RL (K1006572/K1002406D21) AIR HEATER
2 2-29 106B CN8-11 0.5LY CN10-6 106A (544-00007 ) E ALTERNATOR 50A
V 0.5GW CN4-2 136A RxD 151C CN2-9 0.5RY (2-WAY) 0.5RY
0.5B FET 99
(2502-9009 )
3-05 PST SHEAR PRESS BREAKER 1.25B COMPRESSOR 8B
FUEL 0.5GL 135A TxD UP CN11-1 99 - +
1 CN4-1 M (2208-6013B )
TEMPERATURE 2-34 3-14 CYL. 4 AUXI MODE RESISTOR TML 1 0 2
SENSOR
t RS-232
(545-00011 ) 1WAY-2WAY S/V (OPT) 99 107B CN8-12 0.5LW CN10-1 107A
2 2-17 9 BLOWER MAGNET ALTERNATOR 80A(OPTION)
V 0.85BrB 94A 93B 0.85RL 54J 0.85LW 47C CLUTCH
1.25BrR
(0 281 002 209) (CONN.3) 0.5WR CN11-4 (502-00003A)
0.85BG
0.5GBr
0.85RY
0.5WR
0.85W
SHEAR 10
0.5Br
152A
2RW
0.5G
SELECT 152D 0.85RB 152C 1 0.85RY 151A 108A CN9-13 0.5GrG CN10-2 108B FRE (P1) 47A 47B
COOLANT 1 2-36 VEHICLE 5 1
3 INTAKE
t 101A CN1-10 0.85Or 101B 1 109A CN9-12 0.5GrY CN10-20 109B REC (P2) ACTUATOR
TEMPERATURE CONN 5
7 0.85BrR 133G M
2 DA2-3 151B
DIODE 4
2-18 CHECK 0.85LgR (B) DA2-1 14
SENSOR V 94B 2
P/V-(A) 3 0.85BrR 133H
(0 281 002 209) CONN 95A 95B 13
80C 1-35 CAN B H 0.5Y 110A CN9-15 0.5OrR CN10-12 110B DEF (P1)
0.5GL 135B 0.85RL 150A 0.85B 0.85B
1 102B CN1-21 0.85OrB 102A 3 152B 11
81C 1-34 CAN B L 0.5YB 6 0.85LgW (426-00263 ) 111A CN9-14 0.5OrW CN10-13 111B VENT (P2)
0.5GW 136B 4 6 M
1-33 2 0.85B 96B 96A DA2-2 6 MODE
82C SHIELD PUMP 43A CN9-16 0.5YB CN10-11 43B Vref MODE
0.85RL
12
0.85W
DUCT
2RW
1 0.5B 99 (R)
1 2-25 13 (426-00263 ) (ROTATING-CW) SENSOR
INCREMENT SPEED SENSOR 163A 163B 2 3 164A 68A CN2-18 0.85BG 68B 0.85B PILOT FILTER SW
N
AMP 070 16P
1-09 0.85B 2B 72B 0.85YR CN3-7 72A 148C 148B 1 5 71C 4 0.85GY 142A CN8-3 0.5Lg 2 - + 1 4 3
20 19 18 17 16 15 14 13 12 11 10
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
(CLOSE) (C)
AMP 040 20P
27B 0.85LgW CN3-10 27A GND 92B CN3-17 0.5GB 92A 3 (R)
(k1003296) 8 (SHEAR-OPEN) AMP 12P + 18P
HIGH DA6-4 149D 180F 180C
0.85BrW (1)
4 3 0.85B JOYSTICK LEVER SWITCH A/C CONTROL PANEL
5
19B 1-01 0.85RW (543-00107 ) DA3-1
(420-00468 ) 0.5WR
0 1 70F 1 70C
19C 1-07 0.85RW 2RW (ON JOYSTICK R.H) 179B 2 0.85GB
0.85RY
3 180A 180G 180D 2-PUMP S/V
19D 1-12 0.85RW 0.5GBr 0.5GBr 0.5GBr I 0.85BrW 0.85BrW (2)
19E 2RW 2RW 2RW 2RW 2RW 0.5WR 54R 8 7 0.5B 6
1-13 0.85RW DA3-2
7C 1-39 0.5Br (KEY SW) 0.5Br 0.5Br 0.5Br 70G 2
0.85GB 70D
2-PUMP SWITCH
153A 1-16 0.85W (AIR HEATER RELAY) 0.85W 0.85W 0.85W (549-00101/K1002406DXX) 180H 0.85BrW 180E
(3)
154B 1-04 0.85BG (AIR HEATER RELAY) 0.85BG 0.85BG 0.85BG 7
DA3-3
0.85GB 0.85GB 0.85GB 70H 3 0.85GB 70E
(CONN.2) (CONN.1)
WIPER
CONTROLLER WIPER AUDIO
SWITCH PANEL CONTROL PANEL
6-LAMP ASS'Y (OPT) ROTATING BEACON (OPT) LOWER WIPER (OPT) (543-00106 )
(543-00095) (543-00096)
STARTER SWITCH CONNECTION WORKING LAMP 50B
(534-00064 )x2 87a - 155B 2 5 (CONT) 0.5LR 3
0.85LW 3 155A 159A 159B
+
AIR SUSPENSION
0.5RW
(545-000 )
0.85L
(2531-1003 ) 18B
KET 118 9P DIAGNOSTIC CONN. 14P 99 SOCKET 12C 4C
CN6-3 3 54B 0.5WR 0.5WR 0.5WR - E B P
4 3 2 1 ILL. (527-00006) 0.85B
CN6-1 1 28B 0.85R 0.85R 0.85BL
0.5R 0.85B 13B 12B
1.25WG
89A
0.85RG
0.85BR
0.85RY
1.25R
0.85R
(516-00011 ) 0
1.25W
0.85LR
L4 2.5R 59A 87
2RG
0.85L
2RL
2RY
0.85BY
12 17 18 35
36 53
OVER LOAD WARNING (OPT) 4bar
7 8 0.5WR RELAY
(2544-9033 )
SWITCH
4G
17 18 2E
4D
15
2B
16
11A
54M ALARM RELAY (549-00101/K1002406D2) 15R 98A B
7 11 54 71 SWING PRESS SW (2544-9033 )
ALARM SWITCH 5W 5W ACC C
1 6 72 89 (549-00010 ) 0.5B 2.5B FUSE BOX 2 FUSE BOX 1
OVER LOAD (549-00103/K1002406D14) 5W 5W 13A
ONLY SWING (OPT) FUEL HEATER (K1001263A) (K1001263A)
WARNING SWITCH B
(549-00102/K1002406D4) 4F 2D 4E 10A 6B BR 0.85Br
ECU CON.1 (89-PIN) 1 0 0.5RG 15 16 2WR 17 18 2C 2WR R2
2 140B 0.5BrY 57B 0.85RY 7A
VEHICLE CONN. A
0.5B 3 I 0.5RW 0.5RW HORN 1 10A 10A 10A 10A 10A 10A 10A 10A 30A 20A 20A 15A 15A 15A
H.F 0.85B HORN RELAY R1
8 0.5WR 0.5WR 0.5WR (516-00014 ) (2544-9033 )
0.5B 7 54P
1 2 3 4 5 6 7 8 9 10 11 12 13 14 STARTER SWITCH
WARNING LAMP 87a 60B
1.25RB
0.85RY
(K1001654 )
0.5RW
0.5WR
0 30 56B 0.85RB 56A 66A 30A 93A 166A 40A 130A 83A 42A 133A 143A 21A 19A
0.5GB
0.5BG
L1 : CHARGE 28D 0.85R CN5-4 140A 141A 3 2 21B 57C 0.85RY 57A 87
+ I 0.5RL 0.85RY 60R
L2 : ENG OIL PRESS HORN 2 FUSIBLE LINK
0.85WR
0.85RB
0.85LB
0.85RG
0.85RL
0.5GBr
II
0.85Y
0.5RW
1.25BrR
PRESSURE SENSOR
2RW
139B 0.85BrW CN3-5 139A CN2-6 L.F 0.85B 85 86 56C 0.5RB (2527-1023A)
1.25RB
51D
1.25RL
(OWD) 0
L4 : E/G WARNING 145A 0.85W CN3-6 145B 141B CN2-4 0.5BrB (MANUAL) 0.5BrB 5 21L
(2547-9045 ) - I 0.5RL 0.85LB 2WR 2WR 2R
2WR
L5 : PREHEAT 22B CN2-5 0.5BrW (AUTO) 0.5BrW 22A 6 II
CONTROLLER 0.85RG 0.85RG 0.85Br 2A 1B
L6 : WORK LAMP 28E 0.85R 8 54H
+ (543-00108 ) 0.5B 7 0.5WR 7B 0.5G
ECU CON.3 (16-PIN) ECU CON.2 ( PIN) 0.5G 0.5GBr 0.85RY
PRESSURE SENSOR(A) 74B 0.85GR CN3-1 74A 3W
CYLINDER CONN. ENGINE CONN. LCD DISPLAY PANEL SIG 0.85Y 2RW
(FRONT PUMP) HIGH SPEED SWITCH
WATER TEMPERATURE 75A 0.85W CN3-2 75B DIODE 2 BATTERY RELAY
(2547-9045 ) - 10B CN2-1 0.5BG KEY SW 'START' (549-00103/K1002406D12) 0.5BG 0.5BG 0.5BG CIRCUIT BREAKER
FUEL LEVEL (2544-9024 ) 2R
(2527-9004 )
DIODE ARRAY 89B CN1-15 0.5GB START RELAY 0.5GB 0.5GB 0.5GB 8A 1A
28F 0.85R B
+ Py A
GRAPHIC DISPLAY PRESSURE SENSOR(B) 1.25BrR 8W 8W 8W
76B 0.85GY CN3-3 76A 104A CN2-15 0.85P 104B 0.85B AUTO IDLE (1)
(REAR PUMP) SIG
5 6 7 8 3 4 / TRAVEL SW 0.5RW 0.5RW 0.5RW 4B 3B 3A
(2547-9045 ) 77A 0.85WL CN3-4 77B 19bar
- (2549-9112 ) 1.25BrW
21C CN1-1 0.85RL 0.5WR 0.5WR 1.25BrW 8C BR
CN7-4 4 80A 0.5Y 0.5Y CN4-4 80B 21D CN1-2 0.85RL 1.25RL 1.25RL 1.25RL 1.25RL
1 2 3 4 1 2
E
CN7-5 5 81A 0.5YB 0.5YB CN4-5 81B 9D CN2-14 0.5RW ALT 'I' 0.5RW 0.5RW 0.5RW 9D 3 1 6C 0.5WR 1.25B
CAN A 8B
DA1 ~ DA3 DA4 ~ DA6 CN7-6 6 82A SHIELD SHIELD CN4-6 82B NC 0.85RL 0.5B 2 HOUR
40B 60R
COM 0.85Y
CN1-8 0.85B SOL-VALVE ASS'Y 0.85YG 41A NO HOUR METER
99 OFF
(426-00262 ) 10W (2528-9040 ) DIODE 1 60B 60R
99 CN1-9 0.85B 0.5B E DR B+ 0.5WR
CN7 CN6 0.85YG 41B PILOT CUT-OFF SWITCH
(C1)
AMP 040 12P+16P 41C (549-00089 ) ON 83B
3 PILOT 9B
DA4-1
1 CUT OFF
0.85B 99 ROOM LAMP
ECU - + - +
(539-000 )
0.85YL 0.85YL 61C (C2) QUICK CLAMP(OPT) (534-00079 )
2RW 0.5RW 0.5RW 12V 150AH 12V 150AH
4 61B 15R
ENGINE CYLINDER INJECTOR DA4-2 BREAKER 0.5Br 0.5Br
2
0.85B 99 () 1 BATTERY
AMP 040 12P
0.5GBr
CN4
0.85W
0.5Br
(C4)
PUMP 2-05 CYL. 3 0.5RW P(R) B(B+) R(I)
3-12 5 21H RELIEF SOL-VALVE 1.25LR CN11-2 42C 153B 98B
(0 445 020 011) DA1-1 LED 1~12 130C
PRESS UP CN9-6 C B
23C CN1-11 0.85GrW 23B 1 0.85GrW 23A 0.85B 0.5LR CN10-8 42D
3 2-09 54E CN9-11 0.5WR - +
3-03 0.85RL 0.85RL 21G CN10-18 46B
OIL PRESSURE P& (C5)
200A
15L 15B
BOOST PRESSURE P& 4 2-28
60B CN2-2 0.5BrW (POWER MAX) 0.5BrW 168B CN8-10 0.5LG CN10-16 168A 0.85BG F
SENSOR 3-10 E
(LDF 6T)
t 1 2-21
71B CN2-10 0.5GY (BREAKER) 0.5GY
BREAKER SHEAR SELECT SW A/C THERMO (LOW) 105B CN9-8 0.5LB CN10-5 105A 100A 100B
3-15 CYL. 6 PREHEAT RELAY
(0 281 002 576) 0.5RG CN4-3 137A GND 150E CN2-8 0.5RL (1-WAY) 0.5RL (K1006572/K1002406D21) AIR HEATER
V
2 2-29
0.5GW CN4-2 136A RxD 151C CN2-9 0.5RY (2-WAY) 0.5RY FG001415
0.5B
PST SHEAR PRESS BREAKER
106B CN8-11 0.5LY CN10-6 106A
FET
(544-00007 )
COMPRESSOR 8B
E
99
ALTERNATOR 50A
(2502-9009 )
FUEL 3-05 UP 1.25B CN11-1 99 - +
0.5GL CN4-1 135A TxD M (2208-6013B )
TEMPERATURE 1 2-34 3-14 CYL. 4 AUXI MODE RESISTOR TML 1 0 2
SENSOR
t RS-232
(545-00011 ) 1WAY-2WAY S/V (OPT) 99 107B CN8-12 0.5LW CN10-1 107A
2 2-17 9 BLOWER MAGNET ALTERNATOR 80A(OPTION)
V 0.85BrB 94A 93B 0.85RL 54J 0.85LW 47C CLUTCH
1.25BrR
0.85RY
0.5WR
0.85W
SHEAR 10
0.5Br
152A
2RW
0.5G
SELECT 152D 0.85RB 152C 1 0.85RY 151A 108A CN9-13 0.5GrG CN10-2 108B FRE (P1) 47A 47B
COOLANT 1 2-36 VEHICLE 5 1
3 INTAKE
t 101A CN1-10 0.85Or 101B 1 109A CN9-12 0.5GrY CN10-20 109B REC (P2) ACTUATOR
TEMPERATURE CONN 5
7 0.85BrR 133G M
2 DA2-3 151B
DIODE 4
(170-00004) 0.5OrB AMP 040 28P AMP 070 16P AMP 040 12P AMP 040 20P
0.5GBr
12
0.85W
DUCT
2RW
1 0.5B 99 (R)
1 2-25 13 (426-00263 ) (ROTATING-CW) SENSOR
INCREMENT SPEED SENSOR 163A 163B 2 3 164A 68A CN2-18 0.85BG 68B 0.85B PILOT FILTER SW
N
AMP 070 16P
1-09 0.85B 2B 72B 0.85YR CN3-7 72A 148C 148B 1 5 71C 4 0.85GY 142A CN8-3 0.5Lg 2 - + 1 4 3
20 19 18 17 16 15 14 13 12 11 10
18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
(CLOSE) (C)
AMP 040 20P
27B 0.85LgW CN3-10 27A GND 92B CN3-17 0.5GB 92A 3 (R)
(k1003296) 8 (SHEAR-OPEN) AMP 12P + 18P
HIGH DA6-4 149D 180F 180C
0.85BrW (1)
4 3 0.85B JOYSTICK LEVER SWITCH A/C CONTROL PANEL
5
19B 1-01 0.85RW (543-00107 ) DA3-1
(420-00468 ) 0.5WR
0 1 70F 1 70C
19C 1-07 0.85RW 2RW (ON JOYSTICK R.H) 179B 2 0.85GB
0.85RY
3 180A 180G 180D 2-PUMP S/V
19D 1-12 0.85RW 0.5GBr 0.5GBr 0.5GBr I 0.85BrW 0.85BrW (2)
19E 2RW 2RW 2RW 2RW 2RW 0.5WR 54R 8 7 0.5B 6
1-13 0.85RW DA3-2
7C 1-39 0.5Br (KEY SW) 0.5Br 0.5Br 0.5Br 70G 2
0.85GB 70D
2-PUMP SWITCH
153A 1-16 0.85W (AIR HEATER RELAY) 0.85W 0.85W 0.85W (549-00101/K1002406DXX) 180H 0.85BrW 180E
(3)
154B 1-04 0.85BG (AIR HEATER RELAY) 0.85BG 0.85BG 0.85BG 7
DA3-3
0.85GB 0.85GB 0.85GB 70H 3 0.85GB 70E
(CONN.2) (CONN.1)
FG001435
Figure 1
0.5B 7 8 54Q
SEAT AIR SUSPENSION (OPT)
SEAT HEATER
(545-000 ) AIR SUSPENSION
SEAT HEATER SWITCH (401-00 )
TERMINAL NO LCD GAUGE PANEL
CN2 (549-00101/K1002406D1) 143C
(539-00076B) 1.25B 1.25RB
P
0.5RG
KET 118 9P DIAGNOSTIC CONN. 14P
CN6-3 3 54B 0.5WR 0.5WR 0.5WR
4 3 2 1 ILL.
CN6-1 1 28B 0.5R 0.85R 0.85R
9 8 7 6 5 3 2 1 CN6-2 2 28C 0.5R 2RL 2RL
PILOT BUZZER
7 6 5 4
(CN13) (2516-1116 )
11 10 9 8 L1 +
14 13 12
0.5R 28G TRAVEL/SWING ALARM ASSEMBLY (OPT) FUEL HEATER (OPT)
MOLEX 4P L2 CN6-12 12 29B 0.5WB 29A -
L3 + 31B 0.85RY 0.85RY 87a
CN6-11 11 130D 0.5RW ALARM BUZZER
1 2 3 4 (CN15) 30 20C
(516-00011 ) - 0.85B 0 2RG
(CN14) L4 2.5R 59A 87 1 0
0.5P 3 I 2 0.5W 87a 30B
CN6-9 9 99 0.5B 30 59B 85 86
L5 104C II 32B 0.85RG 0.5RY 39A 3 I
ECU CONNECTOR CN6-10 10 99 0.5B 31A 87 0.5B
L6 0 39B 0.5B 7
I 5 0.5W 0.5W 85 86 0.5RG
0.85B 122B 0.85V 122A 6 II FUEL HEATER
12 17 18 35
32C 32A 30C FUEL
8 0.5WR RELAY
36 53
OVER LOAD WARNING (OPT) 4bar
7
(2544-9033 )
S
54M ALARM RELAY (549-00101/K1
7 11 54 71 SWING PRESS SW
ALARM SWITCH (2544-9033 )
1 6 72 89 (549-00010 ) 0.5B 2.5B
OVER LOAD ONLY SWING (OPT) (549-00103/K1002406D14) FUEL HEATER
WARNING SWITCH
(549-00102/K1002406D4)
ECU CON.1 (89-PIN) 1 0 0.5RG 0.5P
2 140B 0.5BrY 57B 0.85RY
VEHICLE CONN.
0.5B 3 I 0.5RW 0.5RW HORN 1
H.F 0.85B HORN RELAY
7 8 0.5WR 0.5WR 0.5WR (516-00014 ) (2544-9033 )
0.5B 54P
WARNING LAMP 87a
0
L1 : CHARGE 28D 0.85R CN5-4 140A 141A 3 2 21B 57C 0.85RY 57A 87
+ I 0.5RL 0.85RY
L2 : ENG OIL PRESS II HORN 2
PRESSURE SENSOR 139B 0.85BrW CN3-5 139A 55F CN2-6 L.F 0.85B 0.5G 58A 85
L3 : W/T OVER HEAT SIG 0.5RG (516-00015 )
(OWD) 0
L4 : E/G WARNING 145A 0.85W CN3-6 145B 141B CN2-4 0.5BrB (MANUAL) 0.5BrB 5 21L
(2547-9045 ) - I 0.5RL
L5 : PREHEAT 22B CN2-5 0.5BrW (AUTO) 0.5BrW 22A 6 II
L6 : WORK LAMP CONTROLLER 0.85RG
28E 0.85R 0.5B 7 8 54H 0.5WR
+ (K1007725) 0.5G
ECU CON.3 (16-PIN) ECU CON.2 ( PIN)
PRESSURE SENSOR(A) 74B 0.85GR CN3-1 74A
CYLINDER CONN. ENGINE CONN. LCD DISPLAY PANEL SIG
(FRONT PUMP) HIGH SPEED SWITCH
WATER TEMPERATURE 75A 0.85W CN3-2 75B
(2547-9045 ) - 10B CN2-1 0.5BG KEY SW 'START' (549-00103/K1002406D12) 0.5BG
FUEL LEVEL
DIODE ARRAY 89B CN1-15 0.5GB START RELAY 0.5GB
28F 0.85R
+ Py
GRAPHIC DISPLAY PRESSURE SENSOR(B) AUTO IDLE (1)
76B 0.85GY CN3-3 76A 104A CN2-15 0.85P 104B 0.85B
(REAR PUMP) SIG
5 6 7 8 3 4
19bar / TRAVEL SW 0.5RW
(2547-9045 ) 77A 0.85WL CN3-4 77B
- (2549-9112 )
21C CN1-1 0.85RL 0.5WR
CN7-4 4 80A 0.5Y 0.5Y CN4-4 80B 21D CN1-2 0.85RL 1.25RL 1.25RL
1 2 3 4 1 2
CN7-5 5 81A 0.5YB 0.5YB CN4-5 81B 9D CN2-14 0.5RW ALT 'I' 0.5RW
CAN A
DA1 ~ DA3 DA4 ~ DA6 CN7-6 6 82A SHIELD SHIELD CN4-6 82B 185B CN5-1 0.5RW (FAN CONTROL) 0.5RW 185A NC
COM 40B 0.85Y
CN7 CN6 99 CN1-8 0.85B 0.85YG 41A NO
AMP 040 12P+16P SOL-VALVE ASSEMBLY (426-00262 )
99 CN1-9 0.85B
0.85YG 41B PILOT CUT-OFF SWITCH
ECU 3 41C PILOT
(549-00089A) QUICK CLAMP(OPT)
(539-000 ) DA4-1
1 CUT OFF
0.85B 99 0.5Br 0.85Br
ENGINE CYLINDER INJECTOR (C1) () 1
CONN CONN SOLENOIDS 0.85YL 0.85YL 61C 2 0.85LB
84C 84B
3-09 4 61B () 3
DA4-2 BREAKER 66B
DIODE 6
AMP 040 12P
CYL. 1 2 99 84A
3-13 0.85B
AMP MIC 21P
(C2)
SOL-VALVE QUICK CLAMP SW
0.85RL 0.85RL 21F
(549-00092 )
3-04 6 21J HIGH 0.85B
DA1-2
CYL. 3 SPEED
0.5G
3-12 24C CN1-12 0.85Gr 24B 2 0.85Gr 24A
CN4
66D
PUMP 2-05 0.85LB
3-03 5 21H RELIEF 66C
(0 445 020 011) DA1-1 REVERSE FAN
CYL. 2 DIODE 7
3-06 23C CN1-11 0.85GrW 23B 1 0.85GrW 23A PRESS UP
S/V
3 2-09 (C4) 184B 0.85GW 184A
0.85RL 0.85RL 21G
OIL PRESSURE P& 4 2-33
SENSOR 3-11 7 21K SWING AUXI MODE RESISTOR
AMP 070 18P
t DA1-3
(ODFT) 1 2-19 PRIORITY DIODE 9
3-16 CYL. 5 25C CN1-13 0.85GrL 25B 3
0.85GrL 25A 0.85YL 0.85GY (545-00011 )
(0 281 002 420) 2 (C5) 0.85BrB 94A 93B 0.85RL
2-35
V 184C CN1-14 0.5GW (REVERSE FAN) 0.5GW
61D 71A
0.85BrR
3-10
84D CN2-11 0.5Br (QUICK CLAMP) 0.5Br
3 2-10
CN2
3-15 CYL. 6
BOOST PRESSURE P& 4 2-28 0.85RL
SENSOR
(LDF 6T)
t 1 2-21
60B CN2-2 0.5BrW (POWER MAX) 0.5BrW BREAKER SHEAR SELECT SW
3-05
(0 281 002 576) 0.5RG CN4-3 137A GND 71B CN2-10 0.5GY (BREAKER) 0.5GY (K1006572/K1002406D21)
2 2-29 CYL. 4
V 3-14
0.5GW CN4-2 136A RxD 150E CN2-8 0.5RL (1-WAY) 0.5RL
0.5B
PST SHEAR PRESS BREAKER
FUEL 0.5GL 135A TxD UP
(CONN.3) CN4-1 151C CN2-9 0.5RY (2-WAY) 0.5RY
TEMPERATURE 1 2-34 TML 1 0 2
SENSOR
t VEHICLE
RS-232 0.85RL 1WAY-2WAY S/V (OPT) 99
2 2-17 9
(0 281 002 209) V CONN 0.5WR 54J
CHECK 1 SHEAR 152A 10
101A CN1-10 0.85Or 101B
COOLANT 1 2-36 CONN 5 SELECT 152D 0.85RB 152C 5 1 1 0.85RY 151A
3
80C 1-35 CAN B H 0.5Y 0.85LgR P/V-(A)
TEMPERATURE t 0.5GL 135B 94B 2 95A 95B
7 0.85BrR 133G
2 2-18 1-34 CAN B L 1 (B) DA2-3 DA2-1 151B 14
SENSOR V 81C 0.5YB
0.5GW 136B 3 0.85BrR 133H
(0 281 002 209) 2 102B CN1-21 0.85OrB 102A 3 13
82C 1-33 SHIELD 6 0.85LgW
0.5RG 137B 4 152B 0.85RL 150A
3 0.85B 96B 96A 11
PUMP (426-00263 )
80D 1-53 CAN A H 0.5Y 0.5Y 80E 6
4 PROPORTIONAL V/V 6
0.85RY
0.85RL
DA2-2
81D 1-52 CAN A L 0.5YB 0.5YB 81E AUXILIARY MODE SW 2 0.5BrW 60A
5 (549-00090 ) BREAKER 16
1-51 SHIELD 82E 150B
82D SHIELD
6 1 SELECT 150D 0.85RL 150C 2 0.85BrL 134B
15
0
174A 1-64 0.5YB (DIAGNOSTIC LAMP) 0.5YB 174B 183A CN5-8 0.5LY 183B 2 8 0.85YL 61A
7 3 99 (A) DA2-4 12
I 0.5B
175A 1-28 0.5BY (DIAGNOSTIC LAMP) 0.5BY 175B 4 0.85B 3
8 0.5B 7 8 0.5WR JOYSTICK LEVER SWITCH
176A 1-08 0.5Gr (DIAGNOSTIC SW) 0.5Gr 176B
9 (420-00469 )
54Y
177A 1-27 0.5Dr (DIAGNOSTIC SW) 0.5Dr 177B 10 REVERSE FAN SW 99
0.5B 6 3 58B 0.5
165A 1-31 0.5BW 0.5BW 165B (549-00101/190-01168DXX) ROTATING S/V (OPT) (HORN)
11 (C)
E/G EMERGENCY STOP SW
0.5GBr 166B
(K1001702 ) 12 181A CN1-7 0.85GrL 181B CCW 146C 146B 1 0.85OrB 0.85OrB 146A 4 1 133B 0.8
0.5B 99 (ROTATING-CCW)
13 COOLING FAN SPEED 3
(L)
163A 1-19 0.5R 163B 2 3 164A (A) DA5-1
14 182B 0.85GrR 182A PROPORTIONAL V/V
NC CN1-18 1 0.85OrR 147A 5 2 133C 0.8
164B 1-45 0.5BL
1 2-25 (426-00263 ) (ROTATING-CW) (R)
INCREMENT SPEED SENSOR CN15 78A CN1-19 0.85Lg 78B
N 0.5B P/V-(C) (OPTION) 147C 147B 2 0.85OrR
(CRANKSHAFT)(DG6)(VR)#1 2 2-24 CW (ON JOYSTICK L.H)
(TONE WHEEL WITH SLOTS) 0.5GBr FLOW CONTROL 4
V SHIELD 79B CN1-20 0.85LgB 79A (B) DA5-2
(0 281 002 662) 178B CN5-2 178A PROPORTIONAL V/V PEDAL SWITCH
1-29 0.5LW (PREHEAT LAMP) 2 3 0.85B
Px 0.85BrL 134C 133J 0.8
99 1-03 0.85B
2 72B CN3-7 72A 103A CN2-16 0.85V 103B 0.85B
AMP 040 20P
3
AMP 070 16P
2-12 27B 0.85LgW CN3-10 27A 68A CN2-18 0.85BG 68B 0.85B PILOT FILTER SW 71D 0.85OrY 148A 4 1 151J 0.8
RAIL PRESSURE SENSOR P (K1003296) 3 DA6-3 6
2 2-27 (471-00075) (SHEAR-CLOSE)
(RGS3) (426-00263 ) 2 (L)
(0 281 002 534) V 1 2-20 ENG CONTROL DIAL 69A CN5-3 0.85RB 69B 0.85B 149C 149B DA6-2 2 0.85Or 0.85Or 149A 5 2 151K 0.8
RETURN FILTER SW (OPEN)
(K1013846) 1.0bar 8 (SHEAR-OPEN)
LOW CW 1 90B 0.5GR CN3-15 90A +(5V) (549-00094 ) DA6-4 149D (R)
CN5
2 91B 0.5G CN3-16 91A SIG 70A CN5-7 0.85GB 70B 0.85B PEDAL BRAEKER 4 3 0.85B JOYSTICK LEVER SWITCH
19B 1-01 0.85RW PRESSURE SW (OPTION) (420-00468 )
19C 3 92A 0.5GB CN3-17 92B GND (549-00010) (ON JOYSTICK R.H) 0.
1-07 0.85RW 2RW
HIGH
19D 1-12 0.85RW 0.5GBr 0.5GBr 0.
19E 1-13 0.85RW 2RW 2RW 2RW 2R
7C 1-39 0.5Br (KEY SW) 0.5Br 0.5Br 0.
153A 1-16 0.85W (AIR HEATER RELAY) 0.85W 0.85W 0.
154B 1-04 0.85BG (AIR HEATER RELAY) 0.85BG 0.85BG 0.
0.85GB 0.
(CONN.2) (CONN.1)
Figure 2
+
M
160A 8 (INT-1) 0.5LY 4 160B CONT. POWER
LOWER WIPER RELAY 0.85LR 156A 4 0.85LB 4 156B
(2544-9033) 161A 10 (INT-2) 0.5LG 5 161B INT SEEK ANTENNA
ROTATING
WASHER VOL.
ACON SWITCH L 36B 0.85R 36A 87a 0.85G 37B 1 0 162A 11 (WASHER) 0.5L 6 162B
30 38B 2 38A
K1002406D3) 87 88B 3 I 1 0.85WL WINDOW WASHER MODULE
124B 157B 7 157A CAR STEREO
0 + (K1000789 ) (K1002641 )
2 0.85RG STOP RUN B 88H 0.85Br 85 86 88E 0.5B 7 8 54L 158B 5 0.85WB 6 158A 12 0.85RB - + 0.85L (541-00010 )
35C 1 34E
I 0.5WR P SPEAKER
M 190A 63C 6 0.85WR 35A 34C 2 121B 0.5WG 121A 15
8 0.5WR LOWER WIPER SW Vcc(+5V) (2541-9020 )x2
S 37A 0.85G (549-00046/K1002406D5) 0.5RB 0.5L
- 3 123B 0.5W 123A 16 (LH) (RH)
35B 34D 54D MICOM
54K E 0.85B 0.85BR 0.5WR 1
DIODE 5
34B 1 0.85L 0.85L 4 169A 0.5BL 169B 13
2 1 + - + -
130B 13 0.5RW 2 54C
0.5WR
LOWER WIPER MOTOR 190B CN14 MOLEX 4P Vcc(+5V) 117B 118B 119B 120B
(538-00012 ) 0.85B 0.85Lg 9 138A 99 2 0.85B 0.5B 8
2 52B 117A 7 0.5GrR
0.85R LOWER WIPER CUT SW 138B AMP MIC 13P
(549-00077) WIPER CUT SW CN12 CN13 KET 8P 118A 17 0.5BY
0.5BR 17B 14
(549-00086 ) 119A 2 0.5GrL
0.85BR 0.85BR 0.85L 16C 5
5 52C 0.5R
0.5WR 120A 10 0.5BW
0.5WR
FUEL PUMP (OPT) 87a 0.5LW 3 65C
11 0.5B
8 54G 0.5WR 0.85L 16B 30
FUEL PUMP FUEL PUMP SW CIGAR LIGHTER 87 65A 0.85LW 4 65B
(401-00527 ) (549-00093 ) (545-00001) 99
0.5BR 0.5BR 88C 86 85 0.5B 0.85B
1.25B 64B 1.25WL 64A 3 2 63B 1.25WR
P 99
1.25B DC/DC 3 17A 0.85BR
0.85WR 15B 1 STEREO RELAY
CONVERTER 1 (2544-9033 )
2 16A 0.85L
(2531-1003 )
1.25RB 1.25RB STARTER CONTROLLER STARTER RELAY
62B
0.85WR
(2543-9015 ) (2544-1022)
0.85BR
1.25R
0.5RW
0.85L
1.25W N
2RY 14C S 0.85BW D PP 3Y
1.25RB 2 132A 0.85R
0.85RG 0.85LR 1 DC/DC 14B 14A 5A
CONVERTER 2 132B +
DIODE 3
131B 3 0.85BL C B 3W
(2531-1003 ) 12V POWER 18B
0.5WR 99 SOCKET 12C 4C
- E B P
(527-00006) 0.85B
0.85R 12B 0.85BL
0.85B 13B
1.25WG
2RL
0.5RW 0.85LR STARTER RELAY 2
(2544-9033 )
1.25RB 87a 0.85BL
FUEL HEATER (OPT) 0.85BY 30
87 12A
11B
0.5LR 86 85 0.5GB
87a
1.25WR
0.85WR
0.85RG
0.85RY
0.85BR
2RG
1.25R
0.85R
1.25W 89A
0.85LR
2RG
2RY
0.85L
59A 87
2RL
2.5R 1 0
2 0.5GB
59B 85 86 0.5RY 39A 3 I
20B 125A 50A 20A 28A 52A 63A 124A 179A 62A 131A 34A 88A 15A 3Y
0.5B 3W
39B 0.5B 7 8
9 10 11 12 13 14 1 2 3 4 5 6 7 8 6A 1.25WR
STARTER
54K 30A 20A 20A 15A 15A 15A 10A 10A 10A 10A 10A 10A 10A 10A
FUEL HEATER (65.26201-7058A)
1.25WR
5B
0.85LR
0.85BY
FUEL HEATER 1.25WR 2WR
RELAY 50 24V 6.6KW
SWITCH 17 18 2E 15 16
(2544-9033 ) 4G 4D 2B 11A
(549-00101/K1002406D2)
5W 5W ACC C
2.5B FUSE BOX 2 FUSE BOX 1
5W 5W 13A
FUEL HEATER (K1001263A) (K1001263A) B
4F 2D 4E 10A 6B BR 0.85Br
15 16 2WR 17 18 2C 2WR R2
57B 0.85RY 7A
HORN 1 HORN RELAY 10A 10A 10A 10A 10A 10A 10A 10A 30A 20A 20A 15A 15A 15A 15R 98A 30
H.F 0.85B R1
(516-00014 ) (2544-9033 )
1 2 3 4 5 6 7 8 9 10 11 12 13 14 STARTER SWITCH
87a
0.85RY
1.25RB
0.5RW
0.5WR
0.5GB
0.5BG
30 56B 0.85RB 56A 66A 30A 93A 166A 40A 130A 83A 42A 133A 143A 21A 19A (K1001654B)
57C 0.85RY 0.85RY 57A 87
0.85WR
0.85RB
0.85RG
HORN 2
0.85LB
0.85RL
0.85Y
0.5GBr
0.5RW
1.25BrR
2RW
L.F
1.25RB
0.85B 85 86
1.25RL
0.5Br
0.85LB 2WR 2WR
0.85RG 0.85RG
31
85B
0.5G 0.5GBr 0.85RY
3W 85R
0.85Y 2RW
0.85Br
0.5BG 0.5BG 0.5BG
0.5GB 0.5GB 0.5GB 2WR 2R
1.25BrR 8W 7B 2A 1B
0.5G
0.5RW 0.5RW 0.5RW FUSIBLE LINK
DIODE 2 CIRCUIT BREAKER (2527-1023A)
0.5WR 0.5WR
2R
1.25RL 1.25RL (2527-9004 )
1.25RL 1A
8A B
0.5RW 0.5RW 0.5RW 9D 3 1 6C 0.5WR A
8W 8W
185A NC 0.85RL 0.5B 2 HOUR 4B 3B 3A 85R
COM 40B 0.85Y
41A 1.25BrW BR
NO HOUR METER 1.25BrW 8C
OFF 10W
E B+ 0.5WR (2528-9043 )
PILOT CUT-OFF SWITCH 0.5B DR 8B E
(549-00089A) QUICK CLAMP(OPT) ON 83B 1.25B
84A
0.85W 0.85W 15R
SOL-VALVE QUICK CLAMP SW
(549-00092 ) 0.85BG 0.85BG
0.85B 0.5RW - + - +
1.25BrR
0.85RY
0.85BG
0.85RL
0.85LB
0.5GBr
0.85W
0.5Br
2RW
0.5G
CN11-4
0.85RY
0.5GBr
0.5WR
0.85W
10 R
0.5Br
2RW
0.5G
152A 0.85RY 151A 108A CN9-13 0.5GrG CN10-2 108B FRE (P1) 47A
5 1 1 INTAKE 47B - F
3 15B
0.85BrR 133G 109A CN9-12 0.5GrY CN10-20 109B REC (P2) ACTUATOR E
DIODE 4
3 151B 14 M
DA2-1
0.85BrR 133H
13 AIR HEATER E ALTERNATOR 50A
0.85RL 150A 110A CN9-15 0.5OrR CN10-12 110B DEF (P1) 0.85B 0.85B 99
152B 11 (2502-9009 )
111A CN9-14 0.5OrW CN10-13 111B VENT (P2) 8B
6 M
6 MODE ALTERNATOR 80A(OPTION)
0.85RY
0.85RL
0.85OrR 147A 5 2 133C 0.85BrR 116A CN8-2 0.5OrB CN10-15 116B AMP 040 28P AMP 070 16P AMP 040 12P AMP 040 20P
0.5Br
2RW
DUCT
(ROTATING-CW) (R) SENSOR
2 0.85OrR 6 5 4 3 2 1 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
0.85BrR
DX420LC
FG005207
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
F
E
G
C
D
K
H
B I
FG004069
Figure 1
DANGER!
DOOSAN warns any user, that the removal of the
counterweight from the machine, front attachment or any
other part, may affect the stability of the machine. This
could cause unexpected movement, resulting in death or
serious injuries. DOOSAN is not liable for any misuse.
Never remove the counterweight or front attachment unless
the upper structure is in-line with the lower structure.
Never rotate the upper structure once the counterweight or
front attachment has been removed.
FG000371
IMPORTANT Figure 2
WARNING!
This procedure is only intended for routine removal or
replacement of the attachment, while working under
normal, safe operating conditions. In the event of a major
structural collapse of some part of the attachment, an
accident or complete loss of attachment hydraulic function,
DO NOT proceed with attachment disassembly unless you
are completely sure of what you are doing. Please call your
local DOOSAN distributor or DOOSAN After Sales Service
for assistance. DO NOT allow personnel to stand
underneath a weakened or only partially supported
attachment section. Keep clear of hydraulic lines that may
have fluid escaping at high-pressure - it can cause severe
or even fatal injuries.
WARNING!
Secure the swing lock and tag and lock out controls in the
operator's cabin to keep anyone from moving or
inadvertently starting the engine. Restrict access to the
work site while sections of the attachment are in the air, or
while they are being supported by the assist crane. The safe
lifting capacity of the assist crane or hoist that is used must
exceed the weight of the heaviest section of the attachment,
the boom (approximately 2,000 kg [4,400 lb], not including
the weight of accessories or fixtures).
Remove retainers on the end of the mounting pin for the arm
cylinder rod end. Use the assist crane to relieve the weight load
and withdraw the pin. Lower the arm down to the blocking
support for any continued disassembly procedures.
WARNING!
Traveling the excavator, swinging the turntable or
movement over bumps or sloping, uneven surfaces could
all produce loss of control and possible accidents or
injuries, if the turntable deck has been unbalanced by
removal of weight from one end only.
WARNING!
Before assembling the front attachment, make sure that the
individual boom, arm and bucket sections are all
compatible and can be used safely for work intended. Refer
to the General Safety Pages, Lift Ratings, Working Range
Diagrams and Weights of Materials sections in the
Operation and Maintenance Manual. Consult your dealer or
DOOSAN After Sales Service for more information if you
have any questions or require more information.
1Bucket
Edition 1
Bucket SP000041
Page 1
MEMO
SP000041 Bucket
Page 2
Table of Contents
Bucket
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
Bucket Tooth Inspection and Replacement .......... 6
Bucket O-ring Replacement ................................. 7
Bucket Shimming Procedures .............................. 9
New Bucket Installation ................................................... 9
Bucket Attachment, Removal and Reversal ....... 11
Detaching the Bucket .................................................... 11
Attaching the Bucket ..................................................... 11
Reversing the Bucket .................................................... 12
Bucket SP000041
Page 3
MEMO
SP000041 Bucket
Page 4
SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
SP000041 Bucket
Page 5
BUCKET TOOTH INSPECTION
AND REPLACEMENT
There are several different types of attachment methods for
replaceable bucket teeth. Some of the most common types are
shown in the following drawings.
Bucket teeth are usually replaced in sets but it may sometimes
be necessary to replace individual teeth.
Look for the following indications of wear or damage:
Lock pins protrude unevenly on one side.
Lock pins have been worn down so far that they no
longer make full contact through the length of the pin
hole.
Lock washers or pins show obvious damage or
weakness.
Wear points on the working surfaces of tooth points -
pits, cracks, chips or craters - are larger than 8 mm to
10 mm (1/3" to 1/2") across.
HAOC680L
Figure 1
3. Once the worn tooth has been removed, use a putty knife 3
to scrape the adapter as clean as possible.
4. Slide the new tooth into position and insert the lock washer. 2 1 FG000346
Figure 2
5. Insert the locking pin into the tooth and with a hammer,
drive the pin in until the lock washer seats in the locking
groove.
Bucket SP000041
Page 6
BUCKET O-RING
REPLACEMENT
WARNING!
Due to possibility of flying metal objects, always wear
safety helmet, protective gloves and eye protection when
changing pins.
ARO1350L
Figure 3
2. Roll the old O-ring (1, Figure 4) onto the boss (2) around
the bucket pin (3). Remove the bucket pin and move the
1 4
arm or bucket link (4) out of the way. 2
ARO1390L
Figure 4
ARO1391L
Figure 5
SP000041 Bucket
Page 7
5. Roll the new O-ring (1, Figure 6) into the O-ring groove.
ARO1392L
Figure 6
Bucket SP000041
Page 8
BUCKET SHIMMING
PROCEDURES
WARNING!
When performing this adjustment, put the hydraulic
cativation control lever in the LOCKED position and stop
the engine.
Improperly adjusted clearance could cause galing on the
contact surfaces of the bucket and arm, resulting in
excessive noise and damaged O-ring.
3
1 2 8 7
5 10
9 4 6
FG000415
Figure 7
Reference Reference
Description Description
Number Number
1 No Gap 6 Stopper
2 Arm Boss 7 Bolt
3 Bucket Clearance 8 Hard Washer
4 Shim 9 Flange
5 Pin 10 Bucket Boss
SP000041 Bucket
Page 9
Shimming Procedures for Installed Bucket
The clearance of the bucket linkage on this machine can be
adjusted by shimming. If the gap between the bucket and the
arm becomes excessive, adjust bucket clearance to 1.0 mm.
The thickness of the shims are 1.0 mm (0.04 inch)
1. Position the machine on a level surface and lower the
bucket to the ground.
2. Slowly operate the swing control lever until arm boss (2)
and the bucket boss (10) are in full face contact at no gap
(1).
3. Place the hydraulic activation control lever in the LOCKED
position and stop the engine.
4. Measure bucket clearance (3), determine the number of
shim that need to be removed from shims (4) by using the
following calculation;
Subtract 1mm from bucket clearance (3).
5. Remove the appropriate number of shim at location (9) in
order to meet the above thickness. To remove the shim,
detach stopper (6) and bolts (7) from bucket.
6. After correcting the number of shim, install stopper (6) and
tighten bolts (7).
NOTE: Bolt torque: 27 kgm (195 ft lb)
7. After installation, make sure that bucket clearance (3) is
still correct.
Bucket SP000041
Page 10
BUCKET ATTACHMENT,
REMOVAL AND REVERSAL
CAUTION!
Use care pulling out the pin to avoid damaging the dust
seals on either end of the arm.
When the pin has been withdrawn, move the operating joystick
slightly to take weight off the remaining link pin. Disassemble the
link pin end retainers and pull out the pin.
Lift the arm away from the bucket so that the bucket can be
carried away or another end attachment can be put on the
excavator.
SP000041 Bucket
Page 11
When the link pin has been installed, withdraw the temporary
support rod from the bucket pin holes, lower and raise the arm
and boom and install the bucket pin.
WARNING!
When making linkage alignments, never insert fingers into
pin holes. The attachment or bucket could shift position
and cause a severe injury. Match holes by visually lining
them up. Use the sharp-tipped, soft point of a pencil or a FG000607
similar tool to check for high spots or irregularities. Figure 9
WARNING!
Bucket curl and dump levers must be used in opposite
directions, after the bucket has been reversed.
Bucket SP000041
Page 12