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Daewoo Excavator DX340LC Shop Manual K1009684AE – PDF
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Daewoo Excavator DX340LC Shop Manual K1009684AE – PDF DOWNLOAD
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Daewoo Excavator DX340LC Shop Manual K1009684AE – PDF DOWNLOAD
Language : English
Pages : 832
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Daewoo Excavator DX340LC Shop Manual K1009684AE – PDF DOWNLOAD
Table of Contents....................................................................................................... 5 Safety.................................................................................................................. 7 Track Excavator Safety.............................................................................................. 9 Safety Precautions.............................................................................................. 13 Applicable Models............................................................................................... 13 To the Operator of a DOOSAN Excavator........................................................................... 14 Learn the Signal Words Used with the Safety Alert Symbol.................................................... 16 General Safety Essentials....................................................................................... 17 Accessory Applications...................................................................................... 17 Lifting Capacity Rating Configuration....................................................................... 17 Location of Safety Labels....................................................................................... 18 Summary of Safety Precautions for Lifting in Digging Mode....................................................... 18 Unauthorized Modifications...................................................................................... 19 General Hazard Information...................................................................................... 19 Safety Rules................................................................................................ 19 Safety Features............................................................................................. 20 Inside Operator's Compartment............................................................................... 20 Clothing and Personal Protective Items...................................................................... 21 Breathing Masks, Ear Protection May Be Required............................................................. 21 Vibration Level Information................................................................................. 21 Recommendations for Limiting Vibrations..................................................................... 22 Mounting and Dismounting.................................................................................... 23 Fuel, Oil and Hydraulic Fluid Fire Hazards.................................................................. 23 Precautions When Handling Fluids at High Temperature........................................................ 24 Asbestos Dust Hazard Prevention............................................................................. 24 Injury from Work Equipment.................................................................................. 25 Fire Extinguisher and First Aid Kit......................................................................... 25 Protection from Falling or Flying Objects................................................................... 26 Attachment Precautions...................................................................................... 26 Accumulator................................................................................................. 27 Indoor Ventilation.......................................................................................... 27 Emergency Exit.............................................................................................. 27 Before Starting Engine.......................................................................................... 28 Work Site Precautions....................................................................................... 28 Checks Before Starting Engine............................................................................... 29 Engine Starting............................................................................................. 30 Before Operating Machine.................................................................................... 31 Machine Operation............................................................................................... 32 When Swinging or Changing Direction of Travel............................................................... 32 Travel Precautions.......................................................................................... 33 Traveling on Slopes......................................................................................... 34 Prohibited Operations....................................................................................... 34 Precautions for Operation................................................................................... 35 Avoid High Voltage Cables................................................................................... 36 Protecting Cabin from Falling Object (Optional)............................................................. 36 Operate Carefully on Snow, Ice and in Very Cold Temperatures................................................ 37 Operations on Slopes........................................................................................ 37 Parking Machine............................................................................................. 38 Never Let Anyone Ride on Attachment......................................................................... 38 Maintenance..................................................................................................... 39 Warning Tag................................................................................................. 39 Clean Before Inspection or Maintenance...................................................................... 39 Proper Tools................................................................................................ 40 Use of Lighting............................................................................................. 40 Fire Prevention and Explosion Prevention.................................................................... 40 Burn Prevention............................................................................................. 41 Welding Repairs............................................................................................. 41 Treatment for Electrical Welding to the Body Structure.................................................. 42 Warning for Counterweight and Front Attachment Removal...................................................... 43 Precautions for Removal, Installation, and Storage of Attachments........................................... 43 Precautions When Working on Machine......................................................................... 43 Lock Inspection Covers...................................................................................... 44 Crushing Prevention and Cutting Prevention.................................................................. 44 Track Tension Adjustments Require Caution................................................................... 44 Supports and Blocking for Work Equipment.................................................................... 45 Action When Abnormality Is Found During Inspection.......................................................... 45 Precautions with High-pressure Lines, Tubes and Hoses....................................................... 45 Waste Materials............................................................................................. 46 Battery......................................................................................................... 47 Battery Hazard Prevention................................................................................... 47 Boost Starting or Charging Engine Batteries................................................................. 48 Towing.......................................................................................................... 49 Precautions When Towing..................................................................................... 49 Shipping and Transportation..................................................................................... 50 Obey State and Local Over-the-Road Regulations.............................................................. 50 Lifting With Sling.............................................................................................. 50 Specifications.......................................................................................................... 51 Specification for DX340LC........................................................................................... 53 Safety Precautions.............................................................................................. 57 Applicable Models............................................................................................... 57 General Description............................................................................................. 59 Component Locations............................................................................................. 60 General Dimensions.............................................................................................. 62 Working Range................................................................................................... 64 General Specifications.......................................................................................... 66 Engine Performance Curves (Per DIN6270 Standard)............................................................... 68 Approximate Weight of Workload Materials........................................................................ 70 Performance Tests............................................................................................... 72 Excavator Performance Standards................................................................................. 73 Test Conditions............................................................................................. 73 Travel Speed and Travel Motor Balance (Steering Deviation) Tests............................................ 73 Speed Test.............................................................................................. 73 Travel Deviation........................................................................................ 75 Swing Speed and Deceleration Force Test..................................................................... 75 Swing Speed Test........................................................................................ 75 Swing Deceleration Force Test........................................................................... 76 Cylinder Performance Tests.................................................................................. 77 Boom Cylinders Test..................................................................................... 77 Arm Cylinder Test....................................................................................... 77 Bucket Cylinder Test.................................................................................... 77 Hydraulic Cylinder Natural Drop Test.................................................................... 77 Travel Motor Jack-up Test............................................................................... 77 General Maintenance..................................................................................................... 79 General Maintenance Procedures...................................................................................... 81 Safety Precautions.............................................................................................. 85 Applicable Models............................................................................................... 85 Welding Precautions and Guidelines.............................................................................. 86 Hydraulic System - General Precautions.......................................................................... 87 Maintenance Service and Repair Procedure........................................................................ 89 General Precautions......................................................................................... 89 Hydraulic System Cleanliness and Oil Leaks...................................................................... 90 Maintenance Precautions for Hydraulic System Service........................................................ 90 Oil Leakage Precautions..................................................................................... 91 Cleaning and Inspection......................................................................................... 92 General Guidelines.......................................................................................... 92 Bearing inspection.......................................................................................... 93 Normal Bearing.......................................................................................... 94 Bent Cage............................................................................................... 94 Galling................................................................................................. 95 Abrasive Step Wear...................................................................................... 95 Etching................................................................................................. 96 Misalignment............................................................................................ 96 Indentations............................................................................................ 96 Fatigue Spalling........................................................................................ 97 Brinelling.............................................................................................. 97 Cage Wear............................................................................................... 97 Abrasive Roller Wear.................................................................................... 98 Cracked Inner Race...................................................................................... 98 Smears.................................................................................................. 98 Frettage................................................................................................ 99 Heat Discoloration...................................................................................... 99 Stain Discoloration..................................................................................... 99 Standard Torques....................................................................................................101 Safety Precautions..............................................................................................105 Applicable Models...............................................................................................105 Torque Values for Standard Metric Fasteners.....................................................................106 Torque Values for Standard U.S. Fasteners.......................................................................107 Type 8 Phosphate Coated Hardware................................................................................109 Torque Values for Hose Clamps...................................................................................110 Torque Values for Split Flanges.................................................................................111 Torque Wrench Extension Tools...................................................................................112 Torque Multiplication.......................................................................................112 Other Uses for Torque Wrench Extension Tools................................................................113 Tightening Torque Specifications (Metric)...................................................................114 I. "Loctite" Fastener Adhesives.........................................................................115 II. "Loctite" Pipe Thread Sealant.......................................................................115 III. "Loctite" gasket/flange sealer.....................................................................115 IV. "Loctite" retaining compounds.......................................................................116 V. "Loctite" Adhesives..................................................................................116 Upper Structure.........................................................................................................117 Cabin...............................................................................................................119 Safety Precautions..............................................................................................123 Applicable Models...............................................................................................123 Removal.........................................................................................................124 Installation....................................................................................................128 Counterweight.......................................................................................................131 Safety Precautions..............................................................................................135 Applicable Models...............................................................................................135 General.........................................................................................................136 Warning for Counterweight and Front Attachment Removal......................................................136 Removal.........................................................................................................138 Installation....................................................................................................139 Fuel Tank...........................................................................................................141 Safety Precautions..............................................................................................145 Applicable Models...............................................................................................145 General Description.............................................................................................146 Parts List..................................................................................................146 Specifications..............................................................................................147 Removal.........................................................................................................148 Installation....................................................................................................152 Start-up Procedures.............................................................................................155 Fuel Transfer Pump (Opt)............................................................................................157 Safety Precautions..............................................................................................161 Applicable Models...............................................................................................161 General Description.............................................................................................162 Theory of Operation.........................................................................................162 Troubleshooting.................................................................................................163 Replacement of Rotor and Vane...................................................................................163 Replacement of Rear Cover.......................................................................................164 Replacement of Armature.........................................................................................164 Swing Bearing.......................................................................................................165 Safety Precautions..............................................................................................169 Applicable Models...............................................................................................169 Swing Bearing Maintenance.......................................................................................170 Operating Recommendation....................................................................................170 Measuring Swing Bearing Axial Play..........................................................................170 Measuring Bearing Lateral Play..............................................................................170 Swing Bearing Basic Operation...............................................................................171 Disassembly.................................................................................................171 Assembly....................................................................................................173 Swing Reduction Gear................................................................................................175 Safety Precautions..............................................................................................179 Applicable Models...............................................................................................179 General Description.............................................................................................181 Theory of Operation.........................................................................................181 Parts List..................................................................................................182 Specifications..............................................................................................184 Troubleshooting, Testing and Adjustment.........................................................................185 Removal.........................................................................................................186 Disassembly.....................................................................................................187 Assembly........................................................................................................191 Shaft and S/R Bearing Shrinkage Fitting.....................................................................191 Assembly of the Carrier Subassembly.........................................................................193 Washing of the Carrier..................................................................................193 Washing of Planet Gears.................................................................................193 Assembly of the Carrier Subassembly 1...................................................................194 Assembly of the Carrier Subassembly 2...................................................................197 Assembly of Main Case.......................................................................................201 Washing of the Casing and Other Components..............................................................201 Assembly of the Shaft and the Pinion....................................................................201 Assembly of the Seal and the Bearing....................................................................206 Assembly of the Ring Gear...............................................................................210 Assembly of the Carrier.................................................................................212 Test........................................................................................................217 Pneumatic Test..........................................................................................217 Noise and Abnormal Sound Test...........................................................................218 Assembly of the Motor.......................................................................................219 Supply of Gear Oil......................................................................................219 Assembly of the Motor...................................................................................220 Installation....................................................................................................225 Lower Structure and Chassis.............................................................................................227 Track Assembly......................................................................................................229 Safety Precautions..............................................................................................233 Applicable Models...............................................................................................233 General Description.............................................................................................234 Track Tension...................................................................................................235 Cleaning and Inspection (Wear Limits and Tolerances)............................................................237 Track Shoe..................................................................................................238 Lower Roller................................................................................................240 Upper Roller................................................................................................241 Front Idler.................................................................................................242 Track Shoes and Links...........................................................................................243 Track Removal...............................................................................................243 Track Installation..........................................................................................244 Front Idler Roller..............................................................................................246 Parts List..................................................................................................246 Front Idler Roller Disassembly..............................................................................247 Front Idler Roller Reassembly...............................................................................249 Lower Roller....................................................................................................250 Parts List..................................................................................................250 Lower Roller Removal........................................................................................251 Lower Roller Disassembly....................................................................................251 Lower Roller Reassembly.....................................................................................252 Lower Roller Installation...................................................................................253 Upper Roller....................................................................................................254 Parts List..................................................................................................254 Upper Roller Removal........................................................................................255 Upper Roller Disassembly....................................................................................255 Upper Roller Reassembly.....................................................................................257 Track Spring and Track Adjusting Cylinder.......................................................................258 Parts List..................................................................................................258 Engine and Drive Train..................................................................................................259 Drive Coupling (Main Pump)..........................................................................................261 Safety Precautions..............................................................................................265 Applicable Models...............................................................................................265 Drive Coupling..................................................................................................266 Installation of Drive Coupling..................................................................................267 Installation Procedure......................................................................................267 Hydraulics..............................................................................................................269 Hydraulic System Troubleshooting, Testing and Adjustment............................................................271 Safety Precautions..............................................................................................275 Applicable Models...............................................................................................275 Hydraulic System - General Notes................................................................................276 Hydraulic Schematic.............................................................................................277 General Notes...............................................................................................277 Operation of Working Components.................................................................................279 Boom Operating Circuit......................................................................................279 Boom Up Circuit.............................................................................................279 Boom Down Circuit...........................................................................................279 Arm Operating Circuit.......................................................................................280 Arm Crowd Circuit...........................................................................................280 Arm Dump Circuit............................................................................................280 Bucket Operating Circuit....................................................................................281 Bucket Crowd Circuit........................................................................................281 Bucket Dump Circuit.........................................................................................281 Swing Operating Circuit.....................................................................................281 Right Swing Operating Circuit...............................................................................282 Left Swing Operating Circuit................................................................................282 Swing Relief Valve and Makeup Valve.........................................................................282 Travel Operating Circuit....................................................................................282 Forward Travel Circuit......................................................................................283 Reverse Travel Circuit......................................................................................283 Procedural Troubleshooting Baseline Recommendations.............................................................284 Initial Checks and Tests to Establish Operating Condition of the Excavator..................................284 Triage Summary..........................................................................................284 Pilot Pressure..................................................................................................286 Adjustment and Testing......................................................................................286 Power Mode Valve................................................................................................287 Current Signal and Hydraulic Pressure Adjustments...........................................................287 Pressure Up Valve...............................................................................................288 Checks and Adjustments......................................................................................288 Pump Input Power Control........................................................................................290 Pump Regulator Adjustment...................................................................................290 Flow Meter and Flow Meter Kit Installation and Testing..........................................................293 Installation and Testing Procedure..........................................................................293 Swing System Troubleshooting....................................................................................295 Precautions/Initial Checks..................................................................................295 Swing Relief Valve Checking and Adjustment..................................................................296 Troubleshooting – Swing Gearbox.................................................................................298 Troubleshooting – Hydraulic Problems............................................................................299 Troubleshooting – Control Valve.................................................................................301 Troubleshooting – Travel Control Valve..........................................................................302 Troubleshooting – Joystick Control Valve........................................................................302 Accumulator.........................................................................................................303 Safety Precautions..............................................................................................307 Applicable Models...............................................................................................307 General Description.............................................................................................308 Specifications..............................................................................................310 Center Joint (Swivel)...............................................................................................311 Safety Precautions..............................................................................................315 Applicable Models...............................................................................................315 General Description.............................................................................................316 Center Joint Disassembly Diagram............................................................................317 Disassembly.....................................................................................................318 Reassembly......................................................................................................321 Cylinders...........................................................................................................325 Safety Precautions..............................................................................................329 Applicable Models...............................................................................................329 General Description.............................................................................................330 Theory of Operation.........................................................................................330 Parts List..................................................................................................332 Special Tools and Materials.....................................................................................334 Piston Nut..................................................................................................334 Piston Jig..................................................................................................336 Steel Bushing Jig...........................................................................................338 Dust Wiper Jig..............................................................................................340 Slipper Seal Jig............................................................................................342 Slipper Seal Straightening Jig..............................................................................344 Disassembly.....................................................................................................346 Reassembly......................................................................................................351 Swing Motor.........................................................................................................355 Safety Precautions..............................................................................................359 Applicable Models...............................................................................................359 General Description.............................................................................................360 Theory of Operation.........................................................................................360 Structure...............................................................................................360 Circuit Diagram.........................................................................................360 Generation of Rotary Power..............................................................................361 Operation of Relief Valve...............................................................................362 Operation of Parking Brake..............................................................................362 Makeup Check Valve..........................................................................................363 Operation of Time Delay Valve...............................................................................363 External Pilot Pressure: When Pi = 0 (Large Tilt Angle).................................................363 Operation of Swing Reactionless Valve.......................................................................363 Parts List..................................................................................................364 Specifications..............................................................................................366 Torques.....................................................................................................366 Tools and Materials.............................................................................................367 Tools.......................................................................................................367 Troubleshooting, Testing and Adjustment.........................................................................368 General Precautions.........................................................................................368 How to Check Faults of Hydraulic Motor......................................................................368 Troubleshooting.............................................................................................368 Disassembly.....................................................................................................370 General Cautions............................................................................................370 Disassembly of drive shaft subassembly......................................................................370 Disassembly of the cylinder block subassembly...............................................................373 Disassembly of the rear cover subassembly...................................................................374 Cleaning and Inspection (Wear Limits and Tolerances)............................................................376 Reassembly......................................................................................................377 General Cautions............................................................................................377 Reassembly of drive shaft subassembly.......................................................................377 Assembly of Cylinder Block Assembly Subassembly.............................................................380 Assembly of Rear Cover Assembly Subassembly.................................................................384 Air Pressure Test...........................................................................................388 Oil Leakage Check...........................................................................................388 Installation of test bench..................................................................................389 Travel Motor........................................................................................................391 Safety Precautions..............................................................................................395 Applicable Models...............................................................................................395 General Description.............................................................................................397 Theory of Operation.........................................................................................398 Hydraulic Motor.........................................................................................398 Operation of Reduction Gear.............................................................................405 Parts List..................................................................................................406 Hydraulic Motor.........................................................................................406 Reduction Gear..........................................................................................408 Specifications..............................................................................................409 Special Tools and Materials.....................................................................................410 Hydraulic Motor Part........................................................................................410 Reduction Gear Part.........................................................................................411 Tightening Torque Chart.....................................................................................412 Troubleshooting, Testing and Adjustment.........................................................................413 General Precautions.........................................................................................413 Troubleshooting.............................................................................................413 Disassembly.....................................................................................................417 General Caution Matters.....................................................................................417 Reduction Gear Part.........................................................................................417 Hydraulic Motor Part........................................................................................423 Disassembly of Main Body of Motor Section...............................................................423 Disassembly of Valve Casing Subassembly.................................................................426 Disassembly of Cylinder Block Assembly..................................................................427 Cleaning and Inspection (Wear Limits and Tolerances)............................................................428 Maintenance Standard........................................................................................428 Changing Standard of Hydraulic Motor Part...............................................................428 Parts Inspection and Inspection Standard of Reduction Gear..............................................430 Reassembly......................................................................................................431 General Caution Matters.....................................................................................431 Hydraulic Motor Part........................................................................................431 Reassembling of Drive Shaft Subassembly.................................................................431 Assembly of Valve Casing Subassembly....................................................................431 Assembly of Valve Casing Subassembly....................................................................432 Assembly of Cylinder Subassembly........................................................................434 Reduction Gear Part.....................................................................................439 Checkup after Assembly......................................................................................447 Air Test for Reduction Gear.............................................................................447 Air Test for Motor......................................................................................447 Performance Test............................................................................................447 If Test Equipment Is Available..........................................................................447 If on-site performance test is unavoidable as test equipment is not available...........................448 Installation....................................................................................................449 Check.......................................................................................................449 Piping......................................................................................................449 Gear Oil....................................................................................................449 Kind of Oil.............................................................................................449 Oil Drain...............................................................................................449 Oil Filling.................................................................................................450 General Caution Matters.....................................................................................450 Main Pump...........................................................................................................451 Safety Precautions..............................................................................................455 Applicable Models...............................................................................................455 ectional View...................................................................................................456 A8VO200LA1KH1/63............................................................................................456 General Repair Guidelines.......................................................................................458 Seal Kits and Sub- assemblies...................................................................................460 Sealing the Drive Shaft.........................................................................................464 Gear Pump Sealing...............................................................................................466 Remove the Control Housing......................................................................................468 Control Module..................................................................................................472 Control Module LR...........................................................................................472 Control Module H............................................................................................473 Removing the Controller.........................................................................................474 Valve Plate With Valves.........................................................................................476 Remove the Rotary Groups........................................................................................477 Remove the Intermediate Wheel...................................................................................480 Remove Auxiliary Drive..........................................................................................482 Inspection......................................................................................................485 Re-fitting the Rotary Group.....................................................................................490 Pump Assembly...................................................................................................492 Assembly Guideline..........................................................................................493 Adjustment of the Hydraulic Component of the Rotary Group...................................................494 Hydraulic Component - Measurement "D"...........................................................................495 Measuring Device - Hydraulic Component 452 269..............................................................495 Mounting Position...........................................................................................496 Measuring Procedure.........................................................................................498 Installation of Control Housing.................................................................................499 Assembly of Intermediate Wheel..................................................................................502 Installation of Gear Pump.......................................................................................503 Installation of Cover / Auxiliary Drive.........................................................................504 Assembly Guidelines for Tightening Torques......................................................................505 Bolts (To N 08.001).........................................................................................505 Plugs with Internal Hexagon and Profile Seal Ring (to N 02.009).............................................506 Seal-lock - Sealing Nuts (to N 02.100)......................................................................507 Gear Pump...........................................................................................................509 Safety Precautions..............................................................................................513 Applicable Models...............................................................................................513 Disassembling Single Gear Pump (Opt)............................................................................514 Reassembling Single Gear Pump (Opt).............................................................................517 Main Control Valve..................................................................................................521 Safety Precautions..............................................................................................525 Applicable Models...............................................................................................525 General Description.............................................................................................526 Theory of Operation.........................................................................................526 When All Spools are in Neutral..........................................................................526 Single Operation........................................................................................532 Compound Operation......................................................................................546 Antidrift Valve.........................................................................................552 Main Relief Valve.......................................................................................553 Overload Relief Valve...................................................................................554 Low-pressure Relief Valve...............................................................................556 Parts List..................................................................................................558 Specifications..............................................................................................563 Troubleshooting, Testing and Adjustment.........................................................................564 Troubleshooting.............................................................................................564 Overall Control Valve...................................................................................564 Relief Valve............................................................................................565 Overall Oil Pressure....................................................................................565 Adjustment of Valves........................................................................................565 Main Relief Valve.......................................................................................565 Overload Relief Valve...................................................................................566 Disassembly.....................................................................................................567 Caution in Disassembly......................................................................................567 Disassembly of Main Spool Part..............................................................................568 Disassembly of Arm 1 Para-turn Spool Part...................................................................569 Disassembly of Arm Regeneration Release Valve Part..........................................................569 Disassembly of Load Check Valve Part........................................................................570 Disassembly of Antidrift Valve Part.........................................................................571 Disassembly of Relief Valve.................................................................................572 Disassembly of Option Section Part..........................................................................572 Disassembly of Other Plugs..................................................................................572 Disassembly of Valve Housing Bolt...........................................................................573 Disassembly of Main Relief Valve............................................................................574 Disassembly of Overload Relief Valve........................................................................575 Instruction of Disassembly and Assembly of Low-pressure Relief Valve........................................576 Cleaning and Inspection (Wear Limits and Tolerances)............................................................577 Cleaning....................................................................................................577 Inspection..................................................................................................577 Reassembly......................................................................................................578 Caution on Assembly.........................................................................................578 Caution on Handling O-ring..............................................................................578 Caution on Handling Spool...............................................................................578 Method of Painting the Adhesives (screw part and arm screw part of parts requiring the adhesiveness)....578 Sequence of Subassembly.....................................................................................579 Spool Assembly (Main Spool).............................................................................579 Arm 1 Para-turn Spool Assembly..........................................................................579 Antidrift Valve Assembly................................................................................580 Assembly Sequence of Main Body of the Control Valve.....................................................580 Assembly of Relief Valve................................................................................581 Assembly of Load Check Valve............................................................................581 Assembly of Antidrift Valve.............................................................................582 Assembly of Option Section Part.........................................................................582 Assembly of Arm Regeneration Release Valve..............................................................582 Assembly of Arm 1 Para-turn Spool.......................................................................583 Assembly of Main Spool..................................................................................583 Assembly of Other Plugs.................................................................................584 Maintenance of Relief Valves................................................................................585 Reassembly of Main Relief Valve.........................................................................585 Reassembly of Overload Relief Valve (69, Total of 6 Places).............................................586 Reassembly of Low-pressure Relief Valve (70, Total of 2 Places).........................................587 Installation....................................................................................................588 Start-up Procedures.............................................................................................588 Remote Control Valve (Work Lever / Joystick)........................................................................589 Safety Precautions..............................................................................................593 Applicable Models...............................................................................................593 General Description.............................................................................................595 Theory of Operation.........................................................................................595 Structure...............................................................................................595 Function................................................................................................595 Parts List..................................................................................................596 Specifications..............................................................................................598 Performance.............................................................................................598 Torques.....................................................................................................598 Tools and Materials.............................................................................................598 Disassembly.....................................................................................................599 Cleaning and Inspection (Wear Limits and Tolerances)............................................................603 Reassembly......................................................................................................603 Start-up Procedures.............................................................................................610 Travel Control Valve (With Damper)..................................................................................611 Safety Precautions..............................................................................................615 Applicable Models...............................................................................................615 General Description.............................................................................................616 Theory of Operation.........................................................................................616 Deceleration Valve..........................................................................................617 Dampening Parts of the Control Section......................................................................618 Causes of Faults and Measures...................................................................................621 Parts List..................................................................................................622 Specifications..............................................................................................623 Torques.....................................................................................................623 Removal.........................................................................................................624 Disassembly.....................................................................................................625 Cleaning and Inspection (Wear Limits and Tolerances)............................................................628 Assembly........................................................................................................629 Installation....................................................................................................635 Startup Procedures.............................................................................................636 Solenoid Valve Assembly.............................................................................................637 Safety Precautions..............................................................................................641 Applicable Models...............................................................................................641 5Solenoid Valve................................................................................................642 Parts List..................................................................................................642 Functions of 5Solenoid Valve Assembly......................................................................643 Functions and Operations of Solenoid Valves.............................................................643 Detailed Functions and Operations of Solenoid Valves....................................................643 Assembly Diagram and Tools Required.........................................................................646 Cautions During Disassembly and Reassembly..................................................................647 Solenoid Valve Diagram......................................................................................648 Check Points and Solutions for Problems.....................................................................649 Checking of Pilot Pressure for Defects..................................................................649 2Solenoid Valve................................................................................................650 Parts List..................................................................................................650 Assembly Diagram and Tools Required.........................................................................651 Cautions During Disassembly and Reassembly..................................................................652 Solenoid Valve Diagram......................................................................................653 Troubleshooting Guide.......................................................................................653 Breaker EPPR Valve (Opt)............................................................................................655 Safety Precautions..............................................................................................659 Applicable Models...............................................................................................659 Structure.......................................................................................................660 Numbers and Names of Parts..................................................................................660 Functions and Operation.........................................................................................661 Cautions for Operation..........................................................................................661 Maintenance Instructions........................................................................................662 Maintenance.................................................................................................662 Disassembly.................................................................................................663 Assembly....................................................................................................664 Hydraulic Schematic (DX340LC).......................................................................................667 Safety Precautions..............................................................................................671 Applicable Models...............................................................................................671 DX340LC.........................................................................................................673 Electrical System.......................................................................................................674 Electrical System...................................................................................................676 Safety Precautions..............................................................................................681 Applicable Models...............................................................................................681 Introduction....................................................................................................682 Electrical Supply System........................................................................................683 Engine Starting Circuit.........................................................................................685 Start Operation.............................................................................................685 After Start.................................................................................................687 Engine Preheating System........................................................................................689 Engine Stop.....................................................................................................691 Charging System.................................................................................................693 Monitoring System...............................................................................................694 Instrument Panel............................................................................................695 Monitoring System Schematic.................................................................................697 Operation.......................................................................................................699 Instruments.................................................................................................699 Warning and Indicator Lights....................................................................................701 Indication of Warning Lights................................................................................701 Indication of Multifunction Gauge...........................................................................702 Initial Operation...............................................................................................704 Mode Selector Switch............................................................................................704 Graphic Information Area Display................................................................................705 Overview....................................................................................................705 Main Menus for the Graphic Display Area.....................................................................706 Menu Selector Buttons.......................................................................................706 Main Menu.......................................................................................................707 Language....................................................................................................707 Set Clock...................................................................................................708 Filter/Oil Info.............................................................................................708 Adjust Display..............................................................................................709 Set Password................................................................................................710 Special Menu....................................................................................................711 Entering/Accessing and Exiting/Escaping Menus...............................................................711 Special Menu Selections.....................................................................................712 Electronic Hydraulic Control System (eEPOS)....................................................................729 Control System Schematic....................................................................................729 Power Mode Control..............................................................................................731 Operation...................................................................................................733 Power / Economy Mode Control Circuit Diagram..................................................................737 Engine Control System...........................................................................................739 Engine Control Dial.............................................................................................740 Engine Control Circuit Diagram..................................................................................741 Automatic Deceleration Control (Auto Idle Control)..............................................................743 Engine Overheat Protection System...............................................................................745 Power Boost Mode................................................................................................747 Operation...................................................................................................747 Power Boost Control Circuit Diagram.......................................................................749 Automatic Travel Speed Control..................................................................................751 Automatic Travel Speed Control Circuit Diagram............................................................753 Selfdiagnostic Function........................................................................................754 eEPOS Controller...........................................................................................754 Air Conditioner System..........................................................................................756 Outline.....................................................................................................756 Internal and External Filters...............................................................................757 AirConditioning System Layout..............................................................................759 Air Conditioner/heater Circuit Diagram......................................................................760 Air Conditioner/heater Unit.................................................................................761 Ambient Air Temperature Sensor..............................................................................766 Sun Sensor..................................................................................................767 Control Panel...............................................................................................767 Compressor..................................................................................................775 Receiver Dryer..............................................................................................775 Troubleshooting.................................................................................................776 Weight of R134a Gas Used In Machines............................................................................778 Refrigerant System Repairs......................................................................................779 Refrigerant Safe Handling Procedures........................................................................779 Repair and Replacement Procedure............................................................................781 Refrigerant Recovery........................................................................................783 Vacuuming Refrigerant System................................................................................783 Leakage Check...............................................................................................785 Refrigerant Charging........................................................................................785 Inspecting System For Leakage...............................................................................787 Wiper System....................................................................................................788 Wiper Circuit...............................................................................................788 Wiper operation.............................................................................................789 Lighting System.................................................................................................791 Lighting System Circuit Diagram.............................................................................791 Kind of Light...............................................................................................792 Operation...................................................................................................792 Overload Warning Device.........................................................................................793 Overload Warning Device Circuit Diagram.....................................................................793 Audio Controller................................................................................................794 Audio Controller Circuit Diagram............................................................................794 Electrical Schematic DX300/340/350LC................................................................................796 Safety Precautions..............................................................................................800 Applicable Models...............................................................................................800 DX300/340/350LC.................................................................................................802 Attachments.............................................................................................................803 Boom and Arm........................................................................................................805 Safety Precautions..............................................................................................809 Applicable Models...............................................................................................809 Front Attachment Pin Specifications.............................................................................810 DX300LC.....................................................................................................811 DX340LC / DX350LC...........................................................................................812 DX420LC.....................................................................................................813 DX480LC / DX520LC...........................................................................................814 Front Attachment - Removal and Installation.....................................................................815 Arm Removal Procedure.......................................................................................815 Boom Removal Procedure......................................................................................817 Installation....................................................................................................818 Arm Installation Procedure..................................................................................818 Boom Installation Procedure.................................................................................818 Start-up Procedures.............................................................................................819 Bucket..............................................................................................................821 Safety Precautions..............................................................................................825 Applicable Models...............................................................................................825 Bucket Tooth Inspection and Replacement.........................................................................826 Bucket O-ring Replacement.......................................................................................827 Bucket Shimming Procedures......................................................................................829 New Bucket Installation.....................................................................................829 Shimming Procedures for Installed Bucket................................................................830 Bucket Attachment, Removal and Reversal.........................................................................831 Detaching the Bucket........................................................................................831 Attaching the Bucket........................................................................................831 Reversing the Bucket........................................................................................832
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