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Daewoo Excavator DX340LC Shop Manual K1009684E – PDF
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Daewoo Excavator DX340LC Shop Manual K1009684E – PDF DOWNLOAD
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Daewoo Excavator DX340LC Shop Manual K1009684E – PDF DOWNLOAD
Language : English
Pages : 840
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Daewoo Excavator DX340LC Shop Manual K1009684E – PDF DOWNLOAD
Table of Contents....................................................................................................... 3 Safety.................................................................................................................. 5 Safety Precautions.................................................................................................. 11 Applicable Models................................................................................................... 11 To the Operator of a DOOSAN Daewoo Excavator........................................................................ 12 Learn the Signal Words Used with the Safety Alert Symbol........................................................ 14 General Safety Essentials........................................................................................... 16 Accessory Applications.......................................................................................... 16 Lifting Capacity Rating Configuration........................................................................... 16 Location of Safety Labels........................................................................................... 17 Summary of Safety Precautions for Lifting in Digging Mode........................................................... 18 Unauthorized Modifications.......................................................................................... 19 General Hazard Information.......................................................................................... 19 Safety Rules.................................................................................................... 19 Safety Features................................................................................................. 19 Inside Operator's Compartment................................................................................... 20 Clothing and Personal Protective Items.......................................................................... 20 Breathing Masks, Ear Protection May Be Required................................................................. 21 Vibration Level Information..................................................................................... 21 Recommendations for Limiting Vibrations......................................................................... 21 Mounting and Dismounting........................................................................................ 22 Fuel, Oil and Hydraulic Fluid Fire Hazards...................................................................... 23 Precautions When Handling Fluids at High Temperature............................................................ 23 Asbestos Dust Hazard Prevention................................................................................. 24 Injury from Work Equipment...................................................................................... 24 Fire Extinguisher and First Aid Kit............................................................................. 24 Protection from Falling or Flying Objects....................................................................... 25 Attachment Precautions.......................................................................................... 26 Accumulator..................................................................................................... 26 Indoor Ventilation.............................................................................................. 26 Emergency Exit.................................................................................................. 27 Before Starting Engine.............................................................................................. 28 Work Site Precautions........................................................................................... 28 Checks Before Starting Engine................................................................................... 29 Engine Starting................................................................................................. 29 Before Operating Machine........................................................................................ 30 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............................................................................. 44 Lock Inspection Covers.......................................................................................... 44 Crushing Prevention and Cutting Prevention...................................................................... 44 Track Tension Adjustments Require Caution....................................................................... 45 Supports and Blocking for Work Equipment........................................................................ 45 Action When Abnormality Is Found During Inspection.............................................................. 45 Precautions with High-pressure Lines, Tubes and Hoses........................................................... 46 Waste Materials................................................................................................. 47 Battery............................................................................................................. 48 Battery Hazard Prevention....................................................................................... 48 Boost Starting or Charging Engine Batteries..................................................................... 49 Towing.............................................................................................................. 50 Precautions When Towing......................................................................................... 50 Shipping and Transportation......................................................................................... 51 Obey State and Local Over-the-Road Regulations.................................................................. 51 Lifting With Sling.................................................................................................. 51 Specifications.......................................................................................................... 53 Specification for DX340LC........................................................................................... 55 Safety Precautions.............................................................................................. 59 Applicable Models............................................................................................... 59 General Description............................................................................................. 61 Component Locations............................................................................................. 62 General Dimensions.............................................................................................. 64 Working Range................................................................................................... 66 General Specifications.......................................................................................... 68 Engine Performance Curves (Per DIN 6270 Standard)............................................................... 70 Approximate Weight of Workload Materials........................................................................ 72 Performance Tests............................................................................................... 74 Excavator Performance Standards................................................................................. 75 Test Conditions............................................................................................. 75 Travel Speed and Travel Motor Balance (Steering Deviation) Tests............................................ 75 Speed Test.............................................................................................. 75 Travel Deviation........................................................................................ 77 Swing Speed and Deceleration Force Test..................................................................... 77 Swing Speed Test........................................................................................ 77 Swing Deceleration Force Test........................................................................... 78 Cylinder Performance Tests.................................................................................. 79 Boom Cylinders Test..................................................................................... 79 Arm Cylinder Test....................................................................................... 79 Bucket Cylinder Test.................................................................................... 79 Hydraulic Cylinder Natural Drop Test.................................................................... 79 Travel Motor Jack-up Test............................................................................... 79 General Maintenance..................................................................................................... 81 General Maintenance Procedures...................................................................................... 83 Safety Precautions.............................................................................................. 87 Applicable Models............................................................................................... 87 Welding Precautions and Guidelines.............................................................................. 88 Hydraulic System - General Precautions.......................................................................... 89 Maintenance Service and Repair Procedure........................................................................ 91 General Precautions......................................................................................... 91 Hydraulic System Cleanliness and Oil Leaks...................................................................... 92 Maintenance Precautions for Hydraulic System Service........................................................ 92 Oil Leakage Precautions..................................................................................... 93 Cleaning and Inspection......................................................................................... 94 General Guidelines.......................................................................................... 94 Bearing inspection.......................................................................................... 95 Normal Bearing.......................................................................................... 96 Bent Cage............................................................................................... 96 Galling................................................................................................. 97 Abrasive Step Wear...................................................................................... 97 Etching................................................................................................. 98 Misalignment............................................................................................ 98 Indentations............................................................................................ 98 Fatigue Spalling........................................................................................ 99 Brinelling.............................................................................................. 99 Cage Wear............................................................................................... 99 Abrasive Roller Wear....................................................................................100 Cracked Inner Race......................................................................................100 Smears..................................................................................................100 Frettage................................................................................................101 Heat Discoloration......................................................................................101 Stain Discoloration.....................................................................................101 Standard Torques....................................................................................................103 Safety Precautions..............................................................................................107 Applicable Models...............................................................................................107 Torque Values for Standard Metric Fasteners.....................................................................108 Torque Values for Standard U.S. Fasteners.......................................................................109 Type 8 Phosphate Coated Hardware................................................................................111 Torque Values for Hose Clamps...................................................................................112 Torque Values for Split Flanges.................................................................................113 Torque Wrench Extension Tools...................................................................................114 Torque Multiplication.......................................................................................114 Other Uses for Torque Wrench Extension Tools................................................................115 Tightening Torque Specifications (Metric)...................................................................115 I. "Loctite" Fastener Adhesives.........................................................................117 II. "Loctite" Pipe Thread Sealant.......................................................................117 III. "Loctite" gasket/flange sealer.....................................................................117 IV. "Loctite" retaining compounds.......................................................................118 V. "Loctite" Adhesives..................................................................................118 Upper Structure.........................................................................................................119 Swing Reduction Gear................................................................................................165 Safety Precautions..............................................................................................169 Applicable Models...............................................................................................169 General Description.............................................................................................171 Theory of Operation.........................................................................................171 Parts List..................................................................................................172 Specifications..............................................................................................174 Troubleshooting, Testing and Adjustment.........................................................................175 Removal.........................................................................................................176 Disassembly.....................................................................................................177 Assembly........................................................................................................181 Shaft and S/R Bearing Shrinkage Fitting.....................................................................181 Assembly of the Carrier Subassembly.........................................................................183 Washing of the Carrier..................................................................................183 Washing of Planet Gears.................................................................................183 Assembly of the Carrier Subassembly 1...................................................................184 Assembly of the Carrier Subassembly 2...................................................................187 Assembly of Main Case.......................................................................................191 Washing of the Casing and Other Components..............................................................191 Assembly of the Shaft and the Pinion....................................................................191 Assembly of the Seal and the Bearing....................................................................196 Assembly of the Ring Gear...............................................................................200 Assembly of the Carrier.................................................................................202 Test........................................................................................................207 Pneumatic Test..........................................................................................207 Noise and Abnormal Sound Test...........................................................................208 Assembly of the Motor.......................................................................................209 Supply of Gear Oil......................................................................................209 Assembly of the Motor...................................................................................210 Installation....................................................................................................215 Swing Bearing.......................................................................................................157 Safety Precautions..............................................................................................161 Applicable Models...............................................................................................161 Swing Bearing Maintenance.......................................................................................162 Operating Recommendation....................................................................................162 Measuring Swing Bearing Axial Play..........................................................................162 Measuring Bearing Lateral Play..............................................................................162 Swing Bearing Basic Operation...............................................................................163 Rebuilding Swing Bearing....................................................................................163 Fuel Tank...........................................................................................................141 Safety Precautions..............................................................................................145 Applicable Models...............................................................................................145 General Description.............................................................................................146 Parts List..................................................................................................146 Specifications..............................................................................................147 Removal.........................................................................................................148 Installation....................................................................................................153 Start-up Procedures.............................................................................................156 Counterweight.......................................................................................................131 Safety Precautions..............................................................................................135 Applicable Models...............................................................................................135 General.........................................................................................................136 Warning for Counterweight and Front Attachment Removal......................................................136 Removal.........................................................................................................138 Installation....................................................................................................140 Cabin...............................................................................................................121 Safety Precautions..............................................................................................125 Applicable Models...............................................................................................125 Removal.........................................................................................................126 Installation....................................................................................................128 Lower Structure and Chassis.............................................................................................217 Air Conditioner SP000025............................................................................................251 Safety Precautions..............................................................................................255 Applicable Models...............................................................................................255 Air Conditioner System..........................................................................................256 Outline.....................................................................................................256 Internal and External Filters...............................................................................257 How to check Indoor air filter..........................................................................257 How to check outdoor air filter.........................................................................257 Air-Conditioning System Layout..............................................................................259 Air Conditioner/Heater Circuit Diagram......................................................................260 Air Conditioner/Heater Unit.................................................................................261 Air Flow Diagram........................................................................................261 Door Open by Vent Modes.................................................................................262 Main Components.........................................................................................262 Actuator - Internal/external air exchange...............................................................264 Air Flow Control Module.................................................................................264 Relay - Blower..............................................................................................265 Relay - A/C.................................................................................................265 Duct Sensor.................................................................................................265 Water Temp Sensor...........................................................................................266 Internal Air Temp Sensor....................................................................................266 Ambient Air Temperature Sensor..............................................................................266 Sun Sensor..................................................................................................267 Control Panel...............................................................................................267 Appearance and Terminal Arrangement.....................................................................267 Terminal Terms..........................................................................................268 Control Logic...........................................................................................268 Self Diagnosis..........................................................................................273 Ambient Temp Display....................................................................................274 Compressor..................................................................................................275 Receiver Dryer..............................................................................................275 Troubleshooting.................................................................................................276 Refrigerant Pressure Check..................................................................................276 Weight of R134a Gas Used In Machines............................................................................279 Refrigerant System Repairs......................................................................................280 Refrigerant Safe Handling Procedures........................................................................280 Repair and Replacement Procedure............................................................................281 Refrigerant Recovery........................................................................................283 Vacuuming Refrigerant System................................................................................283 Leakage Check...............................................................................................284 Refrigerant Charging........................................................................................285 Inspecting System For Leakage...............................................................................287 Track Assembly......................................................................................................219 Safety Precautions..............................................................................................223 Applicable Models...............................................................................................223 General Description.............................................................................................224 Track Tension...................................................................................................224 Cleaning and Inspection (Wear Limits and Tolerances)............................................................227 Track Shoe..................................................................................................228 Lower Roller................................................................................................230 Upper Roller................................................................................................231 Front Idler.................................................................................................232 Track Shoes and Links...........................................................................................233 Track Removal...............................................................................................233 Track Installation..........................................................................................234 Front Idler Roller..............................................................................................236 Parts List..................................................................................................236 Front Idler Roller Disassembly..............................................................................237 Front Idler Roller Reassembly...............................................................................238 Lower Roller....................................................................................................240 Parts List..................................................................................................240 Lower Roller Removal........................................................................................241 Lower Roller Disassembly....................................................................................241 Lower Roller Reassembly.....................................................................................242 Lower Roller Installation...................................................................................243 Upper Roller....................................................................................................244 Parts List..................................................................................................244 Upper Roller Removal........................................................................................245 Upper Roller Disassembly....................................................................................245 Upper Roller Reassembly.....................................................................................247 Track Spring and Track Adjusting Cylinder.......................................................................248 Parts List..................................................................................................248 Engine and Drive Train..................................................................................................289 Drive Coupling (Main Pump)..........................................................................................291 Safety Precautions..............................................................................................295 Applicable Models...............................................................................................295 Drive Coupling..................................................................................................296 Installation of Drive Coupling..................................................................................297 Installation Procedure......................................................................................297 Hydraulics..............................................................................................................299 Hydraulic System Troubleshooting, Testing and Adjustment............................................................301 Safety Precautions..............................................................................................305 Applicable Models...............................................................................................305 Hydraulic System - General Notes................................................................................306 Hydraulic Schematic.............................................................................................308 General Notes...............................................................................................308 Operation of Working Components.................................................................................310 Boom Operating Circuit......................................................................................310 Boom Up Circuit.............................................................................................310 Boom Down Circuit...........................................................................................310 Arm Operating Circuit.......................................................................................311 Arm Crowd Circuit...........................................................................................311 Arm Dump Circuit............................................................................................311 Bucket Operating Circuit....................................................................................312 Bucket Crowd Circuit........................................................................................312 Bucket Dump Circuit.........................................................................................312 Swing Operating Circuit.....................................................................................312 Right Swing Operating Circuit...............................................................................313 Left Swing Operating Circuit................................................................................313 Swing Relief Valve and Makeup Valve.........................................................................313 Travel Operating Circuit....................................................................................313 Forward Travel Circuit......................................................................................314 Reverse Travel Circuit......................................................................................314 Procedural Troubleshooting Baseline Recommendations.............................................................315 Initial Checks and Tests to Establish Operating Condition of the Excavator..................................315 Triage Summary..........................................................................................315 Pilot Pressure..................................................................................................317 Adjustment and Testing......................................................................................317 Power Mode Valve................................................................................................318 Current Signal and Hydraulic Pressure Adjustments...........................................................318 Swing Priority Valve............................................................................................320 Control Valve Pressure and Current Adjustments..............................................................320 Pressure Up Valve...............................................................................................321 Checks and Adjustments......................................................................................321 Pump Input Power Control........................................................................................323 Pump Regulator Adjustment...................................................................................323 Flow Meter and Flow Meter Kit Installation and Testing..........................................................326 Installation and Testing Procedure..........................................................................326 Swing System Troubleshooting....................................................................................328 Precautions/Initial Checks..................................................................................328 Swing Relief Valve Checking and Adjustment..................................................................328 Troubleshooting - Swing Gearbox.................................................................................331 Troubleshooting - Hydraulic Problems............................................................................332 Troubleshooting - Control Valve.................................................................................333 Troubleshooting - Travel Control Valve..........................................................................335 Troubleshooting - Joystick Control Valve........................................................................335 Accumulator.........................................................................................................337 Safety Precautions..............................................................................................341 Applicable Models...............................................................................................341 General Description.............................................................................................342 Specifications..............................................................................................344 Center Joint (Swivel)...............................................................................................345 Safety Precautions..............................................................................................349 Applicable Models...............................................................................................349 General Description.............................................................................................350 Center Joint Disassembly Diagram............................................................................351 Disassembly.....................................................................................................352 Reassembly......................................................................................................355 Cylinders...........................................................................................................359 Safety Precautions..............................................................................................363 Applicable Models...............................................................................................363 General Description.............................................................................................364 Theory of Operation.........................................................................................364 Parts List..................................................................................................366 Special Tools and Materials.....................................................................................368 Piston Nut..................................................................................................368 Piston Jig..................................................................................................370 Steel Bushing Jig...........................................................................................372 Dust Wiper Jig..............................................................................................374 Slipper Seal Jig............................................................................................376 Slipper Seal Straightening Jig..............................................................................378 Disassembly.....................................................................................................380 Reassembly......................................................................................................385 Swing Motor.........................................................................................................389 Safety Precautions..............................................................................................393 Applicable Models...............................................................................................393 General Description.............................................................................................394 Parts List..................................................................................................394 Specifications..............................................................................................396 Torques.....................................................................................................396 Theory of Operation.........................................................................................397 Structure...............................................................................................397 Circuit Diagram.........................................................................................397 Generation of Rotary Power..............................................................................398 Operation of Relief Valve...............................................................................399 Operation of Parking Brake..............................................................................399 Makeup Check Valve..........................................................................................400 Operation of Time Delay Valve...............................................................................400 External Pilot Pressure: When Pi = 0 (Large Tilt Angle).................................................400 Operation of Swing Reactionless Valve.......................................................................400 Tools and Materials.............................................................................................401 Tools.......................................................................................................401 Troubleshooting, Testing and Adjustment.........................................................................402 General Precautions.........................................................................................402 How to Check Faults of Hydraulic Motor......................................................................402 Troubleshooting.............................................................................................402 Disassembly.....................................................................................................404 General Cautions............................................................................................404 Disassembly of drive shaft subassembly......................................................................404 Disassembly of the cylinder block subassembly...............................................................407 Disassembly of the rear cover subassembly...................................................................408 Cleaning and Inspection (Wear Limits and Tolerances)............................................................411 Reassembly......................................................................................................411 General Cautions............................................................................................411 Reassembly of drive shaft subassembly.......................................................................411 Assembly of Cylinder Block Assembly Subassembly.............................................................414 Assembly of Rear Cover Assembly Subassembly.................................................................418 Air Pressure Test...........................................................................................422 Oil Leakage Check...........................................................................................422 Installation of test bench..................................................................................423 Travel Motor SP000253...............................................................................................425 Safety Precautions..............................................................................................429 Applicable Models...............................................................................................429 General Description.............................................................................................430 Theory of Operation.........................................................................................431 Hydraulic Motor.........................................................................................431 Operation of Reduction Gear.............................................................................438 Parts List..................................................................................................439 Hydraulic Motor.........................................................................................439 Reduction Gear..........................................................................................442 Specifications..............................................................................................443 Special Tools and Materials.....................................................................................444 Hydraulic Motor Part........................................................................................444 Reduction Gear Part.........................................................................................445 Tightening Torque Chart.....................................................................................446 Troubleshooting, Testing and Adjustment.........................................................................447 General Precautions.........................................................................................447 Troubleshooting.............................................................................................447 Disassembly.....................................................................................................451 General Caution Matters.....................................................................................451 Reduction Gear Part.........................................................................................451 Hydraulic Motor Part........................................................................................457 Disassembly of Main Body of Motor Section...............................................................457 Disassembly of Valve Casing Subassembly.................................................................460 Disassembly of Cylinder Block Assembly..................................................................461 Cleaning and Inspection (Wear Limits and Tolerances)............................................................462 Maintenance Standard........................................................................................462 Changing Standard of Hydraulic Motor Part...............................................................462 Parts Inspection and Inspection Standard of Reduction Gear..............................................464 Reassembly......................................................................................................465 General Caution Matters.....................................................................................465 Hydraulic Motor Part........................................................................................465 Reassembling of Drive Shaft Subassembly.................................................................465 Assembly of Valve Casing Subassembly....................................................................465 Assembly of Valve Casing Subassembly....................................................................466 Assembly of Cylinder Subassembly........................................................................468 Reduction Gear Part.....................................................................................472 Checkup after Assembly......................................................................................481 Air Test for Reduction Gear.............................................................................481 Air Test for Motor......................................................................................481 Performance Test............................................................................................481 If Test Equipment Is Available..........................................................................481 If on-site performance test is unavoidable as test equipment is not available...........................482 Installation....................................................................................................483 Check.......................................................................................................483 Piping......................................................................................................483 Gear Oil....................................................................................................483 Kind of Oil.............................................................................................483 Oil Drain...............................................................................................484 Oil Filling.................................................................................................484 General Caution Matters.....................................................................................484 Main Pump...........................................................................................................485 Safety Precautions..............................................................................................489 Applicable Models...............................................................................................489 ectional View...................................................................................................490 A8VO200LA1KH1/63............................................................................................490 General Repair Guidelines.......................................................................................492 Seal Kits and Sub- assemblies...................................................................................493 Sealing the Drive Shaft.........................................................................................497 Remove the Control Housing......................................................................................499 Control Module..................................................................................................503 Control Module LR...........................................................................................503 Control Module H............................................................................................504 Removing the Controller.........................................................................................505 Valve Plate With Valves.........................................................................................507 Remove the Rotary Groups........................................................................................508 Remove the Intermediate Wheel...................................................................................511 Remove Auxiliary Drive (Rotating Group).........................................................................513 Inspection......................................................................................................516 Re-fitting the Rotary Group.....................................................................................521 Pump Assembly...................................................................................................523 Assembly Guideline..........................................................................................524 Adjustment of the Hydraulic Component of the Rotary Group...................................................525 Hydraulic Component - Measurement "D"...........................................................................525 Measuring Device - Hydraulic Component 452 269..............................................................525 Mounting Position...........................................................................................526 Measuring Procedure.........................................................................................527 Installation of Control Housing.................................................................................529 Assembly of Intermediate Wheel..................................................................................532 Assembly Guidelines for Tightening Torques......................................................................533 Bolts (To N 08.001).........................................................................................533 Plugs with Internal Hexagon and Profile Seal Ring (to N 02.009).............................................533 Seal-lock - Sealing Nuts (to N 02.100)......................................................................534 Gear Pump...........................................................................................................535 Safety Precautions..............................................................................................539 Applicable Models...............................................................................................539 Disassembling Single Gear Pump (Opt)............................................................................540 Reassembling Single Gear Pump (Opt).............................................................................543 Main Control Valve..................................................................................................547 Safety Precautions..............................................................................................551 Applicable Models...............................................................................................551 General Description.............................................................................................553 Theory of Operation.........................................................................................553 When All Spools are in Neutral..........................................................................553 Single Operation........................................................................................558 Compound Operation......................................................................................572 Antidrift Valve.........................................................................................578 Main Relief Valve.......................................................................................579 Overload Relief Valve...................................................................................580 Low-pressure Relief Valve...............................................................................582 Parts List..................................................................................................584 Specifications..............................................................................................589 Troubleshooting, Testing and Adjustment.........................................................................590 Troubleshooting.............................................................................................590 Overall Control Valve...................................................................................590 Relief Valve............................................................................................591 Overall Oil Pressure....................................................................................591 Adjustment of Valves........................................................................................591 Main Relief Valve.......................................................................................591 Overload Relief Valve...................................................................................592 Disassembly.....................................................................................................593 Caution in Disassembly......................................................................................593 Disassembly of Main Spool Part..............................................................................594 Disassembly of Arm 1 Para-turn Spool Part...................................................................595 Disassembly of Arm Regeneration Release Valve Part..........................................................595 Disassembly of Load Check Valve Part........................................................................596 Disassembly of Antidrift Valve Part.........................................................................597 Disassembly of Relief Valve.................................................................................598 Disassembly of Option Section Part..........................................................................598 Disassembly of Other Plugs..................................................................................598 Disassembly of Valve Housing Bolt...........................................................................599 Disassembly of Main Relief Valve............................................................................600 Disassembly of Overload Relief Valve........................................................................601 Instruction of Disassembly and Assembly of Low-pressure Relief Valve........................................602 Cleaning and Inspection (Wear Limits and Tolerances)............................................................603 Cleaning....................................................................................................603 Inspection..................................................................................................603 Reassembly......................................................................................................604 Caution on Assembly.........................................................................................604 Caution on Handling O-ring..............................................................................604 Caution on Handling Spool...............................................................................604 Method of Painting the Adhesives (screw part and arm screw part of parts requiring the adhesiveness)....604 Sequence of Subassembly.....................................................................................605 Spool Assembly (Main Spool).............................................................................605 Arm 1 Para-turn Spool Assembly..........................................................................605 Antidrift Valve Assembly................................................................................606 Assembly Sequence of Main Body of the Control Valve.....................................................606 Assembly of Relief Valve................................................................................607 Assembly of Load Check Valve............................................................................607 Assembly of Antidrift Valve.............................................................................608 Assembly of Option Section Part.........................................................................608 Assembly of Arm Regeneration Release Valve..............................................................608 Assembly of Arm 1 Para-turn Spool.......................................................................609 Assembly of Main Spool..................................................................................609 Assembly of Other Plugs.................................................................................610 Maintenance of Relief Valves................................................................................611 Reassembly of Main Relief Valve.........................................................................611 Reassembly of Overload Relief Valve (69, Total of 6 Places).............................................612 Reassembly of Low-pressure Relief Valve (70, Total of 2 Places).........................................613 Installation....................................................................................................614 Start-up Procedures.............................................................................................614 Remote Control Valve (Work Lever / Joystick)........................................................................615 Safety Precautions..............................................................................................619 Applicable Models...............................................................................................619 General Description.............................................................................................621 Theory of Operation.........................................................................................621 Structure...............................................................................................621 Function................................................................................................621 Parts List..................................................................................................622 Specifications..............................................................................................624 Performance.............................................................................................624 Torques.....................................................................................................624 Tools and Materials.............................................................................................624 Disassembly.....................................................................................................625 Cleaning and Inspection (Wear Limits and Tolerances)............................................................629 Reassembly......................................................................................................629 Start-up Procedures.............................................................................................635 Travel Control Valve (With Damper) SP000070.........................................................................637 Safety Precautions..............................................................................................641 Applicable Models...............................................................................................641 General Description.............................................................................................643 Theory of Operation.........................................................................................643 Deceleration Valve..........................................................................................644 Dampening Parts of the Control Section......................................................................645 Causes of Faults and Measures...................................................................................647 Parts List..................................................................................................648 Specifications..............................................................................................649 Torques.....................................................................................................649 Removal.........................................................................................................650 Disassembly.....................................................................................................651 Cleaning and Inspection (Wear Limits and Tolerances)............................................................654 Assembly........................................................................................................655 Installation....................................................................................................661 Startup Procedures..............................................................................................662 Breaker EPPR Valve (Opt)............................................................................................663 Safety Precautions..............................................................................................667 Applicable Models...............................................................................................667 Structure.......................................................................................................668 Numbers and Names of Parts..................................................................................668 Functions and Operation.........................................................................................669 Cautions for Operation..........................................................................................669 Maintenance Instructions........................................................................................670 Maintenance.................................................................................................670 Bolt Tightening Torque..................................................................................670 Tools Used for Disassembly and Assembly.................................................................670 Disassembly.................................................................................................671 Assembly....................................................................................................672 Hydraulic Schematic (DX340LC).......................................................................................675 Safety Precautions..............................................................................................679 Applicable Models...............................................................................................679 General Description.............................................................................................681 DX340LC.........................................................................................................682 Electrical System.......................................................................................................685 Electrical System SP000038..........................................................................................687 Safety Precautions..............................................................................................693 Applicable Models...............................................................................................693 Introduction....................................................................................................695 Electric Wire Color.........................................................................................695 Electrical Supply System........................................................................................696 Engine Starting Circuit.........................................................................................698 Start Operation.............................................................................................698 After Start.................................................................................................700 Operation of the Start Circuit (2) Immediately After Start..............................................701 Engine Preheating System........................................................................................702 Engine Stop.....................................................................................................704 Charging System.................................................................................................706 Monitoring System...............................................................................................707 Instrument Panel............................................................................................708 Monitoring System Schematic.................................................................................710 Operation.......................................................................................................712 Instruments.................................................................................................712 Warning and Indicator Lights....................................................................................714 Indication of Warning Lights................................................................................714 Indication of Multifunction Gauge and Letter Information Area...............................................715 Initial Operation...............................................................................................717 Mode Selector Switch............................................................................................717 Power Mode / Trenching Mode Switch..........................................................................717 Auto Idle Switch............................................................................................717 Graphic Information Area Display................................................................................718 Overview....................................................................................................718 Main Menus for the Graphic Display Area.....................................................................719 Menu Selector Buttons.......................................................................................719 Main Menu.......................................................................................................720 Language....................................................................................................720 Set Clock...................................................................................................721 Filter/Oil Info.............................................................................................721 Menu Display Order and Icon Explanation.................................................................722 Adjust Display..............................................................................................722 Set Password................................................................................................723 Special Menu....................................................................................................724 Entering/Accessing and Exiting/Escaping Menus...............................................................724 Entering/Accessing Menus................................................................................724 Exiting/Escaping Menus..................................................................................725 Special Menu Selections.....................................................................................725 Information of Machine Status...........................................................................725 Failure Information.....................................................................................729 Information of Machine Operation........................................................................737 Machine Operation Info Screen...........................................................................740 Electronic Hydraulic Control System (eEPOS).....................................................................742 Control System Schematic....................................................................................742 Power Mode Control..............................................................................................744 Operation...................................................................................................746 1. Power Mode...........................................................................................746 2. Standard Mode........................................................................................748 3) Operation in case of failure in the control system (Aux mode operation...............................748 Power Mode Control Circuit Diagram..............................................................................750 Work Mode Control...............................................................................................752 Operation...................................................................................................753 1. Digging Mode.........................................................................................753 2. Trenching Mode.......................................................................................753 Work Mode Control Circuit Diagram...............................................................................754 Engine Control System...........................................................................................755 Engine Control Dial.............................................................................................756 Engine Control Circuit Diagram..................................................................................758 Automatic Deceleration Control (Auto Idle Control)..............................................................760 Engine Overheat Protection System...............................................................................762 Power Boost Mode................................................................................................764 Operation...................................................................................................764 Power Boost Control Circuit Diagram.........................................................................766 Automatic Travel Speed Control..................................................................................768 Automatic Travel Speed Control Circuit Diagram..............................................................770 Selfdiagnostic Function.........................................................................................771 eEPOS Controller............................................................................................771 Air Conditioner System..........................................................................................773 Outline.....................................................................................................773 Internal and External Filters...............................................................................774 How to Check Internal Air Filter........................................................................774 How to Check External Air Filter........................................................................774 AirConditioning System Layout...............................................................................776 Air Conditioner/heater Circuit Diagram......................................................................777 Air Conditioner/heater Unit.................................................................................778 Air Flow Diagram........................................................................................778 Door Open by Vent Modes.................................................................................779 Main Components.........................................................................................779 Actuator Wind Direction Control.........................................................................780 Actuator Temperature Control............................................................................780 Actuator Internal/external Air Exchange.................................................................781 Air Flow Control Module.................................................................................781 Ambient Air Temperature Sensor..............................................................................783 Sun Sensor..................................................................................................784 Control Panel...............................................................................................784 Appearance and Terminal Arrangement.....................................................................784 Terminal Terms..........................................................................................785 Control Logic...........................................................................................785 Self Diagnosis..........................................................................................789 Ambient Temperature Display.............................................................................790 Compressor..................................................................................................791 Receiver Dryer..............................................................................................791 Wiper System....................................................................................................792 Wiper Circuit...............................................................................................792 Wiper operation.............................................................................................793 Continuous operation....................................................................................793 Intermittent operation..................................................................................793 Lighting System.................................................................................................796 Lighting System Circuit Diagram.............................................................................796 Kind of Light...............................................................................................797 Operation...................................................................................................797 Overload Warning Device.........................................................................................798 Overload Warning Device Circuit Diagram.....................................................................798 Audio Controller................................................................................................799 Audio Controller Circuit Diagram............................................................................799 Operations Via Audio Control Panel......................................................................800 Electrical Schematic (DX300LC/340LC)................................................................................801 Safety Precautions..............................................................................................805 Applicable Models...............................................................................................805 General Description.............................................................................................807 DX300LC/ 340LC..................................................................................................808 Attachments.............................................................................................................811 Boom and Arm........................................................................................................813 Safety Precautions..............................................................................................817 Applicable Models...............................................................................................817 Front Attachment Pin Specifications.............................................................................818 DX300LC.....................................................................................................819 DX340LC.....................................................................................................820 DX420LC.....................................................................................................821 Front Attachment - Removal and Installation.....................................................................822 Arm Removal Procedure.......................................................................................822 Boom Removal Procedure......................................................................................825 Installation....................................................................................................826 Arm Installation Procedure..................................................................................826 Boom Installation Procedure.................................................................................826 Start-up Procedures.............................................................................................827 Bucket..............................................................................................................829 Safety Precautions..............................................................................................833 Applicable Models...............................................................................................833 Bucket Tooth Inspection and Replacement.........................................................................834 Bucket O-ring Replacement.......................................................................................835 Bucket Shimming Procedures......................................................................................837 New Bucket Installation.....................................................................................837 Shimming Procedures for Installed Bucket................................................................838 Bucket Attachment, Removal and Reversal.........................................................................839 Detaching the Bucket........................................................................................839 Attaching the Bucket........................................................................................839 Reversing the Bucket........................................................................................840
S.S 06/24
