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Daewoo Excavator DX480LC DX520LC Shop Manual K1008703E – PDF
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Daewoo Excavator DX480LC DX520LC Shop Manual K1008703E – PDF DOWNLOAD
FILE DETAILS:
Daewoo Excavator DX480LC DX520LC Shop Manual K1008703E – PDF DOWNLOAD
Language : English
Pages : 878
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Daewoo Excavator DX480LC DX520LC Shop Manual K1008703E – PDF DOWNLOAD
000 K1008703E(DX480LC)TOC(2).pdf.............................................................. 0 000 K1008703E(DX480LC)TOC(2).pdf.......................................................... 0 Table of Contents..................................................................... 3 002 SP000142(46).pdf.......................................................................... 0 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........................................................................ 51 003 s02Specifications(2).pdf.................................................................. 0 Specifications............................................................................ 53 004 SP000143(30).pdf.......................................................................... 0 Specification for DX480LC/ 520LC.......................................................... 55 Safety Precautions.................................................................... 59 Applicable Models..................................................................... 59 General Description................................................................... 61 Component Locations................................................................... 62 General Dimensions (DX480LC).......................................................... 64 General Dimensions (DX520LC).......................................................... 65 Working Range (DX480LC)............................................................... 66 Working Range (DX520LC)............................................................... 68 General Specifications (DX480LC)...................................................... 70 General Specifications (DX520LC)...................................................... 72 Engine Performance Curves (Per DIN 6270 Standard)..................................... 74 Approximate Weight of Workload Materials.............................................. 76 Performance Tests..................................................................... 78 Excavator Performance Standards....................................................... 79 Test Conditions................................................................... 79 Travel Speed and Travel Motor Balance (Steering Deviation) Tests.................. 79 Speed Test.................................................................... 79 Travel Deviation.............................................................. 81 Swing Speed and Deceleration Force Test........................................... 81 Swing Speed Test.............................................................. 81 Swing Deceleration Force Test................................................. 82 Cylinder Performance Tests........................................................ 83 Boom Cylinders Test........................................................... 83 Arm Cylinder Test............................................................. 83 Bucket Cylinder Test.......................................................... 83 Hydraulic Cylinder Natural Drop Test.......................................... 83 Travel Motor Jack-up Test..................................................... 83 005 S03General Maintenance(2).pdf............................................................. 0 General Maintenance....................................................................... 85 006 SP000016(20).pdf.......................................................................... 0 General Maintenance Procedures............................................................ 87 Safety Precautions.................................................................... 91 Applicable Models..................................................................... 91 Welding Precautions and Guidelines.................................................... 92 Hydraulic System - General Precautions................................................ 93 Maintenance Service and Repair Procedure.............................................. 95 General Precautions............................................................... 95 Hydraulic System Cleanliness and Oil Leaks............................................ 96 Maintenance Precautions for Hydraulic System Service.............................. 96 Oil Leakage Precautions........................................................... 97 Cleaning and Inspection............................................................... 98 General Guidelines................................................................ 98 Bearing inspection................................................................ 99 Normal Bearing................................................................100 Bent Cage.....................................................................100 Galling.......................................................................101 Abrasive Step Wear............................................................101 Etching.......................................................................102 Misalignment..................................................................102 Indentations..................................................................102 Fatigue Spalling..............................................................103 Brinelling....................................................................103 Cage Wear.....................................................................103 Abrasive Roller Wear..........................................................104 Cracked Inner Race............................................................104 Smears........................................................................104 Frettage......................................................................105 Heat Discoloration............................................................105 Stain Discoloration...........................................................105 007 SP000017(16).pdf.......................................................................... 0 Standard Torques..........................................................................107 Safety Precautions....................................................................111 Applicable Models.....................................................................111 Torque Values for Standard Metric Fasteners...........................................112 Torque Values for Standard U.S. Fasteners.............................................113 Type 8 Phosphate Coated Hardware......................................................115 Torque Values for Hose Clamps.........................................................116 Torque Values for Split Flanges.......................................................117 Torque Wrench Extension Tools.........................................................118 Torque Multiplication.............................................................118 Other Uses for Torque Wrench Extension Tools......................................119 Tightening Torque Specifications (Metric).........................................119 I. "Loctite" Fastener Adhesives...............................................121 II. "Loctite" Pipe Thread Sealant.............................................121 III. "Loctite" gasket/flange sealer...........................................121 IV. "Loctite" retaining compounds.............................................122 V. "Loctite" Adhesives........................................................122 008 S04Upper Structure(2).pdf................................................................. 0 Upper Structure...........................................................................123 009 SP000018(10).pdf.......................................................................... 0 Cabin.....................................................................................125 Safety Precautions....................................................................129 Applicable Models.....................................................................129 Removal...............................................................................130 Installation..........................................................................132 010 SP000153(10).pdf.......................................................................... 0 Counterweight.............................................................................135 Safety Precautions....................................................................139 Applicable Models.....................................................................139 General...............................................................................140 Warning for Counterweight and Front Attachment Removal............................140 Removal...............................................................................142 Installation..........................................................................144 011 SP000155(16).pdf.......................................................................... 0 Fuel Tank.................................................................................145 Safety Precautions....................................................................149 Applicable Models.....................................................................149 General Description...................................................................150 Parts List........................................................................150 Specifications....................................................................151 Removal...............................................................................152 Installation..........................................................................157 Start-up Procedures...................................................................160 012 SP000158(10).pdf.......................................................................... 0 Swing Bearing.............................................................................161 Safety Precautions....................................................................165 Applicable Models.....................................................................165 Swing Bearing Maintenance.............................................................166 Operating Recommendation..........................................................166 Measuring Swing Bearing Axial Play................................................166 Measuring Bearing Lateral Play....................................................166 Swing Bearing Basic Operation.....................................................167 Rebuilding Swing Bearing..........................................................167 013 SP000160(46).pdf.......................................................................... 0 Swing Reduction Gear......................................................................171 Safety Precautions....................................................................175 Applicable Models.....................................................................175 General Description...................................................................177 Theory of Operation...............................................................177 Parts List........................................................................178 Specifications....................................................................179 Troubleshooting, Testing and Adjustment...............................................180 Removal...............................................................................181 Disassembly...........................................................................182 Cleaning and Inspection (Wear Limits and Tolerances)..................................189 Reassembly............................................................................190 Shaft and S/R Bearing Heatfit.....................................................190 Assembly of Carrier Subassemblies.................................................190 Cleaning Carrier..............................................................190 Cleaning Planet Gear..........................................................190 Assembly of No. 1 Carrier.....................................................190 Assembly of No. 2 Carrier.....................................................193 Assembly of Main Case.............................................................196 Cleaning Casing and Other Parts...............................................196 Assembly of Shaft and Pinion..................................................197 Assembly of Seal and Bearing..................................................200 Assembly of Ring Gear.........................................................205 Assembly of Carrier...........................................................206 Assembly of the Motor.........................................................210 Installation..........................................................................216 Startup Procedures....................................................................216 014 S05Lower Structure and Chassis(2).pdf..................................................... 0 Lower Structure and Chassis...............................................................217 015 SP000171(40).pdf.......................................................................... 0 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...........................................................248 Track Spring and Track Adjusting Cylinder.............................................250 Under Carrige Track Spring............................................................251 Track Spring Assembly Diagram.....................................................251 Track Spring Disassembly Diagram..................................................252 Disassembly of the Track Spring Assembly..........................................253 Assembly of the Track Spring......................................................255 016 SP000025(38).pdf.......................................................................... 0 Air Conditioner SP000025..................................................................259 Safety Precautions....................................................................263 Applicable Models.....................................................................263 Air Conditioner System................................................................264 Outline...........................................................................264 Internal and External Filters.....................................................265 How to check Indoor air filter................................................265 How to check outdoor air filter...............................................265 Air-Conditioning System Layout....................................................267 Air Conditioner/Heater Circuit Diagram............................................268 Air Conditioner/Heater Unit.......................................................269 Air Flow Diagram..............................................................269 Door Open by Vent Modes.......................................................270 Main Components...............................................................270 Actuator - Internal/external air exchange.....................................272 Air Flow Control Module.......................................................272 Relay - Blower....................................................................273 Relay - A/C.......................................................................273 Duct Sensor.......................................................................273 Water Temp Sensor.................................................................274 Internal Air Temp Sensor..........................................................274 Ambient Air Temperature Sensor....................................................274 Sun Sensor........................................................................275 Control Panel.....................................................................275 Appearance and Terminal Arrangement...........................................275 Terminal Terms................................................................276 Control Logic.................................................................276 Self Diagnosis................................................................281 Ambient Temp Display..........................................................282 Compressor........................................................................283 Receiver Dryer....................................................................283 Troubleshooting.......................................................................284 Refrigerant Pressure Check........................................................284 Weight of R134a Gas Used In Machines..................................................287 Refrigerant System Repairs............................................................288 Refrigerant Safe Handling Procedures..............................................288 Repair and Replacement Procedure..................................................289 Refrigerant Recovery..............................................................291 Vacuuming Refrigerant System......................................................291 Leakage Check.....................................................................292 Refrigerant Charging..............................................................293 Inspecting System For Leakage.....................................................295 017 S06Engine and Drive Train(2).pdf.......................................................... 0 Engine and Drive Train....................................................................297 018 SP000026(8).pdf........................................................................... 0 Drive Coupling (Main Pump)................................................................299 Safety Precautions....................................................................303 Applicable Models.....................................................................303 Drive Coupling........................................................................304 Installation of Drive Coupling........................................................305 Installation Procedure............................................................305 019 S07Hydraulics(2).pdf...................................................................... 0 Hydraulics................................................................................307 020 SP000179(38).pdf.......................................................................... 0 Hydraulic System Troubleshooting, Testing and Adjustment..................................309 Safety Precautions....................................................................313 Applicable Models.....................................................................313 Hydraulic System - General Notes......................................................314 Hydraulic Schematic...................................................................316 General Notes.....................................................................316 Operation of Working Components.......................................................318 Boom Operating Circuit............................................................318 Boom Up Circuit...................................................................318 Boom Down Circuit.................................................................319 Arm Operating Circuit.............................................................319 Arm Crowd Circuit.................................................................320 Arm Dump Circuit..................................................................320 Bucket Operating Circuit..........................................................321 Bucket Crowd Circuit..............................................................321 Bucket Dump Circuit...............................................................321 Swing Operating Circuit...........................................................321 Right Swing Operating Circuit.....................................................322 Left Swing Operating Circuit......................................................322 Swing Relief Valve and Makeup Valve...............................................322 Travel Operating Circuit..........................................................322 Forward Travel Circuit............................................................323 Reverse Travel Circuit............................................................323 Procedural Troubleshooting Baseline Recommendations...................................324 Initial Checks and Tests to Establish Operating Condition of the Excavator........324 Triage Summary................................................................324 Pilot Pressure........................................................................326 Adjustment and Testing............................................................326 Power Mode Valve......................................................................327 Current Signal and Hydraulic Pressure Adjustments.................................327 Boom/Front Priority Valve.............................................................329 Control Valve Pressure and Current Adjustments....................................329 Pressure Up Valve.....................................................................330 Checks and Adjustments............................................................330 Pump Input Power Control..............................................................332 Pump Regulator Adjustment.........................................................332 Flow Meter and Flow Meter Kit Installation and Testing................................335 Installation and Testing Procedure................................................335 Swing System Troubleshooting..........................................................337 Precautions/Initial Checks........................................................337 Swing Relief Valve Checking and Adjustment........................................337 Troubleshooting - Swing Gearbox.......................................................340 Troubleshooting - Hydraulic Problems..................................................341 Troubleshooting - Control Valve.......................................................342 Troubleshooting - Travel Control Valve................................................344 Troubleshooting - Joystick Control Valve..............................................344 021 SP000028(8).pdf........................................................................... 0 Accumulator...............................................................................347 Safety Precautions....................................................................351 Applicable Models.....................................................................351 General Description...................................................................352 Specifications....................................................................354 022 SP000181(14).pdf.......................................................................... 0 Center Joint (Swivel).....................................................................355 Safety Precautions....................................................................359 Applicable Models.....................................................................359 General Description...................................................................360 Center Joint Disassembly Diagram..................................................361 Disassembly...........................................................................362 Reassembly............................................................................365 023 SP000193(16).pdf.......................................................................... 0 Cylinders.................................................................................369 Safety Precautions....................................................................373 Applicable Models.....................................................................373 Structure of Cylinder.................................................................374 Structure of Arm Cylinder.........................................................374 Structure of Boom Cylinder........................................................376 Structure of Bucket Cylinder......................................................378 Disassembly of Cylinder...........................................................379 Reassembly of Cylinder............................................................383 024 SP000194(34)์ฃผ์.pdf........................................................................ 0 Swing Motor...............................................................................385 Safety Precautions....................................................................389 Applicable Models.....................................................................389 Operation Manual......................................................................390 Information on Marking............................................................390 Specifications....................................................................391 Structure and Operational Principles..............................................392 Structure.....................................................................392 Operational Principles........................................................394 Brake Subassembly.............................................................398 Cautions..........................................................................399 Check Points..................................................................399 Rotation Direction............................................................399 External Load on Shaft End....................................................400 Active Oil and Temperature Range..............................................400 Filter........................................................................401 Installation and Piping.......................................................402 Fillup and Air Discharge......................................................402 Cautions During Start.........................................................402 Causes and Solutions of Problems..............................................402 General Cautions..............................................................402 How to Check Defects of Motor.................................................403 Symptoms and Solutions of Problems............................................404 Maintenance Instructions..............................................................406 Disassembly and Assembly..........................................................406 Bolt Tightening Torque........................................................406 Tools Used for Disassembly and Assembly.......................................406 Disassembly...................................................................408 Assembly......................................................................412 Maintenance.......................................................................418 References for Replacement of Worn Parts......................................418 Fixing References for Sliding Parts...........................................418 025 SP000185(64).pdf.......................................................................... 0 Travel Motor (With Gearbox) (A6V160HD) SP000185...........................................419 Safety Precautions....................................................................423 Applicable Models.....................................................................423 General Description...................................................................424 Theory Of Operation...............................................................424 Hydraulic Motor Operation.........................................................425 1. Hydraulic Motor operation..................................................425 2. Brake Valve................................................................426 3. Parking Brake..............................................................428 4. High and Low Speed Switching Device........................................430 Reduction Gearbox Operation.......................................................432 Parts List........................................................................434 Travel Motor..................................................................434 Travel Motor - Rotary Group...................................................436 Travel Motor - Control........................................................438 Travel Motor Speed Reduction Gearbox Assembly.................................440 Specifications....................................................................442 Tightening Torques................................................................443 Travel Motor Disassembly..............................................................445 Sectional View....................................................................445 Seal Kits and Component Groups....................................................446 Sealing Drive Shaft...............................................................449 Sealing Control Parts.............................................................450 Sealing Relief Valve..............................................................450 Disassembly Port Plate............................................................451 Exchanging Rotary Group...........................................................456 Travel Motor Speed Reduction Gearbox Disassembly......................................459 Cleaning and Inspection (Wear Limits and Tolerances)..................................468 Travel Motor Speed Reduction Gearbox Reassembly.......................................469 Travel Motor Reassembly...............................................................479 Rotary Group Assembly.............................................................479 Rotary Group Adjustment (See Serve Information)...................................480 Assembly of Port Plate............................................................482 026 SP000186(56).pdf.......................................................................... 0 Main Pump (Rexroth).......................................................................483 Safety Precautions....................................................................487 Applicable Models.....................................................................487 ectional View.........................................................................488 A8VO200LA1KH1/63..................................................................488 General Repair Guidelines.............................................................490 Seal Kits and Sub- assemblies.........................................................492 Sealing the Drive Shaft...............................................................496 Gear Pump Sealing.....................................................................498 Remove the Control Housing............................................................500 Control Module........................................................................504 Control Module LR.................................................................504 Control Module H..................................................................505 Removing the Controller...............................................................506 Valve Plate With Valves...............................................................508 Remove the Rotary Groups..............................................................509 Remove the Intermediate Wheel.........................................................512 Remove Auxiliary Drive................................................................514 Inspection............................................................................517 Re-fitting the Rotary Group...........................................................522 Pump Assembly.........................................................................524 Assembly Guideline................................................................525 Adjustment of the Hydraulic Component of the Rotary Group.........................526 Hydraulic Component - Measurement "D".................................................526 Measuring Device - Hydraulic Component 452 269....................................526 Mounting Position.................................................................527 Measuring Procedure...............................................................528 Installation of Control Housing.......................................................530 Assembly of Intermediate Wheel........................................................533 Installation of Gear Pump.............................................................534 Installation of Cover / Auxiliary Drive...............................................535 Assembly Guidelines for Tightening Torques............................................536 Bolts (To N 08.001)...............................................................536 Plugs with Internal Hexagon and Profile Seal Ring (to N 02.009)...................536 Seal-lock - Sealing Nuts (to N 02.100)............................................537 027 SP000187(58).pdf.......................................................................... 0 Control Valve (Kayaba Model KVMG-400-DA)..................................................539 Safety Precautions....................................................................543 Applicable Models.....................................................................543 General Description...................................................................544 When All Spools are in Neutral....................................................544 Neutral Passage (Figure 1 and Figure 2).......................................544 Signal Passage (Figure 2).....................................................546 Single Operation..................................................................548 Travel Spool Shifting (Figure 3 and Figure 4).................................548 Swing Spool Shifting (Figure 4)...............................................550 Boom Spool Shifting...........................................................551 Spare Spool Shifting (Figure 8)...............................................554 Bucket Spool Shifting (Figure 8)..............................................554 Arm Spool Shifting............................................................555 Neutral-cut Spool Shifting (Figure 11)........................................558 Parallel Throttle for Arm (Figure 11).........................................558 Relief Valve..................................................................559 Combined Operation................................................................560 Travel Combined Operation (Figure 13).........................................560 Swing Combined Operation (Figure 14)..........................................562 Anti Drift Valve..................................................................563 Main Relief Valve.................................................................563 Overload Relief Valve.............................................................564 Low Pressure Relief Valve.........................................................566 Parts List........................................................................567 Spool Assembly (4, Bucket)....................................................571 Spool Assembly (5, Boom)......................................................571 Spool Assembly (6, Travel)....................................................571 Spool Assembly (7, Straight Travel)...........................................572 Spool Assembly (8, Arm1)......................................................572 Spool Assembly (9, Service)...................................................572 Spool Assembly (10, Boom 2)...................................................573 Spool Assembly (11, Swing)....................................................573 Spool Assembly (3, Arm 2).....................................................573 Spool Assembly (20, Arm Regeneration Release Valve............................573 Spool Assembly (24)...........................................................574 Poppet Assembly (36)..........................................................574 Plug Assembly (51)............................................................574 Plug Assembly (58)............................................................574 Relief Valve Assembly (48)....................................................575 Relief Valve Assembly (49)....................................................575 Relief Valve Assembly (50)....................................................576 Specifications....................................................................576 Troubleshooting, Testing and Adjustment...............................................577 General...........................................................................577 Relief Valve......................................................................578 Hydraulic System..................................................................578 Adjustment of Relief Valve........................................................578 Main Relief Valve.............................................................578 Over Load Relief Valve........................................................579 Disassembly...........................................................................580 General Instructions for Disassembly..............................................580 Disassembly of Main Spool (3) - (11)..............................................580 Disassembly of Subspool (24)......................................................581 Disassembly of Subspool (20)......................................................581 Disassembly of Anti Drift Valve of Boom and Arm...................................582 Disassembly of Swing Load Check...................................................582 Disassembly of Load Check.........................................................583 Disassembly of Other Check Valves.................................................583 Disassembly Of Flange.............................................................583 Disassembly of Relief Valve.......................................................584 Disassembly of Other Flange.......................................................584 Disassembly of Main Relief Valve..................................................585 Disassembly of Overload Relief Valve..............................................586 Disassembly of Low Pressure Relief Valve..........................................586 Cleaning and Inspection (Wear Limits and Tolerances)..................................587 Cleaning..........................................................................587 Inspection........................................................................587 Reassembly............................................................................588 Subassembly.......................................................................588 Main Spool (3) - (11).........................................................588 Subspool (20).................................................................588 Subspool (24).................................................................589 Boom, Arm Anti Drift Valve....................................................589 Swing Load Check..............................................................589 Reassembly of Control Valve.......................................................589 Reassembly of Load Check Valve................................................589 Reassembly of Swing Load Check................................................590 Reassembly of Other Check Valve...............................................590 Reassembly of Flange..........................................................591 Reassembly of Boom and Arm Anti Drift Valve...................................591 Reassembly of Relief Valve....................................................591 Reassembly of Subspool (24)...................................................591 Reassembly of Subspool (20)...................................................592 Reassembly of Main Spool (3) - (11)...........................................592 Reassembly of Other Plugs.....................................................592 Reassembly of Main Relief Valve...............................................593 Reassembly of Overload Relief Valve...........................................594 Reassembly of Low Pressure Relief Valve.......................................594 Installation..........................................................................595 Start-up Procedures...................................................................595 028 SP000189(22).pdf.......................................................................... 0 Remote Control Valve (Work Lever / Joystick)..............................................597 Safety Precautions....................................................................601 Applicable Models.....................................................................601 General Description...................................................................603 Structure.........................................................................603 Function..........................................................................603 Parts List........................................................................604 Specifications....................................................................606 Performance...................................................................606 Torques...............................................................................606 Tools and Materials...................................................................606 Disassembly...........................................................................607 Cleaning and Inspection (Wear Limits and Tolerances)..................................611 Reassembly............................................................................611 Start-up Procedures...................................................................617 029 SP000070(26).pdf.......................................................................... 0 Travel Control Valve (With Damper) SP000070...............................................619 Safety Precautions....................................................................623 Applicable Models.....................................................................623 General Description...................................................................624 Theory of Operation...............................................................624 Deceleration Valve................................................................625 Dampening Parts of the Control Section............................................626 Causes of Faults and Measures.........................................................629 Parts List........................................................................630 Specifications....................................................................631 Torques...........................................................................631 Removal...............................................................................632 Disassembly...........................................................................633 Cleaning and Inspection (Wear Limits and Tolerances)..................................636 Assembly..............................................................................637 Installation..........................................................................643 Startup Procedures....................................................................644 030 SP000191(14).pdf.......................................................................... 0 Solenoid Valve Assembly...................................................................645 Safety Precautions....................................................................649 Applicable Models.....................................................................649 Parts List............................................................................650 Functions of 5-Solenoid Valve Assembly Package........................................651 Functions of Solenoid Valve Assembly Package......................................651 This solenoid valve assembly package have the following functions.............651 Functions and Operations of Solenoid Valves...................................651 Detailed Functions and Operations of Solenoid Valves..........................651 Assembly Diagram and Tools Required...............................................653 Cautions During Disassembly and Reassembly....................................654 Solenoid Valve Diagram............................................................655 Check Points and Solutions for Problems...........................................656 Checking of Pilot Pressure for Defects........................................657 031 SP000192(12).pdf.......................................................................... 0 Breaker EPPR Valve (Opt)..................................................................659 Safety Precautions....................................................................663 Applicable Models.....................................................................663 Structure.............................................................................664 Numbers and Names of Parts........................................................664 Functions and Operation...............................................................665 Cautions for Operation................................................................665 Maintenance Instructions..............................................................666 Maintenance.......................................................................666 Bolt Tightening Torque........................................................666 Tools Used for Disassembly and Assembly.......................................666 Disassembly.......................................................................667 Assembly..........................................................................668 032 SP000209(22).pdf.......................................................................... 0 Fan Motor (Vane Type).....................................................................671 Safety Precautions....................................................................675 Applicable Models.....................................................................675 Parts list............................................................................676 Introduction and Description..........................................................677 General...........................................................................677 Description.......................................................................677 Applications......................................................................677 Operation.........................................................................678 Operating Characteristics - Typical...................................................679 Performance Data..................................................................679 Loads on Shaft....................................................................680 Loads on Shaft................................................................680 Lifetime Under Load...........................................................680 Mounting Flange and Coupling..........................................................681 Mounting Flange...................................................................681 Misalignment......................................................................681 Loads on Shaft....................................................................681 Splined Shafts....................................................................681 Shafts............................................................................682 Taper Shafts......................................................................682 Pipe Connection.......................................................................682 Pipe..............................................................................682 Flange Connections................................................................683 External Drain....................................................................683 Cleanliness and Seals.................................................................684 Fluid Cleanliness.................................................................684 Seals S1 : Nbr (Nitrile Base Polymere)............................................684 Seals S4 : Epr (Ethylene Propylene Polymere)......................................684 Seals S5 : Fpm (Fluorocarbon).....................................................684 Maintenance...........................................................................685 General...........................................................................685 Disassembly.......................................................................685 Reassembly........................................................................687 Priming...........................................................................689 Cold Starting.....................................................................689 Changing Porting Position.........................................................689 Cartridge Replacement.............................................................690 End Cap Replacement...............................................................690 Shaft Replacement.................................................................690 Shaft Seal Replacement............................................................690 Seal Driver.......................................................................691 Couping Dimensions....................................................................691 Taper Keyed Shafts................................................................691 033 SP000208(18).pdf.......................................................................... 0 Gear Pump (Fan Cooling Drive).............................................................693 Safety Precautions....................................................................697 Applicable Models.....................................................................697 Disassembling Single Gear Pump........................................................698 Reassembling Single Gear Pump.........................................................701 Disassembling Double Gear Pump(Opt)...................................................704 Reassembling Double Gear Pump(Opt)....................................................707 034 SP000207(6).pdf........................................................................... 0 Fan Cooling Flow In-Out Change Valve......................................................711 Safety Precautions....................................................................715 Applicable Models.....................................................................715 Cooling Fan a Change of Direction Valve...............................................716 035 SP000212(10).pdf.......................................................................... 0 Hydraulic Schematic DX480LC/ 520LC........................................................717 Safety Precautions....................................................................721 Applicable Models.....................................................................721 General Description...................................................................723 DX480LC / DX520LC.....................................................................724 036 S08Electrical System(2).pdf............................................................... 0 Electrical System.........................................................................727 037 SP000197(116).pdf......................................................................... 0 Electrical System SP000197................................................................729 Safety Precautions....................................................................735 Applicable Models.....................................................................735 Introduction..........................................................................737 Electric Wire Color...............................................................737 Electrical Supply System..............................................................738 Engine Starting Circuit...............................................................740 Start Operation...................................................................740 After Start.......................................................................742 Operation of the Start Circuit (2) Immediately After Start....................743 Engine Preheating System..............................................................744 Engine Stop...........................................................................746 Charging System.......................................................................748 Monitoring System.....................................................................749 Instrument Panel..................................................................750 Monitoring System Schematic.......................................................752 Operation.............................................................................754 Instruments.......................................................................754 Warning and Indicator Lights..........................................................756 Indication of Warning Lights......................................................756 Indication of Multifunction Gauge and Letter Information Area.....................757 Initial Operation.....................................................................759 Mode Selector Switch..................................................................759 Power Mode / Trenching Mode Switch................................................759 Auto Idle Switch..................................................................759 Graphic Information Area Display......................................................760 Overview..........................................................................760 Main Menus for the Graphic Display Area...........................................761 Menu Selector Buttons.............................................................761 Menu Selector Buttons.............................................................761 Main Menu.............................................................................762 Language..........................................................................762 Set Clock.........................................................................763 Filter/Oil Info...................................................................763 Menu Display Order and Icon Explanation.......................................764 Adjust Display....................................................................764 Set Password......................................................................765 Special Menu..........................................................................766 Entering/Accessing and Exiting/Escaping Menus.....................................766 Entering/Accessing Menus......................................................766 Exiting/Escaping Menus........................................................767 Special Menu Selections...........................................................767 Information of Machine Status.................................................767 Failure Information...........................................................771 Information of Machine Operation..............................................779 Machine Operation Info Screen.................................................782 Electronic Hydraulic Control System (eEPOS)...........................................784 Control System Schematic..........................................................784 Power Mode Control....................................................................786 Operation.........................................................................788 1. Power Mode.................................................................788 2. Standard Mode..............................................................790 3) Operation in case of failure in the control system (Aux mode operation)....790 Power Mode Control Circuit Diagram....................................................792 Work Mode Control.....................................................................794 Operation.........................................................................795 1. Digging Mode...............................................................795 2. Trenching Mode.............................................................795 Work Mode Control Circuit Diagram.....................................................796 Engine Control System.................................................................797 Engine Control Dial...................................................................798 Engine Control Circuit Diagram........................................................800 Automatic Deceleration Control (Auto Idle Control)....................................802 Engine Overheat Protection System.....................................................804 Power Boost Mode......................................................................806 Operation.........................................................................806 Power Boost Control Circuit Diagram...............................................808 Automatic Travel Speed Control........................................................810 Automatic Travel Speed Control Circuit Diagram....................................812 Selfdiagnostic Function...............................................................813 eEPOS Controller..................................................................813 Air Conditioner System................................................................815 Outline...........................................................................815 Internal and External Filters.....................................................816 How to check Indoor air filter................................................816 How to check outdoor air filter...............................................816 Air-Conditioning System Layout....................................................818 Air Conditioner/Heater Circuit Diagram............................................819 Air Conditioner/Heater Unit.......................................................820 Air Flow Diagram..............................................................820 Door Open by Vent Modes.......................................................821 Main Components...............................................................821 Actuator - Internal/external air exchange.....................................823 Air Flow Control Module.......................................................823 Relay - Blower....................................................................824 Relay - A/C.......................................................................824 Duct Sensor.......................................................................824 Water Temp Sensor.................................................................825 Internal Air Temp Sensor..........................................................825 Ambient Air Temperature Sensor....................................................825 Sun Sensor........................................................................826 Control Panel.....................................................................826 Appearance and Terminal Arrangement...........................................826 Terminal Terms................................................................827 Control Logic.................................................................827 Self Diagnosis................................................................831 Ambient Temp Display..........................................................832 Compressor........................................................................833 Receiver Dryer....................................................................833 Control of Cooling Fan................................................................834 Control of Cooling Fan Speed......................................................834 Control of Reverse Rotation of Cooling Fan........................................834 Cooling Fan Control Circuit.......................................................835 Wiper System..........................................................................836 Wiper Circuit.....................................................................836 Wiper operation...................................................................837 Continuous operation..........................................................837 Intermittent operation........................................................837 Lighting System.......................................................................840 Lighting System Circuit Diagram...................................................840 Kind of Light.....................................................................841 Operation.........................................................................841 Audio Controller......................................................................842 Audio Controller Circuit Diagram..................................................842 Operations Via Audio Control Panel............................................843 038 SP000213(10).pdf.......................................................................... 0 Electrical Schematic DX480LC/ 520LC.......................................................845 Safety Precautions....................................................................849 Applicable Models.....................................................................849 General Description...................................................................851 DX480LC/ 520LC........................................................................852 039 S09Attachments(2).pdf..................................................................... 0 Attachments...............................................................................855 040 SP000205(12).pdf.......................................................................... 0 Boom and Arm..............................................................................857 Safety Precautions....................................................................861 Applicable Models.....................................................................861 Front Attachment Pin Specifications...................................................862 Front Attachment - Removal and Installation...........................................863 Arm Removal Procedure.............................................................863 Boom Removal Procedure............................................................866 Installation..........................................................................867 Arm Installation Procedure........................................................867 Boom Installation Procedure.......................................................867 Start-up Procedures...................................................................868 041 SP000206(10).pdf.......................................................................... 0 Bucket....................................................................................869 Safety Precautions....................................................................873 Applicable Models.....................................................................873 Bucket Tooth Inspection and Replacement...............................................874 Bucket O-ring Replacement.............................................................875 Bucket Attachment, Removal and Reversal...............................................877 Detaching the Bucket..............................................................877 Attaching the Bucket..............................................................877
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