Doosan DX140W-3 DX160W-3 Excavator Shop Manual 950106-00352E – PDF DOWNLOAD
DESCRIPTION:
Doosan DX140W-3 DX160W-3 Excavator Shop Manual 950106-00352E – PDF DOWNLOAD
Serial Number 50001 and Up (Europe Only)
- Know the purpose of all controls, gauges, signals, indicators and monitor displays. Know the rated load capacity, speed range, braking and steering characteristics, turning radius and operating clearances. Keep in mind that rain, snow, ice, loose gravel, soft ground, slopes etc., can change operating capabilities of your machine.
Proper Work Tools and Attachments
- Only use work tools and attachments that are recommended by DOOSAN for use on DOOSAN machines. When installing and using optional attachments, read instruction manual for attachment, and general information related to attachments in this manual.
- Because DOOSAN cannot anticipate, identify or test all attachments that owners may want to install on their machines, contact DOOSAN for written authorization and approval of attachments, and their compatibility with optional kits. Attachments and attachment control systems that are compatible with the machine are required for safe and reliable machine operation. Do not exceed maximum operating weight (machine weight plus attachment) that is listed on ROPS certification plate.
- Make sure that all guards and shields are in place on machine and on work tool. Depending on type or combination of work equipment, there is a potential that work equipment could interfere with the cabin or other parts of machine.
- Before using unfamiliar work equipment, check if there is any potential of interference, and operate with caution. While you are performing any maintenance, testing, or adjustments to attachments, stay clear of the following areas: cutting edges, pinch points, and crushing surfaces.
- Never use attachment as a work platform or manlift. Contact your DOOSAN distributor about auxiliary hydraulic kits for attachments installation. If you are in doubt about compatibility of a particular attachment with a machine, consult
TABLE OF CONTENTS:
Doosan DX140W-3 DX160W-3 Excavator Shop Manual 950106-00352E – PDF DOWNLOAD
DX140W-3/DX160W-3………………………………………………………………………………………………………………………………………. 0
Table of Contents…………………………………………………………………………………………………………………………………… 7
Safety…………………………………………………………………………………………………………………………………………….. 9
Wheeled Excavator Maintenance Safety SP002611………………………………………………………………………………………………………. 11
Safety Instructions………………………………………………………………………………………………………………………….. 15
Applicable Models……………………………………………………………………………………………………………………………. 15
Safety Messages……………………………………………………………………………………………………………………………… 17
Signal Words…………………………………………………………………………………………………………………………….. 17
Other Signal Words……………………………………………………………………………………………………………………….. 18
Safety Decals……………………………………………………………………………………………………………………………….. 18
General…………………………………………………………………………………………………………………………………….. 19
Safe Operation is Operator’s Responsibility…………………………………………………………………………………………………. 19
Know Your Machine………………………………………………………………………………………………………………………… 19
Proper Work Tools and Attachments………………………………………………………………………………………………………….. 20
Pressurized Fluids……………………………………………………………………………………………………………………….. 20
Flying or Falling Objects…………………………………………………………………………………………………………………. 21
Personal Protective Equipment (PPE)………………………………………………………………………………………………………… 22
Correction of Machine Problems…………………………………………………………………………………………………………….. 22
Crushing and Cutting……………………………………………………………………………………………………………………… 22
Hot Coolant and Oils – Burn Prevention……………………………………………………………………………………………………… 23
Fire and Explosion Prevention……………………………………………………………………………………………………………… 24
Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)…………………………………………………………………………………… 27
Electrical System and Electrical Shock……………………………………………………………………………………………………… 28
Rollover Protective Structure (ROPS)……………………………………………………………………………………………………….. 28
Transportation………………………………………………………………………………………………………………………………. 32
Obey State and Local Over-the-Road Regulations………………………………………………………………………………………………. 32
Loading and Unloading…………………………………………………………………………………………………………………….. 32
Transporting Machine……………………………………………………………………………………………………………………… 33
Operation…………………………………………………………………………………………………………………………………… 34
Before Engine Starting……………………………………………………………………………………………………………………. 34
Work Site……………………………………………………………………………………………………………………………….. 35
Mounting/Dismounting……………………………………………………………………………………………………………………… 36
Cleaning………………………………………………………………………………………………………………………………… 37
Operator Station…………………………………………………………………………………………………………………………. 37
Seat Belt……………………………………………………………………………………………………………………………….. 38
Visibility Information……………………………………………………………………………………………………………………. 39
Boost Starting or Charging Engine Batteries…………………………………………………………………………………………………. 40
Starting Engine………………………………………………………………………………………………………………………….. 41
Swinging or Traveling…………………………………………………………………………………………………………………….. 42
Lifting and Digging………………………………………………………………………………………………………………………. 44
Operation on Slopes………………………………………………………………………………………………………………………. 45
Towing………………………………………………………………………………………………………………………………….. 46
Attachment………………………………………………………………………………………………………………………………. 47
Equipment Lowering with Engine Stopped……………………………………………………………………………………………………… 47
Engine Stop……………………………………………………………………………………………………………………………… 47
Parking Machine………………………………………………………………………………………………………………………….. 48
Service Brake……………………………………………………………………………………………………………………………. 49
Preservation/Storing Machine………………………………………………………………………………………………………………. 50
Maintenance…………………………………………………………………………………………………………………………………. 52
Warning Tag……………………………………………………………………………………………………………………………… 55
Cleaning………………………………………………………………………………………………………………………………… 56
Proper Tools and Clothing…………………………………………………………………………………………………………………. 56
Disassembling Precautions…………………………………………………………………………………………………………………. 56
Use of Lighting………………………………………………………………………………………………………………………….. 57
Fire and Explosion Prevention……………………………………………………………………………………………………………… 57
Burn Prevention………………………………………………………………………………………………………………………….. 58
Rubber That Contains Fluorides…………………………………………………………………………………………………………….. 59
Rubber and Plastics………………………………………………………………………………………………………………………. 60
Welding Repairs………………………………………………………………………………………………………………………….. 61
Warning for Counterweight and Front Attachment Removal……………………………………………………………………………………….. 62
Working on Machine……………………………………………………………………………………………………………………….. 63
Lock Inspection Covers……………………………………………………………………………………………………………………. 63
Accumulator……………………………………………………………………………………………………………………………… 64
Compressed Air…………………………………………………………………………………………………………………………… 64
Supports and Blocking for Work Equipment……………………………………………………………………………………………………. 64
High-pressure Lines, Tubes and Hoses……………………………………………………………………………………………………….. 65
Battery…………………………………………………………………………………………………………………………………. 66
Environment and Circumstances…………………………………………………………………………………………………………………. 68
Work Site Areas Requiring Extra Caution…………………………………………………………………………………………………….. 68
High-voltage Cables………………………………………………………………………………………………………………………. 70
Underground Operation…………………………………………………………………………………………………………………….. 71
Working in Water…………………………………………………………………………………………………………………………. 71
Working in Contaminated Environment………………………………………………………………………………………………………… 71
Operation in Extreme Conditions……………………………………………………………………………………………………………. 72
Exhaust Ventilation………………………………………………………………………………………………………………………. 76
Asbestos Information……………………………………………………………………………………………………………………… 76
Silica Dust Information…………………………………………………………………………………………………………………… 77
Disposal of Hazardous Materials……………………………………………………………………………………………………………. 77
Sound…………………………………………………………………………………………………………………………………… 78
Vibration……………………………………………………………………………………………………………………………….. 78
Specifications……………………………………………………………………………………………………………………………………… 79
Specifications for DX140W-3/DX160W-3 SP002612………………………………………………………………………………………………………. 81
Safety Instructions………………………………………………………………………………………………………………………….. 85
Applicable Models……………………………………………………………………………………………………………………………. 85
General Description………………………………………………………………………………………………………………………….. 87
Component Locations………………………………………………………………………………………………………………………….. 88
General Dimensions…………………………………………………………………………………………………………………………… 90
One – Piece Boom…………………………………………………………………………………………………………………………. 90
Two – Piece Boom…………………………………………………………………………………………………………………………. 91
Working Range……………………………………………………………………………………………………………………………….. 92
One – Piece Boom…………………………………………………………………………………………………………………………. 92
Two – Piece Boom…………………………………………………………………………………………………………………………. 94
General Specifications……………………………………………………………………………………………………………………….. 96
Engine Performance Curves (Per KS-R1004 Standard)……………………………………………………………………………………………….. 98
Approximate Weight of Workload Materials……………………………………………………………………………………………………….. 100
Performance Tests……………………………………………………………………………………………………………………………. 102
Excavator Performance Standards……………………………………………………………………………………………………………….. 103
Test Conditions………………………………………………………………………………………………………………………….. 103
Travel Speed Tests……………………………………………………………………………………………………………………….. 104
Swing Speed and Deceleration Force Test…………………………………………………………………………………………………….. 105
Cylinder Performance Tests………………………………………………………………………………………………………………… 107
General Maintenance…………………………………………………………………………………………………………………………………. 109
General Maintenance Instructions SP002454………………………………………………………………………………………………………….. 111
Safety Instructions………………………………………………………………………………………………………………………….. 115
Applicable Models……………………………………………………………………………………………………………………………. 115
Welding Precautions and Instructions…………………………………………………………………………………………………………… 116
Hydraulic System – General Precautions…………………………………………………………………………………………………………. 117
Maintenance Service and Repair Procedure……………………………………………………………………………………………………….. 119
General Precautions………………………………………………………………………………………………………………………. 119
Hydraulic System Cleanliness and Oil Leaks……………………………………………………………………………………………………… 120
Maintenance Precautions for Hydraulic System Service…………………………………………………………………………………………. 120
Oil Leakage Precautions…………………………………………………………………………………………………………………… 121
Cleaning and Inspection………………………………………………………………………………………………………………………. 122
General Instructions……………………………………………………………………………………………………………………… 122
Bearing Inspection……………………………………………………………………………………………………………………….. 123
Standard Torques SP002404………………………………………………………………………………………………………………………… 131
Safety Instructions………………………………………………………………………………………………………………………….. 135
Applicable Models……………………………………………………………………………………………………………………………. 135
Torque Values for Standard Metric Fasteners…………………………………………………………………………………………………….. 136
Torque Values for Standard U.S. Fasteners………………………………………………………………………………………………………. 137
Type 8 Phosphate Coated Hardware………………………………………………………………………………………………………………. 139
Torque Values for Hose Clamps…………………………………………………………………………………………………………………. 140
ORFS Swivel Nut Recommended Torque…………………………………………………………………………………………………………….. 140
Torque Values for Split Flanges……………………………………………………………………………………………………………….. 141
Torque Wrench Extension Tools…………………………………………………………………………………………………………………. 142
Torque Multiplication…………………………………………………………………………………………………………………….. 142
Other Uses for Torque Wrench Extension Tools………………………………………………………………………………………………… 143
Tightening Torque Specifications (Metric)…………………………………………………………………………………………………… 144
Upper Structure…………………………………………………………………………………………………………………………………….. 147
Cabin SP002613………………………………………………………………………………………………………………………………….. 149
Safety Instructions………………………………………………………………………………………………………………………….. 153
Applicable Models……………………………………………………………………………………………………………………………. 153
Cabin Identification…………………………………………………………………………………………………………………………. 154
Rollover Protective Structure (ROPS)……………………………………………………………………………………………………….. 154
Removal…………………………………………………………………………………………………………………………………….. 156
Installation………………………………………………………………………………………………………………………………… 160
Counterweight SP002614…………………………………………………………………………………………………………………………… 163
Safety Instructions………………………………………………………………………………………………………………………….. 167
Applicable Models……………………………………………………………………………………………………………………………. 167
General…………………………………………………………………………………………………………………………………….. 168
Warning for Counterweight and Front Attachment Removal……………………………………………………………………………………….. 168
Removal…………………………………………………………………………………………………………………………………….. 170
Installation………………………………………………………………………………………………………………………………… 171
Fuel Tank SP002615………………………………………………………………………………………………………………………………. 173
Safety Instructions………………………………………………………………………………………………………………………….. 177
Applicable Models……………………………………………………………………………………………………………………………. 177
General Description………………………………………………………………………………………………………………………….. 178
Parts List………………………………………………………………………………………………………………………………. 178
Specifications…………………………………………………………………………………………………………………………… 179
Removal…………………………………………………………………………………………………………………………………….. 180
Installation………………………………………………………………………………………………………………………………… 185
Start-up Procedures………………………………………………………………………………………………………………………….. 188
Fuel Transfer Pump (Option) SP002616………………………………………………………………………………………………………………. 189
Safety Instructions………………………………………………………………………………………………………………………….. 193
Applicable Models……………………………………………………………………………………………………………………………. 193
General Description………………………………………………………………………………………………………………………….. 194
Theory of Operation………………………………………………………………………………………………………………………. 194
Troubleshooting……………………………………………………………………………………………………………………………… 195
Replacement of Rotor and Vane…………………………………………………………………………………………………………………. 195
Replacement of Rear Cover…………………………………………………………………………………………………………………….. 196
Replacement of Armature………………………………………………………………………………………………………………………. 196
Swing Bearing SP002617…………………………………………………………………………………………………………………………… 197
Safety Instructions………………………………………………………………………………………………………………………….. 201
Applicable Models……………………………………………………………………………………………………………………………. 201
Swing Bearing Maintenance…………………………………………………………………………………………………………………….. 202
Operating Recommendation………………………………………………………………………………………………………………….. 202
Measuring Swing Bearing Axial Play…………………………………………………………………………………………………………. 202
Measuring Bearing Lateral Play…………………………………………………………………………………………………………….. 202
Swing Bearing Basic Operation……………………………………………………………………………………………………………… 203
Disassembly……………………………………………………………………………………………………………………………… 203
Assembly………………………………………………………………………………………………………………………………… 205
Air Compressor SP002619………………………………………………………………………………………………………………………….. 207
Safety Instructions………………………………………………………………………………………………………………………….. 211
Applicable Models……………………………………………………………………………………………………………………………. 211
General Description………………………………………………………………………………………………………………………….. 212
Parts List………………………………………………………………………………………………………………………………. 212
Specifications…………………………………………………………………………………………………………………………… 212
Locations of Product Number and Serial Number……………………………………………………………………………………………….. 213
Operation and Inspection……………………………………………………………………………………………………………………… 213
Operating Instructions……………………………………………………………………………………………………………………. 213
Instructions Before Inspection and Maintenance………………………………………………………………………………………………. 214
Maintenance Intervals…………………………………………………………………………………………………………………….. 214
Troubleshooting……………………………………………………………………………………………………………………………… 216
Lower Structure and Chassis………………………………………………………………………………………………………………………….. 217
Ram Lock Valve SP002620………………………………………………………………………………………………………………………….. 219
Safety Instructions………………………………………………………………………………………………………………………….. 223
Applicable Models……………………………………………………………………………………………………………………………. 223
Sectional Drawing and Part Names………………………………………………………………………………………………………………. 224
Hydraulic Circuit……………………………………………………………………………………………………………………………. 224
Operational Principle………………………………………………………………………………………………………………………… 225
In Case of No Pilot Pressure at PI Port…………………………………………………………………………………………………….. 225
In Case of Pilot Pressure (Approx. 20 kg/ cm2) at PI Port…………………………………………………………………………………….. 225
Disassembly and Assembly……………………………………………………………………………………………………………………… 225
General Instructions……………………………………………………………………………………………………………………… 225
Assembly and Disassembly of Chocking Valve………………………………………………………………………………………………….. 226
Performance Test…………………………………………………………………………………………………………………………….. 227
Oil Leakage Test…………………………………………………………………………………………………………………………. 227
Operational Test…………………………………………………………………………………………………………………………. 227
Double Pilot Check Valve SP002621…………………………………………………………………………………………………………………. 229
Safety Instructions………………………………………………………………………………………………………………………….. 233
Applicable Models……………………………………………………………………………………………………………………………. 233
Sectional Drawing and Parts…………………………………………………………………………………………………………………… 234
Hydraulic Diagram……………………………………………………………………………………………………………………………. 234
Operational Principle………………………………………………………………………………………………………………………… 235
A → C, D → B…………………………………………………………………………………………………………………………….. 235
B → D, C → A…………………………………………………………………………………………………………………………….. 235
Disassembly and Assembly……………………………………………………………………………………………………………………… 236
General Cautions…………………………………………………………………………………………………………………………. 236
Assembly and Disassembly of Double Pilot Check Valve…………………………………………………………………………………………. 237
Performance Test…………………………………………………………………………………………………………………………….. 238
Cracking Pressure Test for Check Cartridge Assembly………………………………………………………………………………………….. 239
Pilot Cracking Pressure Test………………………………………………………………………………………………………………. 239
Oil Leakage Test…………………………………………………………………………………………………………………………. 239
Solenoid Valve SP002622………………………………………………………………………………………………………………………….. 241
Safety Instructions………………………………………………………………………………………………………………………….. 245
Applicable Models……………………………………………………………………………………………………………………………. 245
Single Solenoid Valve………………………………………………………………………………………………………………………… 246
Function………………………………………………………………………………………………………………………………… 247
Disassembly and Reassembly Diagrams………………………………………………………………………………………………………… 248
Troubleshooting………………………………………………………………………………………………………………………….. 249
Double Solenoid Valve………………………………………………………………………………………………………………………… 250
Function………………………………………………………………………………………………………………………………… 251
Disassembly and Reassembly Diagrams………………………………………………………………………………………………………… 252
Troubleshooting………………………………………………………………………………………………………………………….. 253
Front Axle SP002623……………………………………………………………………………………………………………………………… 255
Safety Instructions………………………………………………………………………………………………………………………….. 259
Applicable Models……………………………………………………………………………………………………………………………. 259
Examples of Gear Tooth-Contact Patterns for the Gleason Gear Tooth System………………………………………………………………………. 260
Lubrication and Maintenance Specifications for Axle MS-E 3050 / 3060 / 3070 and MS-E 3050 II / 3060 II / 3070 II……………………………………….. 262
Oil Grade……………………………………………………………………………………………………………………………….. 262
Oil Change………………………………………………………………………………………………………………………………. 262
Oil Change Interval………………………………………………………………………………………………………………………. 264
Oil Level Check………………………………………………………………………………………………………………………….. 264
Brake…………………………………………………………………………………………………………………………………… 264
Brake Wear Measurement on Axles of MT/MS-E 3050 / 3050 II / 3060 / 3060 II / 3070 / 3070 II Range…………………………………………………….. 265
Lining Wear Measurement of Multidisk Brake………………………………………………………………………………………………….. 266
Disassembly…………………………………………………………………………………………………………………………………. 267
Steering………………………………………………………………………………………………………………………………… 267
Output………………………………………………………………………………………………………………………………….. 271
Planetary Carrier…………………………………………………………………………………………………………………….. 272
Brake/Hub……………………………………………………………………………………………………………………………. 273
Knuckle Housing………………………………………………………………………………………………………………………. 276
Differential – Input……………………………………………………………………………………………………………………… 279
Differential Version “D-500” and “D-750″………………………………………………………………………………………………… 280
Input……………………………………………………………………………………………………………………………….. 282
Pivot Bearing……………………………………………………………………………………………………………………………. 284
Reassembly………………………………………………………………………………………………………………………………….. 285
Input…………………………………………………………………………………………………………………………………… 285
Determine Shim for Pinion Positioning to Obtain An Optimum Contact Pattern of Crown Wheel/pinion – Refer to Contact Pattern Examples, (See page -6)…. 285
Adjust Rolling Moment of Drive Pinion Bearing 1.0 – 2.0 Nm (Without Seal Ring):……………………………………………………………… 287
Differential Version “D-500” and “D-750″………………………………………………………………………………………………… 289
Adjust Backlash of Bevel Gear Set and Bearing Rolling Moment of Differential Bearing…………………………………………………………. 292
Backlash and Contact Pattern Check……………………………………………………………………………………………………… 295
Input Flange…………………………………………………………………………………………………………………………….. 298
Output………………………………………………………………………………………………………………………………….. 299
Preassemble Axle Housing………………………………………………………………………………………………………………. 300
Knuckle Housing………………………………………………………………………………………………………………………. 302
Hub…………………………………………………………………………………………………………………………………. 306
Multidisk Brake………………………………………………………………………………………………………………………. 310
Planetary Carrier…………………………………………………………………………………………………………………….. 316
Pivot Bearing……………………………………………………………………………………………………………………………. 318
Steering………………………………………………………………………………………………………………………………… 319
Steering Setting and Checking………………………………………………………………………………………………………….. 325
Oil Drain-Oil Filler and Oil Control Plugs and Grease Lubrication Points……………………………………………………………………….. 328
Rear Axle SP002624………………………………………………………………………………………………………………………………. 329
Safety Instructions………………………………………………………………………………………………………………………….. 333
Applicable Models……………………………………………………………………………………………………………………………. 333
Examples of Gear Tooth-Contact Patterns for the Gleason Gear Tooth System………………………………………………………………………. 334
Lubrication and Maintenance Specifications for Axle MT-E 3050 / 3060 / 3070 and MT-E 3050 II / 3060 II / 3070 II……………………………………….. 336
Oil Grade……………………………………………………………………………………………………………………………….. 336
Oil Change………………………………………………………………………………………………………………………………. 336
Oil Change Interval………………………………………………………………………………………………………………………. 338
Oil Level Check………………………………………………………………………………………………………………………….. 338
Brake…………………………………………………………………………………………………………………………………… 338
Brake Wear Measurement on Axles of MT/MS-E 3050 / 3050 II / 3060 / 3060 II / 3070 / 3070 II Range…………………………………………………….. 339
Lining Wear Measurement of Multidisk Brake………………………………………………………………………………………………….. 340
Disassembly…………………………………………………………………………………………………………………………………. 341
Reassembly………………………………………………………………………………………………………………………………….. 347
Hub Carrier / Hub………………………………………………………………………………………………………………………… 347
Multidisk Brake………………………………………………………………………………………………………………………….. 351
Take Leakage Test of Multidisk Brake……………………………………………………………………………………………………. 354
Adjust and Check Disk Clearance/Piston Stroke……………………………………………………………………………………………. 355
Planetary Carrier………………………………………………………………………………………………………………………… 356
Assembly of An Output Assembly (Figure 78)………………………………………………………………………………………………….. 358
Disassembly…………………………………………………………………………………………………………………………………. 359
Differential/Input……………………………………………………………………………………………………………………….. 359
Input – HL Transmission…………………………………………………………………………………………………………………… 360
Differential Type “D 500” and “D-750″………………………………………………………………………………………………………. 363
Reassembly………………………………………………………………………………………………………………………………….. 365
Differential/Input……………………………………………………………………………………………………………………….. 365
Differential – Type “D-500” and “D-750″…………………………………………………………………………………………………. 365
Determine Shim for Backlash (Crown Wheel/Drive Pinion)……………………………………………………………………………………. 368
Check Backlash and Contact Pattern……………………………………………………………………………………………………… 372
Reassembly of Output Assembly (Figure 123 – 125)…………………………………………………………………………………………….. 374
Engine and Drivetrain……………………………………………………………………………………………………………………………….. 375
Transmission SP002625……………………………………………………………………………………………………………………………. 377
Safety Instructions………………………………………………………………………………………………………………………….. 381
Applicable Models……………………………………………………………………………………………………………………………. 381
Layout 2 HL 250/270/290 Axle Attachment………………………………………………………………………………………………………… 382
Layout 2 HL 250/270/290 Separate Installation…………………………………………………………………………………………………… 383
Measuring Points and Connections or Installation View 2 HL 250/ 270/290 Layout “Axle Attachment”……………………………………………………… 384
Measuring Points and Connections on the 2 HL 250/270/290 Transmission – Version “Separate Installation”……………………………………………….. 386
Notes to the Required Oil Quality and Oil Filling Capacity……………………………………………………………………………………….. 387
Oil Quality/Oil Grade…………………………………………………………………………………………………………………….. 387
Oil Filling Capacity for Power Shift Transmissions (2 HL-250/270/290)………………………………………………………………………….. 387
For the Version “Axle Attachment”………………………………………………………………………………………………………….. 387
Separate the HL-Transmission from the Axle Casing……………………………………………………………………………………………….. 388
Disassembly – Brake/ Clutch/Planet Carrier……………………………………………………………………………………………………… 389
Lube Oil Pump/Downshift Interlock………………………………………………………………………………………………………….. 389
Version “Lube Oil Pump”……………………………………………………………………………………………………………….. 389
Speed Transmitter………………………………………………………………………………………………………………………… 390
Emergency Release (Parking Brake)………………………………………………………………………………………………………….. 390
Input Housing and Modulation Valve…………………………………………………………………………………………………………. 391
Brake/Clutch…………………………………………………………………………………………………………………………….. 392
Planet Carrier…………………………………………………………………………………………………………………………… 398
Disassembly – Output…………………………………………………………………………………………………………………………. 402
Version – Axle Attachment…………………………………………………………………………………………………………………. 402
Version – “Separate Installation”………………………………………………………………………………………………………….. 406
Reassembly – Output………………………………………………………………………………………………………………………….. 410
Version – Axle Attachment…………………………………………………………………………………………………………………. 410
Determine Adjusting Shim for Pinion Gap…………………………………………………………………………………………………. 412
Determine the Adjusting Ring for Rolling Moment/Pinion Bearing…………………………………………………………………………….. 416
Check the Rolling Moment of the Pinion Bearing…………………………………………………………………………………………… 418
Shaft Seal/Output Flange………………………………………………………………………………………………………………. 418
Check the Pinion Gap………………………………………………………………………………………………………………….. 420
Version Separate Installation………………………………………………………………………………………………………….. 421
Shaft Seal/Output Flange………………………………………………………………………………………………………………. 425
Reassembly – Brake/ Clutch/Planet Carrier………………………………………………………………………………………………………. 428
Planet Carrier…………………………………………………………………………………………………………………………… 428
Brake/Clutch…………………………………………………………………………………………………………………………….. 434
Disk Components Brake and Clutch……………………………………………………………………………………………………….. 436
Adjust and check the Disk Clearance/Piston Stroke of Brake and Clutch………………………………………………………………………. 438
Modulation Valve and Input Housing…………………………………………………………………………………………………………. 447
Emergency Release (Parking Brake)………………………………………………………………………………………………………….. 449
Check the Emergency Release for Leak Tightness…………………………………………………………………………………………… 451
Check the Multidisk Brake and Multidisk Clutch for Leak Tightness and Closing Pressure……………………………………………………….. 453
Speed Transmitter………………………………………………………………………………………………………………………… 454
Lube Oil Pump/Downshift Interlock………………………………………………………………………………………………………….. 455
Disassembly – Lube Oil Pump/Downshift Interlock…………………………………………………………………………………………………. 456
Version “with” Lube Oil Pump………………………………………………………………………………………………………………. 456
Version “with” Hydraulic Downshift Interlock………………………………………………………………………………………………… 459
Version “with” Electric Downshift Interlock- Mounted to Transmission…………………………………………………………………………… 462
Reassembly – Lube Oil Pump/Downshift Interlock………………………………………………………………………………………………….. 463
Version “with” Lube Oil Pump………………………………………………………………………………………………………………. 463
Version “with” Hydraulic Downshift Interlock………………………………………………………………………………………………… 469
Version “with” Electric Downshift Interlock – Mounted to the Transmission………………………………………………………………………. 476
Attach the HL-Transmission to the Axle…………………………………………………………………………………………………………. 477
Drive Coupling (Main Pump) SP002626……………………………………………………………………………………………………………….. 479
Safety Instructions………………………………………………………………………………………………………………………….. 483
Applicable Models……………………………………………………………………………………………………………………………. 483
Drive Coupling………………………………………………………………………………………………………………………………. 484
Special Tools……………………………………………………………………………………………………………………………….. 486
Drive Coupling Installation…………………………………………………………………………………………………………………… 487
Installation Procedure……………………………………………………………………………………………………………………. 489
Hydraulics…………………………………………………………………………………………………………………………………………. 491
Hydraulic System Troubleshooting, Testing and Adjustment SP002627…………………………………………………………………………………….. 493
Hydraulic System – General Notes………………………………………………………………………………………………………………. 498
Hydraulic Schematic………………………………………………………………………………………………………………………….. 499
General Notes……………………………………………………………………………………………………………………………. 499
Operation of Working Components……………………………………………………………………………………………………………….. 501
Boom Operating Circuit……………………………………………………………………………………………………………………. 501
Boom Up Circuit………………………………………………………………………………………………………………………….. 501
Boom Down Circuit………………………………………………………………………………………………………………………… 501
Arm Operating Circuit…………………………………………………………………………………………………………………….. 502
Arm Crowd Circuit………………………………………………………………………………………………………………………… 502
Arm Dump Circuit…………………………………………………………………………………………………………………………. 502
Bucket Operating Circuit………………………………………………………………………………………………………………….. 503
Bucket Crowd Circuit……………………………………………………………………………………………………………………… 503
Bucket Dump Circuit………………………………………………………………………………………………………………………. 503
Swing Operating Circuit…………………………………………………………………………………………………………………… 503
Right Swing Operating Circuit……………………………………………………………………………………………………………… 504
Left Swing Operating Circuit………………………………………………………………………………………………………………. 504
Swing Relief Valve and Makeup Valve………………………………………………………………………………………………………… 504
Travel Operating Circuit………………………………………………………………………………………………………………….. 505
Forward Travel Circuit……………………………………………………………………………………………………………………. 505
Reverse Travel Circuit……………………………………………………………………………………………………………………. 505
Procedural Troubleshooting Baseline Recommendations……………………………………………………………………………………………… 506
Initial Checks and Tests to Establish Operating Condition of the Excavator……………………………………………………………………… 506
Troubleshooting Summary…………………………………………………………………………………………………………………… 506
Pilot Pressure………………………………………………………………………………………………………………………………. 508
Adjustment and Testing……………………………………………………………………………………………………………………. 508
Power Mode Valve…………………………………………………………………………………………………………………………….. 509
Current Signal and Hydraulic Pressure Adjustments……………………………………………………………………………………………. 509
Pressure Up Valve……………………………………………………………………………………………………………………………. 511
Checks and Adjustments……………………………………………………………………………………………………………………. 511
Pump Input Power Control……………………………………………………………………………………………………………………… 513
Pump Regulator Adjustment…………………………………………………………………………………………………………………. 513
Flow Meter and Flow Meter Kit Installation and Testing…………………………………………………………………………………………… 517
Installation and Testing Procedure…………………………………………………………………………………………………………. 517
Swing System Troubleshooting………………………………………………………………………………………………………………….. 519
Precautions/Initial Checks………………………………………………………………………………………………………………… 519
Swing Relief Valve Checking and Adjustment………………………………………………………………………………………………….. 520
Troubleshooting – Swing Gearbox……………………………………………………………………………………………………………….. 522
Troubleshooting – Hydraulic Problems…………………………………………………………………………………………………………… 523
Troubleshooting – Control Valve……………………………………………………………………………………………………………….. 525
Troubleshooting – Travel Control Valve…………………………………………………………………………………………………………. 526
Troubleshooting – Joystick Control Valve……………………………………………………………………………………………………….. 526
Safety Instructions………………………………………………………………………………………………………………………….. 497
Applicable Models……………………………………………………………………………………………………………………………. 497
Accumulator SP002628…………………………………………………………………………………………………………………………….. 527
Safety Instructions………………………………………………………………………………………………………………………….. 531
Applicable Models……………………………………………………………………………………………………………………………. 531
General Description………………………………………………………………………………………………………………………….. 532
Specifications…………………………………………………………………………………………………………………………… 534
Center Joint (Swivel) SP002629……………………………………………………………………………………………………………………. 535
Safety Instructions………………………………………………………………………………………………………………………….. 539
Applicable Models……………………………………………………………………………………………………………………………. 539
General Description………………………………………………………………………………………………………………………….. 540
Parts List………………………………………………………………………………………………………………………………. 541
Troubleshooting, Testing and Adjustment………………………………………………………………………………………………………… 542
Inspection………………………………………………………………………………………………………………………………. 542
Testing…………………………………………………………………………………………………………………………………. 542
Disassembly…………………………………………………………………………………………………………………………………. 543
Reassembly………………………………………………………………………………………………………………………………….. 547
Cylinders SP002630………………………………………………………………………………………………………………………………. 549
Safety Instructions………………………………………………………………………………………………………………………….. 553
Applicable Models……………………………………………………………………………………………………………………………. 553
General Description………………………………………………………………………………………………………………………….. 554
Theory of Operation………………………………………………………………………………………………………………………. 554
Parts List………………………………………………………………………………………………………………………………. 556
Special Tools and Materials…………………………………………………………………………………………………………………… 562
Piston Nut………………………………………………………………………………………………………………………………. 562
Piston Jig………………………………………………………………………………………………………………………………. 564
Steel Bushing Jig………………………………………………………………………………………………………………………… 567
Dust Wiper Jig…………………………………………………………………………………………………………………………… 570
Slipper Seal Jig…………………………………………………………………………………………………………………………. 573
Slipper Seal Straightening Jig…………………………………………………………………………………………………………….. 576
Disassembly…………………………………………………………………………………………………………………………………. 579
Reassembly………………………………………………………………………………………………………………………………….. 584
Swing Device SP002632……………………………………………………………………………………………………………………………. 589
Safety Instructions………………………………………………………………………………………………………………………….. 593
Applicable Models……………………………………………………………………………………………………………………………. 593
Indication of Type…………………………………………………………………………………………………………………………… 594
Specifications………………………………………………………………………………………………………………………………. 595
Structure and Principle of Operation…………………………………………………………………………………………………………… 596
Structure……………………………………………………………………………………………………………………………….. 596
Principles of Operation…………………………………………………………………………………………………………………… 601
Valve Casing…………………………………………………………………………………………………………………………….. 602
Brake Part………………………………………………………………………………………………………………………………. 605
Operation Instructions……………………………………………………………………………………………………………………….. 606
Inspection………………………………………………………………………………………………………………………………. 606
Direction of Rotation…………………………………………………………………………………………………………………….. 606
External Load at the End of Shaft………………………………………………………………………………………………………….. 607
Hydraulic Oil and Temperature Range………………………………………………………………………………………………………… 607
Filter………………………………………………………………………………………………………………………………….. 608
Installation and Piping…………………………………………………………………………………………………………………… 608
Oil Filling and Air Breather………………………………………………………………………………………………………………. 609
Instructions before Starting to Operate…………………………………………………………………………………………………….. 609
Troubleshooting……………………………………………………………………………………………………………………………… 610
General Precautions………………………………………………………………………………………………………………………. 610
Examination of Hydraulic Motor…………………………………………………………………………………………………………….. 610
Troubleshooting………………………………………………………………………………………………………………………….. 611
Disassembly and Reassembly……………………………………………………………………………………………………………………. 614
Remove Swing Device………………………………………………………………………………………………………………………. 616
Disassemble the Reduction Gear…………………………………………………………………………………………………………….. 627
Reassemble the Reduction Gear……………………………………………………………………………………………………………… 631
Maintenance Instructions………………………………………………………………………………………………………………….. 636
Main Pump and PTO SP002633……………………………………………………………………………………………………………………….. 639
Safety Instructions………………………………………………………………………………………………………………………….. 643
Applicable Models……………………………………………………………………………………………………………………………. 643
Section…………………………………………………………………………………………………………………………………….. 645
General Repair Guidelines…………………………………………………………………………………………………………………….. 646
Seal Kits and Subassemblies…………………………………………………………………………………………………………………… 647
Disassembly…………………………………………………………………………………………………………………………………. 651
Sealing the Driveshaft……………………………………………………………………………………………………………………. 651
Gear Pump Sealing………………………………………………………………………………………………………………………… 653
Control Housing………………………………………………………………………………………………………………………….. 654
Control Module LR………………………………………………………………………………………………………………………… 657
Control Module H…………………………………………………………………………………………………………………………. 658
Controller………………………………………………………………………………………………………………………………. 659
Rotary Groups……………………………………………………………………………………………………………………………. 661
Intermediate Wheel……………………………………………………………………………………………………………………….. 664
Auxiliary Drive………………………………………………………………………………………………………………………….. 666
Inspection Hints…………………………………………………………………………………………………………………………….. 669
Assembly……………………………………………………………………………………………………………………………………. 674
Rotary Group…………………………………………………………………………………………………………………………….. 674
Pump……………………………………………………………………………………………………………………………………. 675
Assembly Guideline……………………………………………………………………………………………………………………. 677
Hydraulic Component – Measurement “D”………………………………………………………………………………………………………. 678
Control Housing………………………………………………………………………………………………………………………….. 681
Intermediate Wheel……………………………………………………………………………………………………………………….. 684
Gear Pump……………………………………………………………………………………………………………………………….. 685
Cover/Auxiliary Drive…………………………………………………………………………………………………………………….. 686
Assembly Guidelines for Tightening Torques……………………………………………………………………………………………………… 687
Bolts (to N 08.001)………………………………………………………………………………………………………………………. 687
Plugs with Internal Hexagon and Profile Seal Ring (to N 02.009)……………………………………………………………………………….. 688
Seal-Lock – Sealing Nuts (to N 02.100)……………………………………………………………………………………………………… 688
Main Control Valve SP002634………………………………………………………………………………………………………………………. 689
Safety Instructions………………………………………………………………………………………………………………………….. 693
Applicable Models……………………………………………………………………………………………………………………………. 693
General Description………………………………………………………………………………………………………………………….. 695
Theory of Operation………………………………………………………………………………………………………………………. 696
Service Spool Movement………………………………………………………………………………………………………………… 696
Swing Spool Movement………………………………………………………………………………………………………………….. 697
Bucket Spool Movement…………………………………………………………………………………………………………………. 697
Boom Spool Movement…………………………………………………………………………………………………………………… 698
Arm Spool Movement……………………………………………………………………………………………………………………. 701
Parallel Orifices for Arm……………………………………………………………………………………………………………… 704
Neutral Cut Spool Movement (First Service convergence)……………………………………………………………………………………. 705
Add-on Spool Movement…………………………………………………………………………………………………………………. 705
Relief Valve…………………………………………………………………………………………………………………………. 706
Antidrift Valve………………………………………………………………………………………………………………………….. 707
Disassembly…………………………………………………………………………………………………………………………………. 709
Precautions for Disassembly……………………………………………………………………………………………………………….. 709
Disassembling Procedures………………………………………………………………………………………………………………….. 709
Disassembly of Main Spool……………………………………………………………………………………………………………… 709
Disassembly of Sub-Spool………………………………………………………………………………………………………………. 711
Disassembly of Sub-Spool………………………………………………………………………………………………………………. 711
Disassembly of Boom, Arm Antidrift Valve………………………………………………………………………………………………… 711
Disassembly of Travel Right, Swing, Bucket, Boom1, 2, Arm1,Boom Swing, Blade, Second Service, Load check Valve………………………………….. 712
Disassembly of Check Valve in the Straight Travel Orifice (travel left section)……………………………………………………………… 712
Disassemble of Arm2 Load Check Valve……………………………………………………………………………………………………. 712
Disassembly of the External Convergence Check Valve of the First Service……………………………………………………………………. 713
Disassembly of the Common Check Valve…………………………………………………………………………………………………… 713
Disassembly of the Arm1 Semi Para Check Valve……………………………………………………………………………………………. 713
Disassembly of the Relief Valve………………………………………………………………………………………………………… 713
Disassembly of the Shutoff Valve……………………………………………………………………………………………………….. 713
Disassembly of Other Plugs…………………………………………………………………………………………………………….. 714
Disassembly of the Add-on Section………………………………………………………………………………………………………. 714
Washing…………………………………………………………………………………………………………………………………….. 715
Inspection………………………………………………………………………………………………………………………………….. 715
Assembling………………………………………………………………………………………………………………………………….. 716
Subassembly……………………………………………………………………………………………………………………………… 716
Main Spool…………………………………………………………………………………………………………………………… 716
Sub Spool……………………………………………………………………………………………………………………………. 717
Sub-Spool Part……………………………………………………………………………………………………………………….. 717
Boom, Arm Antidrift Valve……………………………………………………………………………………………………………… 717
Shutoff Valve………………………………………………………………………………………………………………………… 718
Assembling Control Valve………………………………………………………………………………………………………………….. 719
Assembling Add-on Section……………………………………………………………………………………………………………… 719
Assembling Right Travel, Swing, Bucket, Boom1, 2, Arm1, and Blade Load Check Part……………………………………………………………. 720
Assembling Arm2 Load Check Valve Part…………………………………………………………………………………………………… 720
Assembling Travel Orifice (left travel section) Check Valve……………………………………………………………………………….. 721
First Service, Assembling External Joint Flow Check Valve…………………………………………………………………………………. 721
Assembling Common Check Valve………………………………………………………………………………………………………….. 721
Assembling Arm1 Semi Para Check Valve…………………………………………………………………………………………………… 721
Assembling Boom, Arm Antidrift Valve……………………………………………………………………………………………………. 722
Assembling Relief Valve……………………………………………………………………………………………………………….. 722
Assembling Sub-Spool………………………………………………………………………………………………………………….. 722
Assembling Sub Spool………………………………………………………………………………………………………………….. 723
Assembling Main Spool…………………………………………………………………………………………………………………. 723
Assembling Other Plugs………………………………………………………………………………………………………………… 724
Relief Valve………………………………………………………………………………………………………………………………… 725
Main Relief Valve………………………………………………………………………………………………………………………… 725
Body Main Relief Valve Operation……………………………………………………………………………………………………….. 725
Disassembling / Reassembling Body Main Relief Valve………………………………………………………………………………………. 726
Add-on Main Relief Valve Operation……………………………………………………………………………………………………… 727
Disassembling / Reassembling Add-on Main Relief Valve…………………………………………………………………………………….. 728
Overload Relief Valve…………………………………………………………………………………………………………………….. 729
Relief Valve Operation………………………………………………………………………………………………………………… 729
Suction operation…………………………………………………………………………………………………………………….. 730
Disassembling / Reassembling Overload Relief Valve……………………………………………………………………………………….. 731
Negacon Relief Valve……………………………………………………………………………………………………………………… 732
Negacon Relief Valve Operation…………………………………………………………………………………………………………. 732
Disassembling / Reassembling Negacon Relief Valve………………………………………………………………………………………… 733
Adjusting Relief Valve……………………………………………………………………………………………………………………. 734
Main Relief Valve (common for body and add-on)…………………………………………………………………………………………… 734
Overload Relief Valve…………………………………………………………………………………………………………………. 734
Installation………………………………………………………………………………………………………………………………… 735
Operation…………………………………………………………………………………………………………………………………… 735
Control Valve Specification…………………………………………………………………………………………………………………… 736
Troubleshooting……………………………………………………………………………………………………………………………… 737
Control Valve: overall……………………………………………………………………………………………………………………. 737
Hydraulic System: Overall…………………………………………………………………………………………………………………. 738
Gear Pump SP002635………………………………………………………………………………………………………………………………. 739
Safety Instructions………………………………………………………………………………………………………………………….. 743
Applicable Models……………………………………………………………………………………………………………………………. 743
Single Gear Pump…………………………………………………………………………………………………………………………….. 745
Disassembly……………………………………………………………………………………………………………………………… 745
Reassembly………………………………………………………………………………………………………………………………. 747
Double Gear Pump…………………………………………………………………………………………………………………………….. 751
Disassembly……………………………………………………………………………………………………………………………… 751
Reassembly………………………………………………………………………………………………………………………………. 753
Travel Motor SP002636……………………………………………………………………………………………………………………………. 757
Safety Instructions………………………………………………………………………………………………………………………….. 761
Applicable Models……………………………………………………………………………………………………………………………. 761
General Repair Instructions…………………………………………………………………………………………………………………… 764
Seal Kits and Subassemblies…………………………………………………………………………………………………………………… 765
Replace Seal Nut…………………………………………………………………………………………………………………………. 767
Disassembly…………………………………………………………………………………………………………………………………. 767
Sealing the Driveshaft……………………………………………………………………………………………………………………. 767
Seal of the Control Parts…………………………………………………………………………………………………………………. 769
Seal of the Relief Valve / Counterbalance Valve……………………………………………………………………………………………… 771
Spare Parts List…………………………………………………………………………………………………………………………. 773
Counterbalance Valve………………………………………………………………………………………………………………….. 773
Brake Release Valve (Pos.50)…………………………………………………………………………………………………………… 774
Shuttle Valve (Pos.25)………………………………………………………………………………………………………………… 774
Disassembly of the Port Plate……………………………………………………………………………………………………………… 775
Removal of the Positioning Piston………………………………………………………………………………………………………….. 776
Remove Rotary Group………………………………………………………………………………………………………………………. 778
Exchanging of the Rotary Group…………………………………………………………………………………………………………….. 779
Inspection Notes…………………………………………………………………………………………………………………………. 780
Assembly……………………………………………………………………………………………………………………………………. 783
Rotary Group Assembly…………………………………………………………………………………………………………………….. 783
Rotary Group Adjustment (See Service Information)……………………………………………………………………………………………. 785
Assembly of the Port Plate………………………………………………………………………………………………………………… 787
Tightening Torques…………………………………………………………………………………………………………………………… 789
Shaft Bolts……………………………………………………………………………………………………………………………… 789
Locking Screws VSTI………………………………………………………………………………………………………………………. 789
Seal-Locknuts……………………………………………………………………………………………………………………………. 790
Cross-slotted Lens Head Screws DIN 7985…………………………………………………………………………………………………….. 790
Test Procedure………………………………………………………………………………………………………………………………. 791
Hydraulics Schematic……………………………………………………………………………………………………………………… 793
Counterbalance Valve SP002637…………………………………………………………………………………………………………………….. 795
Safety Instructions………………………………………………………………………………………………………………………….. 799
Applicable Models……………………………………………………………………………………………………………………………. 799
General Description………………………………………………………………………………………………………………………….. 800
While Operating to Run Forward…………………………………………………………………………………………………………….. 800
While Operating to Stop…………………………………………………………………………………………………………………… 800
While Operating to Back…………………………………………………………………………………………………………………… 801
Adjustment of Relief Valve………………………………………………………………………………………………………………… 802
Troubleshooting……………………………………………………………………………………………………………………………… 803
Counterbalance Valve…………………………………………………………………………………………………………………………. 804
Recommended Tools………………………………………………………………………………………………………………………… 804
Disassembly……………………………………………………………………………………………………………………………… 804
Order of Disassembly and Torque Values……………………………………………………………………………………………………… 805
Reassembly………………………………………………………………………………………………………………………………. 806
Service Brake Supply Valve SP002638……………………………………………………………………………………………………………….. 811
Safety Instructions………………………………………………………………………………………………………………………….. 815
Applicable Models……………………………………………………………………………………………………………………………. 815
Diagram of Brake Supply Valve Assembly Package………………………………………………………………………………………………. 816
Functions of Brake Supply Valve Assembly Package…………………………………………………………………………………………….. 817
Functions……………………………………………………………………………………………………………………………. 817
Functions of Each Valve……………………………………………………………………………………………………………….. 817
Detailed Functions and Application of Brake Supply Valve Assembly Package…………………………………………………………………… 817
Exploded View and Tools…………………………………………………………………………………………………………………… 819
Cautions for Disassembly and Reassembly…………………………………………………………………………………………………….. 820
Troubleshooting Guide…………………………………………………………………………………………………………………….. 821
How to Check Brake Pressure……………………………………………………………………………………………………………….. 822
Remote Control Valve (Work Lever / Joystick) SP002639……………………………………………………………………………………………….. 823
Safety Instructions………………………………………………………………………………………………………………………….. 827
Applicable Models……………………………………………………………………………………………………………………………. 827
General Description………………………………………………………………………………………………………………………….. 829
Theory of Operation………………………………………………………………………………………………………………………. 829
Parts List………………………………………………………………………………………………………………………………. 830
Specifications…………………………………………………………………………………………………………………………… 832
Torques…………………………………………………………………………………………………………………………………. 832
Tools and Materials………………………………………………………………………………………………………………………….. 832
Disassembly…………………………………………………………………………………………………………………………………. 833
Reassembly………………………………………………………………………………………………………………………………….. 836
Start-up Procedures………………………………………………………………………………………………………………………….. 844
Steering Valve SP002640………………………………………………………………………………………………………………………….. 845
Safety Instructions………………………………………………………………………………………………………………………….. 849
Applicable Models……………………………………………………………………………………………………………………………. 849
General Description………………………………………………………………………………………………………………………….. 850
Theory of Operation………………………………………………………………………………………………………………………. 851
OSPD……………………………………………………………………………………………………………………………………. 852
Tools………………………………………………………………………………………………………………………………………. 854
Disassembly…………………………………………………………………………………………………………………………………. 855
Assembly……………………………………………………………………………………………………………………………………. 860
Hydraulic Connections…………………………………………………………………………………………………………………….. 864
Max. Tightening Torque……………………………………………………………………………………………………………………. 864
Accelerator Pedal Valve (Hydraulic) SP002641……………………………………………………………………………………………………….. 865
Safety Instructions………………………………………………………………………………………………………………………….. 869
Applicable Models……………………………………………………………………………………………………………………………. 869
Structure…………………………………………………………………………………………………………………………………… 870
Parts List………………………………………………………………………………………………………………………………….. 870
Performance Curve……………………………………………………………………………………………………………………………. 871
Hydraulics Symbol……………………………………………………………………………………………………………………………. 871
Disassembly and Assembly Tools………………………………………………………………………………………………………………… 871
Disassembly…………………………………………………………………………………………………………………………………. 872
Assembly……………………………………………………………………………………………………………………………………. 873
Solenoid Valve Assembly SP002642………………………………………………………………………………………………………………….. 875
Safety Instructions………………………………………………………………………………………………………………………….. 879
Applicable Models……………………………………………………………………………………………………………………………. 879
4-Solenoid Valve…………………………………………………………………………………………………………………………….. 880
Diagram of 4-Solenoid Valve Assembly Package………………………………………………………………………………………………… 880
Functions of 4-Solenoid Valve Assembly Package………………………………………………………………………………………………. 881
Functions……………………………………………………………………………………………………………………………. 881
Application by Function of Each Solenoid Valve…………………………………………………………………………………………… 881
Detailed Functions and Application of Each Solenoid Valve…………………………………………………………………………………. 881
Exploded View and Tools…………………………………………………………………………………………………………………… 883
Disassembly, Re-assembly of Solenoid Valve Package, and Necessary Tools…………………………………………………………………….. 883
Instructions for Disassembly and Re- assembly……………………………………………………………………………………………….. 884
Solenoid Valve Diagram………………………………………………………………………………………………………………… 885
Troubleshooting Guide…………………………………………………………………………………………………………………….. 885
Parts……………………………………………………………………………………………………………………………….. 885
How to Check Pilot Pressure……………………………………………………………………………………………………………. 886
4-Solenoid Valve…………………………………………………………………………………………………………………………….. 887
Diagram of 4-Solenoid Valve Assembly Package………………………………………………………………………………………………… 887
Functions of 4-Solenoid Valve Assembly Package………………………………………………………………………………………………. 888
Functions……………………………………………………………………………………………………………………………. 888
Application by Function of Each Solenoid Valve…………………………………………………………………………………………… 888
Detailed Functions and Application of Each Solenoid Valve…………………………………………………………………………………. 889
Exploded View and Tools…………………………………………………………………………………………………………………… 890
Disassembly, Re-assembly of Solenoid Valve Package, and Necessary Tools…………………………………………………………………….. 890
Instructions for Disassembly and Re- assembly……………………………………………………………………………………………….. 891
Solenoid Valve Diagram………………………………………………………………………………………………………………… 892
Troubleshooting Guide…………………………………………………………………………………………………………………….. 892
Parts……………………………………………………………………………………………………………………………….. 892
How to Check Pilot Pressure……………………………………………………………………………………………………………. 893
3-Solenoid Valve…………………………………………………………………………………………………………………………….. 894
Diagram of 3-Solenoid Valve Assembly Package………………………………………………………………………………………………… 894
Functions of 3-Solenoid Valve Assembly Package………………………………………………………………………………………………. 895
Functions……………………………………………………………………………………………………………………………. 895
Application by Function of Each Solenoid Valve…………………………………………………………………………………………… 895
Detailed Functions and Application of Each Solenoid Valve…………………………………………………………………………………. 896
Exploded View and Tools…………………………………………………………………………………………………………………… 897
Disassembly, Re-assembly of Solenoid Valve Package, and Necessary Tools…………………………………………………………………….. 897
Instructions for Disassembly and Re- assembly……………………………………………………………………………………………….. 898
Solenoid Valve Diagram………………………………………………………………………………………………………………… 899
Troubleshooting Guide…………………………………………………………………………………………………………………….. 899
Parts……………………………………………………………………………………………………………………………….. 899
How to Check Pilot Pressure……………………………………………………………………………………………………………. 900
Breaker EPPR Valve (Option) SP002458………………………………………………………………………………………………………………. 901
Safety Instructions………………………………………………………………………………………………………………………….. 905
Applicable Models……………………………………………………………………………………………………………………………. 905
Structure…………………………………………………………………………………………………………………………………… 906
Parts List………………………………………………………………………………………………………………………………. 906
Functions and Operation………………………………………………………………………………………………………………………. 907
Cautions for Operation……………………………………………………………………………………………………………………….. 907
Maintenance Instructions……………………………………………………………………………………………………………………… 908
Maintenance……………………………………………………………………………………………………………………………… 908
Disassembly……………………………………………………………………………………………………………………………… 909
Assembly………………………………………………………………………………………………………………………………… 910
Intelligent Floating Boom (Option) SP002645………………………………………………………………………………………………………… 913
Safety Instructions………………………………………………………………………………………………………………………….. 917
Applicable Models……………………………………………………………………………………………………………………………. 917
General Description………………………………………………………………………………………………………………………….. 918
Parts List………………………………………………………………………………………………………………………………. 918
Assembly Diagram and Tools Required………………………………………………………………………………………………………… 919
Functions and Operations……………………………………………………………………………………………………………………… 920
Operation Instructions……………………………………………………………………………………………………………………. 920
Disassembly and Reassembly Instructions…………………………………………………………………………………………………….. 921
Quick Fit Valve SP002689…………………………………………………………………………………………………………………………. 923
Safety Instructions………………………………………………………………………………………………………………………….. 927
Applicable Models……………………………………………………………………………………………………………………………. 927
General Description………………………………………………………………………………………………………………………….. 928
Parts List………………………………………………………………………………………………………………………………. 928
Assembly Diagram and Tools Required………………………………………………………………………………………………………… 929
Functions and Operations……………………………………………………………………………………………………………………… 930
Operation Instructions……………………………………………………………………………………………………………………. 930
Disassembly and Reassembly Instructions…………………………………………………………………………………………………….. 931
Dozer Valve SP002529…………………………………………………………………………………………………………………………….. 933
Safety Instructions………………………………………………………………………………………………………………………….. 937
Applicable Models……………………………………………………………………………………………………………………………. 937
Structure Diagram……………………………………………………………………………………………………………………………. 938
Performance Specification…………………………………………………………………………………………………………………….. 939
Hydraulic Pressure Circuit Diagram…………………………………………………………………………………………………………….. 939
Parts List………………………………………………………………………………………………………………………………….. 940
Disassembly and Assembly Tools………………………………………………………………………………………………………………… 941
Disassembly…………………………………………………………………………………………………………………………………. 941
Assembly Method……………………………………………………………………………………………………………………………… 943
Service Brake Pedal Valve SP002647………………………………………………………………………………………………………………… 947
Safety Instructions………………………………………………………………………………………………………………………….. 951
Applicable Models……………………………………………………………………………………………………………………………. 951
Functions of Brake Pedal……………………………………………………………………………………………………………………… 953
Internal Structure and Operation Principles…………………………………………………………………………………………………….. 954
Internal Structure……………………………………………………………………………………………………………………….. 954
Operation Principles……………………………………………………………………………………………………………………… 956
Disassembly…………………………………………………………………………………………………………………………………. 957
Reassembly………………………………………………………………………………………………………………………………….. 957
Reassembly of the Lower Part………………………………………………………………………………………………………………. 957
Reassembly of the Upper Part………………………………………………………………………………………………………………. 959
Assembly of Pedal Plate…………………………………………………………………………………………………………………… 962
Hydraulic Schematic (DX140W-3/DX160W-3) SP002648……………………………………………………………………………………………………. 969
Safety Instructions………………………………………………………………………………………………………………………….. 973
Applicable Models……………………………………………………………………………………………………………………………. 973
DX140W-3/DX160W-3……………………………………………………………………………………………………………………………. 975
Electrical System…………………………………………………………………………………………………………………………………… 977
Electrical System SP002649……………………………………………………………………………………………………………………….. 979
Safety Instructions………………………………………………………………………………………………………………………….. 985
Applicable Models……………………………………………………………………………………………………………………………. 985
Introduction………………………………………………………………………………………………………………………………… 987
Electrical Supply System……………………………………………………………………………………………………………………… 988
Engine Starting Circuit………………………………………………………………………………………………………………………. 990
Start Operation………………………………………………………………………………………………………………………….. 990
After Start……………………………………………………………………………………………………………………………… 992
Engine Preheating System……………………………………………………………………………………………………………………… 994
Engine Stop…………………………………………………………………………………………………………………………………. 996
Charging System……………………………………………………………………………………………………………………………… 998
Monitoring System……………………………………………………………………………………………………………………………. 999
Instrument Panel………………………………………………………………………………………………………………………….1000
Functional Check………………………………………………………………………………………………………………………….1000
Monitoring System Schematic………………………………………………………………………………………………………………..1002
Operation……………………………………………………………………………………………………………………………………1004
Instruments………………………………………………………………………………………………………………………………1004
Warning and Indicator Lights…………………………………………………………………………………………………………………..1006
Indication of Warning Lights……………………………………………………………………………………………………………….1006
Indication of Multifunction Gauge…………………………………………………………………………………………………………..1008
Initial Operation…………………………………………………………………………………………………………………………….1010
Graphic Information Area Display……………………………………………………………………………………………………………….1012
Overview…………………………………………………………………………………………………………………………………1012
Main Menus for the Graphic Display Area……………………………………………………………………………………………………..1012
Menu Selector Buttons……………………………………………………………………………………………………………………..1012
User Menu……………………………………………………………………………………………………………………………………1013
User Menu – Access and Escape Methods……………………………………………………………………………………………………….1013
Special Menu…………………………………………………………………………………………………………………………………1041
Entering/Accessing and Exiting/Escaping Menus………………………………………………………………………………………………..1041
Special Menu Selections……………………………………………………………………………………………………………………1042
Electronic Hydraulic Control System (EPOS)………………………………………………………………………………………………………1068
Control System Schematic…………………………………………………………………………………………………………………..1068
Power Plus Mode Control……………………………………………………………………………………………………………………….1070
Operation………………………………………………………………………………………………………………………………..1072
Power Mode Control – Circuit Diagram……………………………………………………………………………………………………………1074
Engine Control System…………………………………………………………………………………………………………………………1076
Engine Control Dial…………………………………………………………………………………………………………………………..1077
Acceleration pedal……………………………………………………………………………………………………………………………1078
Engine Control Circuit Diagram…………………………………………………………………………………………………………………1080
Automatic Deceleration Control (Auto Idle Control)……………………………………………………………………………………………….1082
Engine Overheat Protection System………………………………………………………………………………………………………………1084
Power Boost Mode……………………………………………………………………………………………………………………………..1086
Operation………………………………………………………………………………………………………………………………..1086
Power Boost Control – Circuit Diagram……………………………………………………………………………………………………….1088
cruise control……………………………………………………………………………………………………………………………….1090
Operation………………………………………………………………………………………………………………………………..1090
Cruise Control Circuit…………………………………………………………………………………………………………………….1092
Self-diagnostic Function………………………………………………………………………………………………………………………1094
EPOS Controller…………………………………………………………………………………………………………………………..1094
Air Conditioner System………………………………………………………………………………………………………………………..1096
Outline………………………………………………………………………………………………………………………………….1096
Internal and External Filters………………………………………………………………………………………………………………1097
Air-Conditioning System Layout……………………………………………………………………………………………………………..1099
Air Conditioner/heater Circuit Diagram………………………………………………………………………………………………………1100
Air Conditioner/heater Unit………………………………………………………………………………………………………………..1101
Ambient Air Temperature Sensor……………………………………………………………………………………………………………..1106
Sun Sensor……………………………………………………………………………………………………………………………….1107
Control Panel…………………………………………………………………………………………………………………………….1107
Compressor……………………………………………………………………………………………………………………………….1115
Receiver Dryer……………………………………………………………………………………………………………………………1115
Wiper System…………………………………………………………………………………………………………………………………1116
Wiper Circuit…………………………………………………………………………………………………………………………….1116
Wiper Operation…………………………………………………………………………………………………………………………..1117
Lighting System………………………………………………………………………………………………………………………………1120
Lighting System Circuit Diagram…………………………………………………………………………………………………………….1120
Type…………………………………………………………………………………………………………………………………….1121
Operation………………………………………………………………………………………………………………………………..1121
Overload Warning Device……………………………………………………………………………………………………………………….1122
Overload Warning Device Circuit Diagram……………………………………………………………………………………………………..1122
Audio Controller……………………………………………………………………………………………………………………………..1123
Audio Controller Circuit Diagram……………………………………………………………………………………………………………1123
ram lock device………………………………………………………………………………………………………………………………1124
Ram Lock Control Circuit…………………………………………………………………………………………………………………..1124
Electrical Schematic SP002650……………………………………………………………………………………………………………………..1125
Safety Instructions…………………………………………………………………………………………………………………………..1129
Applicable Models…………………………………………………………………………………………………………………………….1129
DX140W-3/DX160W-3/DX170W-3/DX190W-3…………………………………………………………………………………………………………….1131
Attachments…………………………………………………………………………………………………………………………………………1133
Boom and Arm SP002651…………………………………………………………………………………………………………………………….1135
Safety Instructions…………………………………………………………………………………………………………………………..1139
Applicable Models…………………………………………………………………………………………………………………………….1139
Front Attachment Pin Specifications…………………………………………………………………………………………………………….1140
DX140W-3…………………………………………………………………………………………………………………………………1141
Front Attachment – Removal and Installation……………………………………………………………………………………………………..1142
Arm Removal Procedure……………………………………………………………………………………………………………………..1142
Boom Removal Procedure…………………………………………………………………………………………………………………….1144
Installation…………………………………………………………………………………………………………………………………1145
Arm Installation Procedure…………………………………………………………………………………………………………………1145
Boom Installation Procedure………………………………………………………………………………………………………………..1145
Start-up Procedures…………………………………………………………………………………………………………………………..1146
Bucket SP002506………………………………………………………………………………………………………………………………….1147
Safety Instructions…………………………………………………………………………………………………………………………..1151
Applicable Models…………………………………………………………………………………………………………………………….1151
Bucket Tooth Inspection and Replacement…………………………………………………………………………………………………………1152
Bucket O-ring Replacement……………………………………………………………………………………………………………………..1153
Attachments………………………………………………………………………………………………………………………………….1155
Bucket Replacement and Reversal…………………………………………………………………………………………………………….1155
Replacement………………………………………………………………………………………………………………………………1156
Reversal…………………………………………………………………………………………………………………………………1157
Quick Coupler Operation (Optional)………………………………………………………………………………………………………….1158
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