Doosan DX235LCR-5 Excavator Shop Manual 950106-01109E-1 – PDF DOWNLOAD
DESCRIPTION:
Doosan DX235LCR-5 Excavator Shop Manual 950106-01109E-1 – PDF DOWNLOAD
- Know how to operate your machine.
- 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 your DOOSAN distributor.
Doosan DX235LCR-5 Excavator Shop Manual 950106-01109E-1 – PDF DOWNLOAD
DX235LCR-5………………………………………………………………………………………….. 0
NOTICE………………………………………………………………………………………….. 7
Table of Contents………………………………………………………………………………… 9
Safety………………………………………………………………………………………….. 11
Track Excavator Maintenance Safety……………………………………………………………… 13
Safety Instructions……………………………………………………………………….. 17
Safety Messages…………………………………………………………………………… 17
General………………………………………………………………………………….. 18
Safe Operation is Operator’s Responsibility………………………………………………. 18
Know Your Machine……………………………………………………………………… 18
Proper Work Tools and Attachments……………………………………………………….. 19
Pressurized Fluids…………………………………………………………………….. 19
Flying or Falling Objects………………………………………………………………. 20
Personal Protective Equipment (PPE)……………………………………………………… 21
Correction of Machine Problems………………………………………………………….. 21
Crushing and Cutting…………………………………………………………………… 21
Hot Coolant and Oils – Burn Prevention…………………………………………………… 22
Fire and Explosion Prevention…………………………………………………………… 23
Fire Extinguisher and First-aid Kit (Emergency Medical Kit)………………………………… 26
Electrical System and Electrical Shock…………………………………………………… 27
Roll-over Protective Structure (ROPS)……………………………………………………. 27
Transportation……………………………………………………………………………. 31
Obey State and Local Over-the-Road Regulations……………………………………………. 31
Loading and Unloading………………………………………………………………….. 31
Transporting Machine…………………………………………………………………… 32
Operation………………………………………………………………………………… 33
Before Engine Starting…………………………………………………………………. 33
Work Site…………………………………………………………………………….. 34
Mounting/Dismounting…………………………………………………………………… 35
Cleaning……………………………………………………………………………… 36
Operator Station………………………………………………………………………. 36
Seat Belt…………………………………………………………………………….. 37
Visibility Information…………………………………………………………………. 38
Boost Starting or Charging Engine Batteries………………………………………………. 39
Starting Engine……………………………………………………………………….. 40
Swinging or Traveling………………………………………………………………….. 41
Lifting and Digging……………………………………………………………………. 43
Operation on Slopes……………………………………………………………………. 44
Towing……………………………………………………………………………….. 45
Attachment……………………………………………………………………………. 46
Equipment Lowering with Engine Stopped…………………………………………………… 46
Engine Stop…………………………………………………………………………… 47
Parking Machine……………………………………………………………………….. 47
Preservation/Storing Machine……………………………………………………………. 48
Maintenance………………………………………………………………………………. 50
Warning Tag…………………………………………………………………………… 52
Cleaning……………………………………………………………………………… 53
Proper Tools and Clothing………………………………………………………………. 53
Disassembling Precautions………………………………………………………………. 53
Use of Lighting……………………………………………………………………….. 53
Fire and Explosion Prevention…………………………………………………………… 54
Burn Prevention……………………………………………………………………….. 55
Rubber That Contains Fluorides………………………………………………………….. 56
Rubber and Plastics……………………………………………………………………. 57
Welding Repairs……………………………………………………………………….. 58
Warning for Counterweight and Front Attachment Removal…………………………………….. 59
Lock Inspection Covers…………………………………………………………………. 60
Working on Machine…………………………………………………………………….. 60
Accumulator…………………………………………………………………………… 61
Compressed Air………………………………………………………………………… 61
Track Tension Adjustments………………………………………………………………. 62
Supports and Blocking for Work Equipment…………………………………………………. 62
High-pressure Lines, Tubes and Hoses…………………………………………………….. 63
Battery………………………………………………………………………………. 64
Environment and Circumstances………………………………………………………………. 66
Work Site Areas Requiring Extra Caution………………………………………………….. 66
High-voltage Cables……………………………………………………………………. 68
Underground Operation………………………………………………………………….. 69
Working in Water………………………………………………………………………. 69
Working in Contaminated Environment……………………………………………………… 69
Operation in Extreme Conditions…………………………………………………………. 70
Exhaust Ventilation……………………………………………………………………. 74
Asbestos Information…………………………………………………………………… 75
Silica Dust Information………………………………………………………………… 75
Disposal of Hazardous Materials…………………………………………………………. 76
Sound………………………………………………………………………………… 76
Vibration Information………………………………………………………………….. 77
Specifications…………………………………………………………………………………… 79
Specifications……………………………………………………………………………….. 81
Safety Instructions……………………………………………………………………….. 85
General Description……………………………………………………………………….. 85
Component Locations……………………………………………………………………….. 86
Overall Dimensions………………………………………………………………………… 90
One – Piece Boom………………………………………………………………………. 90
Two – Piece Boom………………………………………………………………………. 91
Working Range…………………………………………………………………………….. 92
One – Piece Boom………………………………………………………………………. 92
Two – Piece Boom………………………………………………………………………. 94
General Specifications…………………………………………………………………….. 96
Approximate Weight of Workload Materials…………………………………………………….. 98
Performance Tests…………………………………………………………………………. 100
Purpose of Performance Tests……………………………………………………………. 100
Kinds of Tests………………………………………………………………………… 100
Performance Standards………………………………………………………………….. 100
Precautions for Evaluation of Test Data………………………………………………….. 100
Definition of “Performance Standard”…………………………………………………….. 100
Preparation for Performance Tests…………………………………………………………… 101
The Machine…………………………………………………………………………… 101
Test Area…………………………………………………………………………….. 101
Precautions…………………………………………………………………………… 101
Make Precise Measurement……………………………………………………………….. 101
Operational Performance Standard Table………………………………………………………. 102
Operational Performance Test……………………………………………………………….. 104
Hydraulic Cylinder Cycle Time…………………………………………………………… 104
Travel Speed………………………………………………………………………….. 106
Track Revolution Speed…………………………………………………………………. 107
Mistrack Check………………………………………………………………………… 109
Swing Speed…………………………………………………………………………… 111
Swing Function Drift Check……………………………………………………………… 112
General Maintenance………………………………………………………………………………. 113
General Maintenance Instructions……………………………………………………………….. 115
Safety Instructions……………………………………………………………………….. 119
Welding Precautions and Instructions………………………………………………………… 120
Hydraulic System – General Precautions………………………………………………………. 121
Maintenance Service and Repair Procedure…………………………………………………….. 123
General Precautions……………………………………………………………………. 123
Hydraulic System Cleanliness and Oil Leaks…………………………………………………… 124
Maintenance Precautions for Hydraulic System Service………………………………………. 124
Oil Leakage Precautions………………………………………………………………… 125
Cleaning and Inspection……………………………………………………………………. 126
General Instructions…………………………………………………………………… 126
Bearing Inspection…………………………………………………………………….. 127
Standard Torques……………………………………………………………………………… 135
Safety Instructions……………………………………………………………………….. 139
Torque Values for Standard Metric Fasteners………………………………………………….. 140
Torque Values for Standard U.S. Fasteners……………………………………………………. 141
Type 8 Phosphate Coated Hardware……………………………………………………………. 143
Torque Values for Hose Clamps………………………………………………………………. 144
ORFS Swivel Nut Recommended Torque………………………………………………………….. 144
Torque Values for Split Flanges…………………………………………………………….. 145
Torque Wrench Extension Tools………………………………………………………………. 146
Torque Multiplication………………………………………………………………….. 146
Other Uses for Torque Wrench Extension Tools……………………………………………… 147
Tightening Torque Specifications (Metric)………………………………………………… 148
Engine………………………………………………………………………………………….. 151
Engine………………………………………………………………………………………. 153
Safety Instructions……………………………………………………………………….. 157
Overview…………………………………………………………………………………. 158
General Information……………………………………………………………………….. 159
General Description……………………………………………………………………. 159
Engine Maintenance…………………………………………………………………….. 163
Inspection and Repair of the Engine……………………………………………………… 166
Engine Identification……………………………………………………………………… 168
Engine Data Plate……………………………………………………………………… 168
Engine Specification………………………………………………………………………. 170
Engine Performance Curves………………………………………………………………….. 171
Special Tools…………………………………………………………………………….. 172
Tightening Torques………………………………………………………………………… 176
Major Parts Tightening Torque…………………………………………………………… 176
Tightening Torque for General Bolts……………………………………………………… 178
Tightening Torque of Plug Screw…………………………………………………………. 179
Hollow Screw (4-Hole) Tightening Torque………………………………………………….. 179
Engine Disassembly………………………………………………………………………… 180
Engine Disassembly…………………………………………………………………….. 180
Engine Assembly…………………………………………………………………………… 196
Engine Assembly……………………………………………………………………….. 196
Cylinder…………………………………………………………………………………. 219
General Information……………………………………………………………………. 219
Cylinder Head…………………………………………………………………………. 219
Cylinder Block………………………………………………………………………… 224
Valve Mechanism……………………………………………………………………….. 226
Actuating System………………………………………………………………………….. 238
Camshaft……………………………………………………………………………… 238
Piston……………………………………………………………………………….. 240
Connecting Rod………………………………………………………………………… 244
Crankshaft……………………………………………………………………………. 246
Timing Gear…………………………………………………………………………… 251
Lubrication system………………………………………………………………………… 252
General Information……………………………………………………………………. 252
Oil Pan………………………………………………………………………………. 256
Oil Pump……………………………………………………………………………… 258
Oil Filter……………………………………………………………………………. 260
Exhaust System……………………………………………………………………………. 263
Turbocharger………………………………………………………………………….. 263
EGR (Exhaust Gas Recirculation) System…………………………………………………… 275
DNOx System…………………………………………………………………………… 282
Cooling System……………………………………………………………………………. 293
General information……………………………………………………………………. 293
Thermostat……………………………………………………………………………. 294
Cooling fan…………………………………………………………………………… 297
Fuel System………………………………………………………………………………. 299
General Information……………………………………………………………………. 299
Fuel High-pressure System Components…………………………………………………….. 300
Injector……………………………………………………………………………… 301
Common Rail…………………………………………………………………………… 305
Fuel Injection Pump……………………………………………………………………. 310
Electrical System…………………………………………………………………………. 313
Electrical Parts………………………………………………………………………. 313
Switches and Sensors…………………………………………………………………… 314
ECU (Electronic Control Unit)…………………………………………………………… 318
Starter………………………………………………………………………………. 320
Exhaust Gas Reduction………………………………………………………………….. 322
Circuit Diagram……………………………………………………………………….. 326
Upper Structure………………………………………………………………………………….. 333
Cabin……………………………………………………………………………………….. 335
Safety Instructions……………………………………………………………………….. 339
Cabin Identification………………………………………………………………………. 339
Roll-over Protective Structure (ROPS)……………………………………………………. 339
Removal………………………………………………………………………………….. 341
Installation……………………………………………………………………………… 348
Completing work…………………………………………………………………………… 348
Dimensions of Cabin Glass………………………………………………………………….. 349
Removal and Installation of Cabin Glass……………………………………………………… 353
Removal of Cabin Glass…………………………………………………………………. 353
Installation of Cabin Glass…………………………………………………………….. 355
Installation of Upper Door Glass………………………………………………………… 360
Installation of Upper Front Glass……………………………………………………….. 360
Counterweight………………………………………………………………………………… 361
Safety Instructions……………………………………………………………………….. 365
General………………………………………………………………………………….. 366
Warning for Counterweight and Front Attachment Removal…………………………………….. 366
Removal………………………………………………………………………………….. 368
Installation……………………………………………………………………………… 369
Hydraulic Oil Tank……………………………………………………………………………. 371
Safety Instructions……………………………………………………………………….. 375
General………………………………………………………………………………….. 375
Specification…………………………………………………………………………. 375
Parts List……………………………………………………………………………. 376
Air Breather………………………………………………………………………….. 378
Removal………………………………………………………………………………….. 379
Installation……………………………………………………………………………… 390
Completing Work…………………………………………………………………………… 391
Fuel Tank……………………………………………………………………………………. 393
Safety Instructions……………………………………………………………………….. 397
General………………………………………………………………………………….. 397
Specification…………………………………………………………………………. 397
Parts List……………………………………………………………………………. 398
Removal………………………………………………………………………………….. 400
Installation……………………………………………………………………………… 409
Completing Work…………………………………………………………………………… 410
Main Pump……………………………………………………………………………………. 411
Safety Instructions……………………………………………………………………….. 415
General………………………………………………………………………………….. 415
Specifications………………………………………………………………………… 415
Overview……………………………………………………………………………… 418
Hydraulic Circuit……………………………………………………………………… 419
Parts List……………………………………………………………………………. 420
Theory of Operation……………………………………………………………………. 424
Section View……………………………………………………………………………… 437
Removal………………………………………………………………………………….. 438
Installation……………………………………………………………………………… 447
Completing Work…………………………………………………………………………… 448
Assembly Guidelines for Tightening Torques…………………………………………………… 449
Bolts………………………………………………………………………………… 449
Plugs with Internal Hexagon and Profile Seal Ring…………………………………………. 450
Seal-lock – Sealing Nuts……………………………………………………………….. 450
Disassembly and Reassembly…………………………………………………………………. 451
General Repair Guidelines………………………………………………………………. 451
Seal Kits and Subassemblies…………………………………………………………….. 453
Sealing the Driveshaft…………………………………………………………………. 457
Gear Pump Sealing……………………………………………………………………… 459
Removing Control Housing……………………………………………………………….. 460
Control Module………………………………………………………………………… 463
Removing the Controller………………………………………………………………… 465
Valve Plate with Valves………………………………………………………………… 467
Remove Rotary Groups…………………………………………………………………… 468
Remove Intermediate Wheel………………………………………………………………. 471
Remove Auxiliary Drive…………………………………………………………………. 473
Inspection……………………………………………………………………………. 476
Assembling the Rotary Group…………………………………………………………….. 481
Pump Assembly…………………………………………………………………………. 483
Hydraulic Component – Measurement “D”……………………………………………………. 486
Installation of Control Housing…………………………………………………………. 489
Assembly of Intermediate Wheel………………………………………………………….. 492
Installation of Gear Pump………………………………………………………………. 493
Installation of Cover/Auxiliary Drive……………………………………………………. 494
Troubleshooting…………………………………………………………………………… 495
How to Proceed for Troubleshooting………………………………………………………. 495
Malfunction Table……………………………………………………………………… 496
Drive Coupling (Main Pump)…………………………………………………………………….. 499
Safety Instructions……………………………………………………………………….. 503
General………………………………………………………………………………….. 503
Description…………………………………………………………………………… 503
Specification…………………………………………………………………………. 503
Parts List……………………………………………………………………………. 504
Section View……………………………………………………………………………… 506
Tools………………………………………………………………………………… 507
Disassembly………………………………………………………………………………. 508
Reassembly……………………………………………………………………………….. 509
Main Control Valve……………………………………………………………………………. 511
Safety Instructions……………………………………………………………………….. 515
General………………………………………………………………………………….. 515
Specification…………………………………………………………………………. 515
Overview……………………………………………………………………………… 516
Parts List……………………………………………………………………………. 522
Theory of Operation……………………………………………………………………. 528
Cautions for Operation…………………………………………………………………. 559
Precaution……………………………………………………………………………….. 560
Tools and Torques……………………………………………………………………… 560
Removal………………………………………………………………………………….. 561
Installation……………………………………………………………………………… 577
Completing Work…………………………………………………………………………… 577
Disassembly………………………………………………………………………………. 578
Caution on Disassembly…………………………………………………………………. 578
Sequence of Disassembly………………………………………………………………… 579
Cleaning and Inspection……………………………………………………………………. 591
Cleaning……………………………………………………………………………… 591
Inspection……………………………………………………………………………. 591
Reassembly……………………………………………………………………………….. 592
Caution on Assembly……………………………………………………………………. 592
Sequence of Reassembly…………………………………………………………………. 593
Adjustment of Valves…………………………………………………………………… 602
Troubleshooting…………………………………………………………………………… 604
Swing Device…………………………………………………………………………………. 607
Safety Instructions……………………………………………………………………….. 611
General………………………………………………………………………………….. 611
Specification…………………………………………………………………………. 611
Overview……………………………………………………………………………… 612
Parts List……………………………………………………………………………. 614
Theory of Operation……………………………………………………………………. 619
Cautions for Operation…………………………………………………………………. 627
Removal………………………………………………………………………………….. 630
Installation……………………………………………………………………………… 635
Completing work…………………………………………………………………………… 635
Precaution……………………………………………………………………………….. 636
Tools for Disassembly and Assembly………………………………………………………. 636
Tightening Torque……………………………………………………………………… 636
Disassembly………………………………………………………………………………. 638
Swing Motor…………………………………………………………………………… 638
Swing Reduction Gear…………………………………………………………………… 643
Reassembly……………………………………………………………………………….. 647
Swing Motor…………………………………………………………………………… 647
Swing Reduction Gear…………………………………………………………………… 653
Troubleshooting…………………………………………………………………………… 662
General Instructions…………………………………………………………………… 662
Examination of Hydraulic Motor………………………………………………………….. 662
Troubleshooting……………………………………………………………………….. 663
Maintenance Instructions…………………………………………………………………… 666
Replacement Standard of Worn Parts………………………………………………………. 666
Standard of Sliding Surface Correction…………………………………………………… 666
Joystick Valve (Work Lever)……………………………………………………………………. 667
Safety Instructions……………………………………………………………………….. 671
General………………………………………………………………………………….. 671
Specifications………………………………………………………………………… 671
Overview……………………………………………………………………………… 672
Parts List……………………………………………………………………………. 674
Theory of Operation……………………………………………………………………. 676
Tools and Torques……………………………………………………………………… 677
Section View……………………………………………………………………………… 678
Removal………………………………………………………………………………….. 680
Installation……………………………………………………………………………… 685
Completing work…………………………………………………………………………… 686
Tools and Torques…………………………………………………………………………. 687
Disassembly………………………………………………………………………………. 687
Reassembly……………………………………………………………………………….. 691
Dozer Joystick Valve………………………………………………………………………….. 699
Safety Instructions……………………………………………………………………….. 703
General………………………………………………………………………………….. 703
Specifications………………………………………………………………………… 703
Overview……………………………………………………………………………… 704
Hydraulic Circuit……………………………………………………………………… 705
Parts List……………………………………………………………………………. 706
Theory of Operation……………………………………………………………………. 707
Tools……………………………………………………………………………………. 709
Removal………………………………………………………………………………….. 710
Installation……………………………………………………………………………… 714
Completing work…………………………………………………………………………… 715
Disassembly………………………………………………………………………………. 716
Reassembly……………………………………………………………………………….. 719
Travel Control Valve (with Damper)……………………………………………………………… 725
Safety Instructions……………………………………………………………………….. 729
General………………………………………………………………………………….. 730
Specification…………………………………………………………………………. 730
Overview……………………………………………………………………………… 731
Parts List……………………………………………………………………………. 732
Theory of Operation……………………………………………………………………. 734
Tools and Torques……………………………………………………………………… 735
Section View……………………………………………………………………………… 736
Removal………………………………………………………………………………….. 737
Installation……………………………………………………………………………… 741
Completing Work…………………………………………………………………………… 742
Disassembly………………………………………………………………………………. 743
Reassembly……………………………………………………………………………….. 746
Troubleshooting…………………………………………………………………………… 751
Solenoid Valve……………………………………………………………………………….. 753
Safety Instructions……………………………………………………………………….. 757
General………………………………………………………………………………….. 757
Specification…………………………………………………………………………. 757
Overview……………………………………………………………………………… 758
Parts List……………………………………………………………………………. 760
Theory of Operation……………………………………………………………………. 761
Disassembly and Reassembly…………………………………………………………………. 762
Troubleshooting…………………………………………………………………………… 763
EPPR Valve (One or Two Way)……………………………………………………………………. 765
Safety Instructions……………………………………………………………………….. 769
General………………………………………………………………………………….. 770
Specification…………………………………………………………………………. 770
Overview……………………………………………………………………………… 771
Hydraulic Circuit……………………………………………………………………… 772
Troubleshooting…………………………………………………………………………… 772
Accumulator………………………………………………………………………………….. 773
Safety Instructions……………………………………………………………………….. 777
General………………………………………………………………………………….. 777
Specifications………………………………………………………………………… 779
Gear Pump (Rotating)………………………………………………………………………….. 781
Safety Instructions……………………………………………………………………….. 785
General………………………………………………………………………………….. 785
Specification…………………………………………………………………………. 785
Overview……………………………………………………………………………… 786
Location……………………………………………………………………………… 786
Parts List……………………………………………………………………………. 787
Single Gear Pump………………………………………………………………………….. 788
Disassembly…………………………………………………………………………… 788
Reassembly……………………………………………………………………………. 790
One Spool Valve(Rotating)……………………………………………………………………… 795
Safety Instructions……………………………………………………………………….. 799
General………………………………………………………………………………….. 799
Specification…………………………………………………………………………. 799
Overview……………………………………………………………………………… 800
Port and Hydraulic Circuit………………………………………………………….. 800
Theory of Operation……………………………………………………………………. 801
In the Neutral Condition……………………………………………………………. 801
Spool Operation……………………………………………………………………. 801
Disassembly and Assembly…………………………………………………………………… 803
General Cautions………………………………………………………………………. 803
Replacement of Spool…………………………………………………………………… 804
Replacement of Main Relief Valve………………………………………………………… 806
Replacement of Overload Relief Valve…………………………………………………….. 807
Replacement of Sub-Block……………………………………………………………….. 809
Lower Structure and Chassis……………………………………………………………………….. 811
Swing Bearing………………………………………………………………………………… 813
Safety Instructions……………………………………………………………………….. 817
General………………………………………………………………………………….. 818
General Description……………………………………………………………………. 818
Parts List……………………………………………………………………………. 818
Maintenance Guidelines…………………………………………………………………….. 819
Disassembly………………………………………………………………………………. 820
Reassembly……………………………………………………………………………….. 822
Center Joint…………………………………………………………………………………. 823
Safety Instructions……………………………………………………………………….. 827
General………………………………………………………………………………….. 827
General Description……………………………………………………………………. 827
Overview……………………………………………………………………………… 828
Parts List……………………………………………………………………………. 829
Section View……………………………………………………………………………… 830
Removal (Without Dozer)……………………………………………………………………. 831
Installation……………………………………………………………………………… 836
Completing Work…………………………………………………………………………… 836
Disassembly………………………………………………………………………………. 837
Reassembly……………………………………………………………………………….. 840
Troubleshooting, Testing and Adjustment……………………………………………………… 842
Inspection……………………………………………………………………………. 842
Testing………………………………………………………………………………. 842
Center Joint (Dozer)………………………………………………………………………….. 843
Safety Instructions……………………………………………………………………….. 847
General………………………………………………………………………………….. 847
General Description……………………………………………………………………. 847
Overview……………………………………………………………………………… 848
Parts List……………………………………………………………………………. 850
Section View……………………………………………………………………………… 852
Removal (With Dozer)………………………………………………………………………. 853
Installation……………………………………………………………………………… 858
Completing Work…………………………………………………………………………… 858
Disassembly………………………………………………………………………………. 859
Reassembly……………………………………………………………………………….. 861
Troubleshooting, Testing and Adjustment……………………………………………………… 863
Inspection……………………………………………………………………………. 863
Testing………………………………………………………………………………. 863
Travel Device………………………………………………………………………………… 865
Safety Instructions……………………………………………………………………….. 869
General………………………………………………………………………………….. 869
Specification…………………………………………………………………………. 869
Overview……………………………………………………………………………… 870
Parts List……………………………………………………………………………. 872
Theory of Operation……………………………………………………………………. 878
Cautions for Operation…………………………………………………………………. 886
Precaution……………………………………………………………………………….. 890
Tools List for Disassembly and Reassembly………………………………………………… 890
Removal………………………………………………………………………………….. 893
Installation……………………………………………………………………………… 899
Completing Work…………………………………………………………………………… 899
Section View……………………………………………………………………………… 900
Disassembly………………………………………………………………………………. 902
General Cautions………………………………………………………………………. 902
Disassembly Procedure………………………………………………………………….. 902
Reassembly……………………………………………………………………………….. 913
General Precautions……………………………………………………………………. 913
Reassembly Procedure…………………………………………………………………… 913
Performance Test………………………………………………………………………. 928
Summary of Seal Information…………………………………………………………….. 929
Troubleshooting……………………………………………………………………….. 930
Track Assembly……………………………………………………………………………….. 933
Safety Instructions……………………………………………………………………….. 937
General………………………………………………………………………………….. 937
Track Tension…………………………………………………………………………….. 938
Track Shoes and Links……………………………………………………………………… 940
Parts List……………………………………………………………………………. 940
Track Removal…………………………………………………………………………. 941
Track Installation…………………………………………………………………….. 943
Wear Limits and Tolerances……………………………………………………………… 944
Sprocket…………………………………………………………………………………. 946
Wear Limits and Tolerances……………………………………………………………… 946
Front Idler………………………………………………………………………………. 947
Overview……………………………………………………………………………… 947
Parts List……………………………………………………………………………. 948
Front Idler Disassembly………………………………………………………………… 949
Front Idler Reassembly…………………………………………………………………. 951
Wear Limits and Tolerances……………………………………………………………… 952
Upper Roller……………………………………………………………………………… 953
Overview……………………………………………………………………………… 953
Parts List……………………………………………………………………………. 954
Upper Roller Removal…………………………………………………………………… 955
Upper Roller Disassembly……………………………………………………………….. 955
Upper Roller Reassembly………………………………………………………………… 957
Wear Limits and Tolerances……………………………………………………………… 958
Lower Roller……………………………………………………………………………… 959
Overview……………………………………………………………………………… 959
Parts List……………………………………………………………………………. 960
Lower Roller Removal…………………………………………………………………… 961
Lower Roller Installation………………………………………………………………. 961
Lower Roller Disassembly……………………………………………………………….. 962
Lower Roller Reassembly………………………………………………………………… 963
Wear Limits and Tolerances……………………………………………………………… 964
Track Adjuster……………………………………………………………………………. 966
Parts List……………………………………………………………………………. 966
Disassembly…………………………………………………………………………… 967
Assembly……………………………………………………………………………… 968
Dozer System…………………………………………………………………………………. 971
Safety Instructions……………………………………………………………………….. 975
General Description……………………………………………………………………….. 976
Hydraulic Circuit…………………………………………………………………………. 977
Front…………………………………………………………………………………………… 979
Boom and Arm…………………………………………………………………………………. 981
Safety Instructions……………………………………………………………………….. 985
Specifications……………………………………………………………………………. 986
One – Piece Boom………………………………………………………………………. 986
Two – Piece Boom………………………………………………………………………. 987
Removal………………………………………………………………………………….. 988
Arm Removal…………………………………………………………………………… 988
Boom Removal………………………………………………………………………….. 990
Installation……………………………………………………………………………… 991
Arm Installation………………………………………………………………………. 991
Boom Installation……………………………………………………………………… 991
Completing Work…………………………………………………………………………… 991
Bucket………………………………………………………………………………………. 993
Safety Instructions……………………………………………………………………….. 997
Bucket Tooth Inspection and Replacement……………………………………………………… 998
Bucket O-ring Replacement………………………………………………………………….. 999
Bucket Detaching and Reversal……………………………………………………………….1000
Detaching……………………………………………………………………………..1000
Reversal………………………………………………………………………………1000
Cylinders…………………………………………………………………………………….1001
Safety Instructions………………………………………………………………………..1005
General…………………………………………………………………………………..1005
General Description…………………………………………………………………….1005
Specification………………………………………………………………………….1005
Parts List…………………………………………………………………………….1006
Theory of Operation…………………………………………………………………….1014
Seal of Cylinder……………………………………………………………………….1015
Special Tools and Materials…………………………………………………………………1017
Piston Nut…………………………………………………………………………….1017
Piston Jig…………………………………………………………………………….1018
Steel Bushing Jig………………………………………………………………………1019
Dust Wiper Jig…………………………………………………………………………1020
Slipper Seal Jig……………………………………………………………………….1021
Slipper Seal Straightening Jig…………………………………………………………..1022
Rod Bushing (DD-bushing) Pushing-in Jig…………………………………………………..1023
Disassembly……………………………………………………………………………….1024
Reassembly………………………………………………………………………………..1029
Troubleshooting……………………………………………………………………………1033
Hydraulic System………………………………………………………………………………….1035
Hydraulic System………………………………………………………………………………1037
Safety Instructions………………………………………………………………………..1041
Hydraulic System…………………………………………………………………………..1041
General Description…………………………………………………………………….1041
Hydraulic Schematic………………………………………………………………………..1042
General Description…………………………………………………………………….1042
Hydraulic Component and Oil Flow…………………………………………………………….1044
Hydraulic Components……………………………………………………………………1044
Main Oil Circuit……………………………………………………………………….1046
Pilot Oil Circuit………………………………………………………………………1047
Return Oil Circuit……………………………………………………………………..1048
Safety Cutoff Valve Operation……………………………………………………………….1049
Power Up Valve Operation……………………………………………………………………1050
Travel High-speed Valve Operation……………………………………………………………1051
Swing Brake Release Operation……………………………………………………………….1054
Travel Forward and Backward Operation………………………………………………………..1056
Boom Up Operation………………………………………………………………………….1057
Boom Up Stability Operation…………………………………………………………………1058
Boom Down Operation………………………………………………………………………..1060
Arm Dump Operation…………………………………………………………………………1062
Arm Crowd Operation………………………………………………………………………..1064
Bucket Dump Operation………………………………………………………………………1066
Bucket Crowd Operation……………………………………………………………………..1068
Combined Bucket Crowd and Boom Up Operation…………………………………………………..1070
Combined Travel and Boom, Arm, Bucket or Swing Operation……………………………………….1072
Hydraulic System Testing and Adjustment………………………………………………………….1075
Safety Instructions………………………………………………………………………..1079
Procedural Troubleshooting Baseline Recommendations……………………………………………1080
Initial Checks and Tests to Establish Operating Condition of the Excavator……………………1080
Pilot Pressure…………………………………………………………………………….1082
Adjustment and Testing………………………………………………………………….1082
Power Mode Valve…………………………………………………………………………..1083
Current Signal and Hydraulic Pressure Adjustments………………………………………….1083
Pressure Up Valve………………………………………………………………………….1084
Checks and Adjustments………………………………………………………………….1084
Pump Input Power Control……………………………………………………………………1086
Pump Regulator Adjustment……………………………………………………………….1086
Flow Meter and Flow Meter Kit Installation and Testing…………………………………………1089
Swing System Troubleshooting………………………………………………………………..1091
Precautions/Initial Checks………………………………………………………………1091
Swing Relief Valve Checking and Adjustment………………………………………………..1092
Hydraulic System Troubleshooting………………………………………………………………..1095
Safety Instructions………………………………………………………………………..1099
Hydraulic System…………………………………………………………………………..1099
Unusual Noise Comes Out from Pump Connection………………………………………………1099
Engine Starts but Machine Does Not Operate………………………………………………..1100
Hydraulic Oil is Cloudy…………………………………………………………………1101
Hydraulic Oil Overheated………………………………………………………………..1101
Hydraulic Pump Cavitation……………………………………………………………….1102
Hydraulic Oil is Contaminated……………………………………………………………1102
Boom, Arm, Bucket Speed is Slow………………………………………………………….1103
Boom, Arm or Bucket Power is Weak………………………………………………………..1104
Cylinder Moves When Remote Control Valve is in the Neutral Position………………………….1104
TR (L), TR (R) Swing Does Not Operate When Remote Control Valve Operated……………………..1105
Swing Speed is Slow…………………………………………………………………….1106
Machine Swings but Does Not Stop…………………………………………………………1107
One Side Speed is Falls and the Machine Curves…………………………………………….1108
Machine Does Not Stop on a Slope…………………………………………………………1109
Travel Motor is Powerless (Travel Only)…………………………………………………..1109
Machine Makes a Curved Travel, When Travel and Actuator Operation are Executed a the Same Time….1110
Does Not Travel is 2nd Speed or Auto Speed………………………………………………..1110
Troubleshooting – Swing Gearbox……………………………………………………………..1111
Troubleshooting – Hydraulic Problems…………………………………………………………1112
Troubleshooting – Control Valve……………………………………………………………..1114
Troubleshooting – Travel Control Valve……………………………………………………….1115
Troubleshooting – Joystick Control Valve……………………………………………………..1116
Electrical System…………………………………………………………………………………1117
Electrical System……………………………………………………………………………..1119
Safety Instructions………………………………………………………………………..1125
Introduction………………………………………………………………………………1125
Electrical Supply System……………………………………………………………………1126
Engine Starting Circuit…………………………………………………………………….1128
Start Operation………………………………………………………………………..1128
After Start……………………………………………………………………………1130
Engine Preheating System……………………………………………………………………1132
Engine Stop……………………………………………………………………………….1134
Charging System……………………………………………………………………………1136
Monitoring System………………………………………………………………………….1137
Instrument Panel……………………………………………………………………….1138
Functional Check……………………………………………………………………….1138
Monitoring System Schematic……………………………………………………………..1140
Operation…………………………………………………………………………………1142
Instruments……………………………………………………………………………1142
Warning and Indicator Lights………………………………………………………………..1144
Indication of Warning Lights…………………………………………………………….1144
Indication of Multifunction Gauge………………………………………………………..1147
Initial Operation………………………………………………………………………….1149
Graphic Information Area Display…………………………………………………………….1150
Overview………………………………………………………………………………1150
Main Menus for the Graphic Display Area…………………………………………………..1150
Menu Selector Buttons…………………………………………………………………..1150
User Menu…………………………………………………………………………………1151
User Menu – Access and Escape Methods…………………………………………………….1151
Special Menu………………………………………………………………………………1187
Entering/Accessing and Exiting/Escaping Menus……………………………………………..1187
Special Menu Selections…………………………………………………………………1188
Failure Code………………………………………………………………………………1204
Failure Code at Machine…………………………………………………………………1204
Failure Code at Engine Side……………………………………………………………..1207
FMIs (Failure Mode Identifier)…………………………………………………………..1239
Electronic Hydraulic Control System (EPOS)……………………………………………………1240
Control System Schematic………………………………………………………………..1240
Power Plus Mode Control…………………………………………………………………….1242
Operation……………………………………………………………………………..1244
Power Mode Control…………………………………………………………………………1246
Smart Power Control (SPC)…………………………………………………………………..1248
Operation……………………………………………………………………………..1248
Engine Control System………………………………………………………………………1251
Engine Control Dial………………………………………………………………………..1252
Engine Control…………………………………………………………………………….1254
Automatic Deceleration Control (Auto Idle Control)…………………………………………….1256
Engine Overheat Protection System……………………………………………………………1258
Power Boost Mode…………………………………………………………………………..1261
Operation……………………………………………………………………………..1261
Power Boost Control…………………………………………………………………….1262
Automatic Travel Speed Control………………………………………………………………1264
Automatic Travel Speed Control…………………………………………………………..1266
Water in Fuel Warning System………………………………………………………………..1267
Operation……………………………………………………………………………..1267
Self-diagnostic Function……………………………………………………………………1268
EPOS Controller………………………………………………………………………..1268
Air Conditioner System……………………………………………………………………..1270
Outline……………………………………………………………………………….1270
Internal and External Filters……………………………………………………………1271
Air-Conditioning System Layout…………………………………………………………..1273
Air Conditioner/Heater Circuit Diagram……………………………………………………1274
Air Conditioner/Heater Unit……………………………………………………………..1275
Refrigerant Circulation…………………………………………………………………….1276
Ambient Air Temperature Sensor…………………………………………………………..1281
Sun Sensor…………………………………………………………………………….1282
Control Panel………………………………………………………………………….1282
Receiver Dryer…………………………………………………………………………1289
Compressor…………………………………………………………………………….1289
Troubleshooting……………………………………………………………………………1290
Refrigerant System Repairs………………………………………………………………….1292
Refrigerant Safe Handling Procedures……………………………………………………..1292
Repair and Replacement Procedure…………………………………………………………1293
Refrigerant Recovery……………………………………………………………………1295
Vacuuming Refrigerant System…………………………………………………………….1295
Leakage Check………………………………………………………………………….1297
Refrigerant Charging……………………………………………………………………1297
Inspecting System For Leakage……………………………………………………………1299
Wiper System………………………………………………………………………………1300
Wiper Circuit………………………………………………………………………….1300
Wiper Operation………………………………………………………………………..1301
Lighting System……………………………………………………………………………1304
Lighting System Circuit Diagram………………………………………………………….1304
Kind of Light………………………………………………………………………….1305
Operation……………………………………………………………………………..1305
Overload Warning Device…………………………………………………………………….1306
Overload Warning Device Circuit Diagram…………………………………………………..1306
Audio Controller…………………………………………………………………………..1307
Audio Controller Circuit Diagram…………………………………………………………1307
Options………………………………………………………………………………………….1309
One Way………………………………………………………………………………………1311
Safety Instructions………………………………………………………………………..1315
General…………………………………………………………………………………..1315
General Description…………………………………………………………………….1315
Theory of Operation…………………………………………………………………….1315
Hydraulic Circuit………………………………………………………………………1316
Caution for Installation………………………………………………………………..1317
Installation Procedure……………………………………………………………………..1318
Main Piping – One Way…………………………………………………………………..1318
Pilot Piping – One Way………………………………………………………………….1320
Boom Piping – One and Two-way……………………………………………………………1322
Arm Piping – One and Two-way…………………………………………………………….1324
After Installation Precautions…………………………………………………………..1325
Air Bleeding…………………………………………………………………………..1325
Completing Work……………………………………………………………………………1326
Two-way………………………………………………………………………………………1327
Safety Instructions………………………………………………………………………..1331
General…………………………………………………………………………………..1331
General Description…………………………………………………………………….1331
Theory of Operation…………………………………………………………………….1331
Structure……………………………………………………………………………..1332
Hydraulic Circuit………………………………………………………………………1333
Caution for Installation………………………………………………………………..1335
Installation Procedure……………………………………………………………………..1336
Main Piping – Two-way…………………………………………………………………..1336
Pilot Piping – Two-way………………………………………………………………….1338
Pilot Piping – Two-way (Pedal)…………………………………………………………..1340
Boom Piping – One and Two-way……………………………………………………………1342
Arm Piping – One and Two-way…………………………………………………………….1344
After Installation Precautions…………………………………………………………..1345
Air Bleeding…………………………………………………………………………..1345
Completing Work……………………………………………………………………………1346
Rotating……………………………………………………………………………………..1347
Safety Instructions………………………………………………………………………..1351
General…………………………………………………………………………………..1351
General Description…………………………………………………………………….1351
Theory of Operation…………………………………………………………………….1351
Structure……………………………………………………………………………..1352
Hydraulic Circuit………………………………………………………………………1353
Caution for Installation………………………………………………………………..1354
Installation Procedure……………………………………………………………………..1356
Main Piping – Rotating………………………………………………………………….1356
Pilot Piping – Rotating…………………………………………………………………1358
Boom Piping – Rotating………………………………………………………………….1360
Arm Piping – Rotating…………………………………………………………………..1362
After Installation Precautions…………………………………………………………..1363
Air Bleeding…………………………………………………………………………..1363
Completing Work……………………………………………………………………………1363
Quick Coupler…………………………………………………………………………………1365
Safety Instructions………………………………………………………………………..1369
General…………………………………………………………………………………..1369
General Description…………………………………………………………………….1369
Theory of Operation…………………………………………………………………….1369
Hydraulic Circuit………………………………………………………………………1370
Caution for Installation………………………………………………………………..1371
Quick Coupler Operation…………………………………………………………………….1372
Securing Work Tool……………………………………………………………………..1372
Attaching Quick Coupler to Excavator……………………………………………………..1372
Releasing the Work Tool…………………………………………………………………1374
Installation Procedure……………………………………………………………………..1376
Main Piping – Quick Coupler……………………………………………………………..1376
Electric Parts – Quick Coupler…………………………………………………………..1377
Boom Piping – Quick Coupler……………………………………………………………..1378
Arm Piping – Quick Coupler………………………………………………………………1380
After Installation Precautions…………………………………………………………..1381
Air Bleeding…………………………………………………………………………..1381
Completing Work……………………………………………………………………………1381
Schematic………………………………………………………………………………………..1383
Hydraulic Schematic / Electrical Schematic……………………………………………………….1385
Hydraulic Schematic………………………………………………………………………..1387
Electrical Schematic……………………………………………………………………….1389
Blank Page…………………………………………………………………………………………..1388
Blank Page…………………………………………………………………………………………..1390
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Jordan Carl –
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