Doosan DX340LC-3 DX350LC-3 Excavator Shop Manual 950106-00225E (1) – PDF DOWNLOAD
DESCRIPTION:
Doosan DX340LC-3 DX350LC-3 Excavator Shop Manual 950106-00225E (1) – PDF DOWNLOAD
Serial Number 50001 and Up (Europe Only)
TABLE OF CONTENTS:
Doosan DX340LC-3 DX350LC-3 Excavator Shop Manual 950106-00225E (1) – PDF DOWNLOAD
DX340LC-3/DX350LC-3……………………………………………………………………………………………………… 0
Table of Contents……………………………………………………………………………………………………. 7
Safety……………………………………………………………………………………………………………… 9
Track Excavator Maintenance Safety SP002322…………………………………………………………………………. 11
Safety Instructions…………………………………………………………………………………………… 15
Applicable Models…………………………………………………………………………………………….. 15
Safety Messages………………………………………………………………………………………………. 16
Signal Words……………………………………………………………………………………………… 16
Safety Decals………………………………………………………………………………………………… 17
General……………………………………………………………………………………………………… 17
Safe Operation is Operator’s Responsibility………………………………………………………………….. 17
Know Your Machine…………………………………………………………………………………………. 17
Proper Work Tools and Attachments…………………………………………………………………………… 18
Pressurized Fluids………………………………………………………………………………………… 18
Flying or Falling Objects………………………………………………………………………………….. 19
Personal Protective Equipment (PPE)…………………………………………………………………………. 20
Correction of Machine Problems……………………………………………………………………………… 20
Crushing and Cutting………………………………………………………………………………………. 20
Hot Coolant and Oils – Burn Prevention………………………………………………………………………. 21
Fire and Explosion Prevention………………………………………………………………………………. 22
Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)……………………………………………………. 25
Electrical System and Electrical Shock………………………………………………………………………. 25
Rollover Protective Structure (ROPS)………………………………………………………………………… 26
Transportation……………………………………………………………………………………………….. 30
Obey State and Local Over-the-Road Regulations……………………………………………………………….. 30
Loading and Unloading……………………………………………………………………………………… 30
Transporting Machine………………………………………………………………………………………. 31
Operation……………………………………………………………………………………………………. 32
Before Engine Starting…………………………………………………………………………………….. 32
Work Site………………………………………………………………………………………………… 33
Mounting/Dismounting………………………………………………………………………………………. 34
Cleaning…………………………………………………………………………………………………. 35
Operator Station………………………………………………………………………………………….. 35
Seat Belt………………………………………………………………………………………………… 36
Visibility Information…………………………………………………………………………………….. 37
Boost Starting or Charging Engine Batteries………………………………………………………………….. 38
Starting Engine…………………………………………………………………………………………… 39
Swinging or Traveling……………………………………………………………………………………… 40
Lifting and Digging……………………………………………………………………………………….. 42
Operation on Slopes……………………………………………………………………………………….. 43
Towing…………………………………………………………………………………………………… 44
Attachment……………………………………………………………………………………………….. 45
Equipment Lowering with Engine Stopped………………………………………………………………………. 45
Engine Stop………………………………………………………………………………………………. 45
Parking Machine…………………………………………………………………………………………… 46
Preservation/Storing Machine……………………………………………………………………………….. 47
Maintenance………………………………………………………………………………………………….. 49
Warning Tag………………………………………………………………………………………………. 52
Cleaning…………………………………………………………………………………………………. 53
Proper Tools and Clothing………………………………………………………………………………….. 53
Disassembling Precautions………………………………………………………………………………….. 53
Use of Lighting…………………………………………………………………………………………… 54
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………………………………………………………………………………………. 74
Silica Dust Information……………………………………………………………………………………. 75
Disposal of DHazardous Materials……………………………………………………………………………. 75
Sound……………………………………………………………………………………………………. 76
Vibration………………………………………………………………………………………………… 76
Specifications………………………………………………………………………………………………………. 77
Specification for DX340LC-3/ DX350LC-3……………………………………………………………………………… 79
Safety Instructions…………………………………………………………………………………………… 83
Applicable Models…………………………………………………………………………………………….. 83
General Description…………………………………………………………………………………………… 85
Component Locations…………………………………………………………………………………………… 86
General Dimensions……………………………………………………………………………………………. 88
One – Piece Boom………………………………………………………………………………………….. 88
Two – Piece Boom………………………………………………………………………………………….. 89
Working Range………………………………………………………………………………………………… 90
One – Piece Boom………………………………………………………………………………………….. 90
Two – Piece Boom………………………………………………………………………………………….. 92
General Specifications………………………………………………………………………………………… 94
Engine Performance Curves (Per KS-R1004 Standard)………………………………………………………………… 96
Approximate Weight of Workload Materials………………………………………………………………………… 98
Performance Tests…………………………………………………………………………………………….. 100
Excavator Performance Measurements……………………………………………………………………………… 101
Test Conditions…………………………………………………………………………………………… 101
Travel Speed and Travel Motor Balance (Steering Deviation) Tests……………………………………………….. 101
Speed Test……………………………………………………………………………………………. 101
Travel Deviation………………………………………………………………………………………. 103
Swing Speed and Deceleration Force Test……………………………………………………………………… 103
Swing Speed Test………………………………………………………………………………………. 103
Swing Deceleration Force Test…………………………………………………………………………… 104
Cylinder Performance Tests…………………………………………………………………………………. 105
Boom Cylinders Test……………………………………………………………………………………. 105
Arm Cylinder Test……………………………………………………………………………………… 105
Bucket Cylinder Test…………………………………………………………………………………… 105
Hydraulic Cylinder Natural Drop Test…………………………………………………………………….. 105
Travel Motor Jack-up Test………………………………………………………………………………. 105
General Maintenance………………………………………………………………………………………………….. 107
General Maintenance Instructions SP002454…………………………………………………………………………… 109
Safety Instructions…………………………………………………………………………………………… 113
Applicable Models…………………………………………………………………………………………….. 113
Welding Precautions and Instructions……………………………………………………………………………. 114
Hydraulic System – General Precautions………………………………………………………………………….. 115
Maintenance Service and Repair Procedure………………………………………………………………………… 117
General Precautions……………………………………………………………………………………….. 117
Hydraulic System Cleanliness and Oil Leaks………………………………………………………………………. 118
Maintenance Precautions for Hydraulic System Service………………………………………………………….. 118
Oil Leakage Precautions……………………………………………………………………………………. 119
Cleaning and Inspection……………………………………………………………………………………….. 120
General Instructions………………………………………………………………………………………. 120
Bearing Inspection………………………………………………………………………………………… 121
Standard Torques SP002404…………………………………………………………………………………………. 129
Safety Instructions…………………………………………………………………………………………… 133
Applicable Models…………………………………………………………………………………………….. 133
Torque Values for Standard Metric Fasteners……………………………………………………………………… 134
Torque Values for Standard U.S. Fasteners……………………………………………………………………….. 135
Type 8 Phosphate Coated Hardware……………………………………………………………………………….. 137
Torque Values for Hose Clamps………………………………………………………………………………….. 138
ORFS Swivel Nut Recommended Torque……………………………………………………………………………… 138
Torque Values for Split Flanges………………………………………………………………………………… 139
Torque Wrench Extension Tools………………………………………………………………………………….. 140
Torque Multiplication……………………………………………………………………………………… 140
Other Uses for Torque Wrench Extension Tools…………………………………………………………………. 141
Tightening Torque Specifications (Metric)……………………………………………………………………. 142
Upper Structure……………………………………………………………………………………………………… 145
Cabin SP002324…………………………………………………………………………………………………… 147
Safety Instructions…………………………………………………………………………………………… 151
Applicable Models…………………………………………………………………………………………….. 151
Cabin Identification………………………………………………………………………………………….. 152
Rollover Protective Structure (ROPS)………………………………………………………………………… 152
Removal……………………………………………………………………………………………………… 154
Installation…………………………………………………………………………………………………. 158
Counterweight SP002409……………………………………………………………………………………………. 161
Safety Instructions…………………………………………………………………………………………… 165
Applicable Models…………………………………………………………………………………………….. 165
General……………………………………………………………………………………………………… 166
Warning for Counterweight and Front Attachment Removal………………………………………………………… 166
Removal……………………………………………………………………………………………………… 168
Installation…………………………………………………………………………………………………. 169
Fuel Tank SP002410……………………………………………………………………………………………….. 171
Safety Instructions…………………………………………………………………………………………… 175
Applicable Models…………………………………………………………………………………………….. 175
General Description…………………………………………………………………………………………… 176
Parts List……………………………………………………………………………………………….. 176
Specifications……………………………………………………………………………………………. 177
Removal……………………………………………………………………………………………………… 178
Installation…………………………………………………………………………………………………. 182
Start-up Procedures…………………………………………………………………………………………… 185
Fuel Transfer Pump (Option) SP002394……………………………………………………………………………….. 187
Safety Instructions…………………………………………………………………………………………… 191
Applicable Models…………………………………………………………………………………………….. 191
General Description…………………………………………………………………………………………… 192
Theory of Operation……………………………………………………………………………………….. 192
Troubleshooting………………………………………………………………………………………………. 194
Replacement of Rotor and Vane………………………………………………………………………………….. 194
Replacement of Rear Cover……………………………………………………………………………………… 195
Replacement of Armature……………………………………………………………………………………….. 195
Swing Bearing SP002329……………………………………………………………………………………………. 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
Lower Structure and Chassis…………………………………………………………………………………………… 207
Track Assembly SP002330…………………………………………………………………………………………… 209
Safety Instructions…………………………………………………………………………………………… 213
Applicable Models…………………………………………………………………………………………….. 213
General Description…………………………………………………………………………………………… 214
Track Tension………………………………………………………………………………………………… 215
Cleaning and Inspection (Wear Limits and Tolerances)……………………………………………………………… 217
Track Shoe……………………………………………………………………………………………….. 218
Lower Roller……………………………………………………………………………………………… 220
Upper Roller……………………………………………………………………………………………… 221
Front Idler………………………………………………………………………………………………. 222
Track Shoes and Links…………………………………………………………………………………………. 223
Track Removal…………………………………………………………………………………………….. 223
Track Installation………………………………………………………………………………………… 224
Front Idler Roller……………………………………………………………………………………………. 226
Parts List……………………………………………………………………………………………….. 226
Front Idler Roller Disassembly……………………………………………………………………………… 227
Front Idler Roller Reassembly………………………………………………………………………………. 229
Lower Roller…………………………………………………………………………………………………. 230
Parts List……………………………………………………………………………………………….. 230
Lower Roller Removal………………………………………………………………………………………. 231
Lower Roller Disassembly…………………………………………………………………………………… 231
Lower Roller Reassembly……………………………………………………………………………………. 232
Lower Roller Installation………………………………………………………………………………….. 233
Upper Roller…………………………………………………………………………………………………. 234
Parts List……………………………………………………………………………………………….. 234
Upper Roller Removal………………………………………………………………………………………. 235
Upper Roller Disassembly…………………………………………………………………………………… 235
Upper Roller Reassembly……………………………………………………………………………………. 237
Track Spring and Track Adjusting Cylinder……………………………………………………………………….. 238
Parts List……………………………………………………………………………………………….. 238
Engine and Drivetrain………………………………………………………………………………………………… 241
Engine Coolant Heater (Option) SP002328…………………………………………………………………………….. 243
Safety Instructions…………………………………………………………………………………………… 247
Applicable Models…………………………………………………………………………………………….. 247
Disassembly and Assembly………………………………………………………………………………………. 248
Changing the Circulating Pump………………………………………………………………………………. 248
Changing the Temperature Limiter……………………………………………………………………………. 250
Changing the Temperature Sensor…………………………………………………………………………….. 251
Changing the Combustion Air Fan…………………………………………………………………………….. 253
Changing the Burner, Flame Monitor and Glow Plug……………………………………………………………… 255
Changing the Burner Head…………………………………………………………………………………… 257
Changing the Heat Exchanger………………………………………………………………………………… 259
Drive Coupling (Main Pump) SP002411………………………………………………………………………………… 261
Safety Instructions…………………………………………………………………………………………… 265
Applicable Models…………………………………………………………………………………………….. 265
Drive Coupling……………………………………………………………………………………………….. 266
Installation of Drive Coupling…………………………………………………………………………………. 267
Installation Procedure…………………………………………………………………………………….. 267
Hydraulics………………………………………………………………………………………………………….. 269
Hydraulic System Troubleshooting, Testing and Adjustment SP002412……………………………………………………… 271
Safety Instructions…………………………………………………………………………………………… 275
Applicable Models…………………………………………………………………………………………….. 275
Hydraulic System – General Notes……………………………………………………………………………….. 276
Hydraulic Schematic…………………………………………………………………………………………… 277
General Notes…………………………………………………………………………………………….. 277
Operation of Working Components………………………………………………………………………………… 279
Boom Operating Circuit…………………………………………………………………………………….. 279
Boom Up Circuit…………………………………………………………………………………………… 279
Boom Down Circuit…………………………………………………………………………………………. 279
Arm Operating Circuit……………………………………………………………………………………… 280
Arm Crowd Circuit…………………………………………………………………………………………. 280
Arm Dump Circuit………………………………………………………………………………………….. 280
Bucket Operating Circuit…………………………………………………………………………………… 281
Bucket Crowd Circuit………………………………………………………………………………………. 281
Bucket Dump Circuit……………………………………………………………………………………….. 281
Swing Operating Circuit……………………………………………………………………………………. 281
Right Swing Operating Circuit………………………………………………………………………………. 282
Left Swing Operating Circuit……………………………………………………………………………….. 282
Swing Relief Valve and Makeup Valve…………………………………………………………………………. 282
Travel Operating Circuit…………………………………………………………………………………… 282
Forward Travel Circuit…………………………………………………………………………………….. 283
Reverse Travel Circuit…………………………………………………………………………………….. 283
Procedural Troubleshooting Baseline Recommendations………………………………………………………………. 284
Initial Checks and Tests to Establish Operating Condition of the Excavator………………………………………. 284
Troubleshooting Recommendations…………………………………………………………………………. 284
Pilot Pressure……………………………………………………………………………………………….. 285
Adjustment and Testing…………………………………………………………………………………….. 285
Pump Swash Plate……………………………………………………………………………………………… 286
Adjustment and Testing…………………………………………………………………………………….. 286
Pump EPPRV…………………………………………………………………………………………………… 287
Adjustment and Testing…………………………………………………………………………………….. 287
Pump Pressure………………………………………………………………………………………………… 288
Adjustment and Testing…………………………………………………………………………………….. 288
Pump Regulator……………………………………………………………………………………………….. 289
Adjustment and Testing…………………………………………………………………………………….. 289
Installation and Testing of Flow Meter and Flow Meter Kit…………………………………………………………. 291
Installation and Testing Procedures…………………………………………………………………………. 291
Swing System Troubleshooting…………………………………………………………………………………… 292
Precautions/Initial Checks…………………………………………………………………………………. 292
Swing Relief Valve Checking and Adjustment…………………………………………………………………… 293
Troubleshooting – Swing Gearbox………………………………………………………………………………… 295
Troubleshooting – Hydraulic Problems……………………………………………………………………………. 296
Troubleshooting – Main Pump……………………………………………………………………………………. 299
Troubleshooting – Control Valve………………………………………………………………………………… 301
Troubleshooting – Travel Control Valve………………………………………………………………………….. 303
Troubleshooting – Joystick Control Valve………………………………………………………………………… 304
Accumulator SP002455……………………………………………………………………………………………… 305
Safety Instructions…………………………………………………………………………………………… 309
Applicable Models…………………………………………………………………………………………….. 309
General Description…………………………………………………………………………………………… 310
Specifications……………………………………………………………………………………………. 312
Center Joint (Swivel) SP002545…………………………………………………………………………………….. 313
Safety Instructions…………………………………………………………………………………………… 317
Applicable Models…………………………………………………………………………………………….. 317
General Description…………………………………………………………………………………………… 319
Center Joint Disassembly Diagram……………………………………………………………………………. 320
Troubleshooting, Testing and Adjustment…………………………………………………………………………. 321
Inspection……………………………………………………………………………………………….. 321
Testing………………………………………………………………………………………………….. 321
Disassembly………………………………………………………………………………………………….. 322
Reassembly…………………………………………………………………………………………………… 325
Cylinders SP002422……………………………………………………………………………………………….. 329
Safety Instructions…………………………………………………………………………………………… 333
Applicable Models…………………………………………………………………………………………….. 333
General Description…………………………………………………………………………………………… 334
Theory of Operation……………………………………………………………………………………….. 334
Parts List……………………………………………………………………………………………….. 336
Special Tools and Materials……………………………………………………………………………………. 342
Piston Nut……………………………………………………………………………………………….. 342
Piston Jig……………………………………………………………………………………………….. 344
Steel Bushing Jig…………………………………………………………………………………………. 347
Dust Wiper Jig……………………………………………………………………………………………. 350
Slipper Seal Jig………………………………………………………………………………………….. 353
Slipper Seal Straightening Jig……………………………………………………………………………… 356
Disassembly………………………………………………………………………………………………….. 359
Reassembly…………………………………………………………………………………………………… 364
Swing Device SP002413…………………………………………………………………………………………….. 369
Safety Instructions…………………………………………………………………………………………… 373
Applicable Models…………………………………………………………………………………………….. 373
Structure and Principle of Operation………………………………………………………………………… 374
Structure…………………………………………………………………………………………….. 374
Principle of Operation…………………………………………………………………………………. 379
Valve Casing………………………………………………………………………………………….. 380
Brake Part……………………………………………………………………………………………. 383
Cautions for Operation…………………………………………………………………………………….. 384
Inspection……………………………………………………………………………………………. 384
Direction of Rotation………………………………………………………………………………….. 384
External Load at the End of Shaft……………………………………………………………………….. 385
Hydraulic Oil and Temperature Range……………………………………………………………………… 385
Filter……………………………………………………………………………………………….. 386
Installation and Piping………………………………………………………………………………… 386
Oil Filling and Air Ventilation…………………………………………………………………………. 387
Cautions before Start Operation…………………………………………………………………………. 387
Troubleshooting…………………………………………………………………………………………… 388
General Caution……………………………………………………………………………………….. 388
Examination of Hydraulic Motor………………………………………………………………………….. 388
Troubleshooting……………………………………………………………………………………….. 389
Disassembly and Reassembly…………………………………………………………………………………. 392
Tightening Torque of Bolts……………………………………………………………………………… 392
Tools for Disassembly and Reassembly…………………………………………………………………….. 392
Remove and Install Swing Device………………………………………………………………………………… 394
Removal………………………………………………………………………………………………….. 394
Remove Swing Motor…………………………………………………………………………………….. 396
Install Swing Motor……………………………………………………………………………………. 396
Installation……………………………………………………………………………………………… 397
Disassemble Swing Motor………………………………………………………………………………… 399
Reassemble Swing Motor…………………………………………………………………………………. 403
Disassemble the Reduction Gear………………………………………………………………………….. 409
Reassemble the Reduction Gear…………………………………………………………………………… 413
Maintenance Guidelines…………………………………………………………………………………….. 420
Replacement Standard of Worn Parts………………………………………………………………………. 420
Standard of Sliding Surface Correction…………………………………………………………………… 421
Travel Device SP002414……………………………………………………………………………………………. 423
Safety Instructions…………………………………………………………………………………………… 427
Applicable Models…………………………………………………………………………………………….. 427
Basic Structure and Drawings……………………………………………………………………………….. 429
Basic Structure of TM Motor…………………………………………………………………………….. 429
Motor (M)…………………………………………………………………………………………….. 430
Reduction Gear (R)…………………………………………………………………………………….. 432
Operation Principle……………………………………………………………………………………….. 434
Reduction Gear………………………………………………………………………………………… 434
Hydraulic Motor (Brake Valve, Parking Brake, High-Low 2- Stage Switching Mechanism)…………………………… 435
Cautions for Operation…………………………………………………………………………………….. 443
Installation Method (refer to the Outline Drawing)………………………………………………………… 443
Pipeline……………………………………………………………………………………………… 443
Hydraulic Oil…………………………………………………………………………………………. 444
Lubricant…………………………………………………………………………………………….. 445
Maintenance/Service……………………………………………………………………………………. 446
Troubleshooting…………………………………………………………………………………………… 446
Maintenance Instructions…………………………………………………………………………………… 448
Jigs and Tools for Assembly and Disassembly………………………………………………………………. 448
Remove and Install Travel Device……………………………………………………………………………….. 451
Removal………………………………………………………………………………………………….. 451
Disassembly………………………………………………………………………………………………. 452
General Cautions for Maintenance Work……………………………………………………………………. 452
Disassembly Sequence…………………………………………………………………………………… 452
Assembly…………………………………………………………………………………………………. 462
General Cautions for Maintenance Work……………………………………………………………………. 462
Assembly Sequence……………………………………………………………………………………… 462
Installation……………………………………………………………………………………………… 479
Matters to Check after Assembly…………………………………………………………………………….. 480
Performance Test………………………………………………………………………………………….. 480
Main Pump SP002415……………………………………………………………………………………………….. 483
Safety Instructions…………………………………………………………………………………………… 487
Applicable Models…………………………………………………………………………………………….. 487
Product description…………………………………………………………………………………………… 488
Performance Description……………………………………………………………………………………. 488
Device Description………………………………………………………………………………………… 488
Assembly of the Axial Piston Unit……………………………………………………………………….. 489
Functional Description…………………………………………………………………………………. 490
Manual Override…………………………………………………………………………………………… 491
Product Identification…………………………………………………………………………………….. 493
Parts List……………………………………………………………………………………………….. 494
Sectional Drawings…………………………………………………………………………………….. 494
Transport and storage…………………………………………………………………………………………. 496
Transporting the Axial Piston Unit………………………………………………………………………….. 496
Transporting with Lifting Device………………………………………………………………………… 497
Storing the Axial Piston Unit………………………………………………………………………………. 498
Installation…………………………………………………………………………………………………. 501
Unpacking………………………………………………………………………………………………… 501
Installation Conditions……………………………………………………………………………………. 502
Installation Position……………………………………………………………………………………… 504
Below-reservoir Installation (Standard)………………………………………………………………….. 504
Installing the Axial Piston Unit……………………………………………………………………………. 506
Dimensions……………………………………………………………………………………………. 508
General Instructions…………………………………………………………………………………… 508
Installation with Coupling……………………………………………………………………………… 509
Mounting on an Engine………………………………………………………………………………….. 510
Completing Assembly……………………………………………………………………………………. 510
Hydraulically Connecting the Axial Piston Unit……………………………………………………………. 512
Commissioning………………………………………………………………………………………………… 518
Initial Commissioning……………………………………………………………………………………… 519
Filling the Axial Piston Unit…………………………………………………………………………… 520
Testing the Hydraulic Fluid Supply………………………………………………………………………. 522
Performing Functional Test……………………………………………………………………………… 522
Performing Flushing Cycle………………………………………………………………………………. 523
Recommissioning After Standstill……………………………………………………………………………. 524
Running-in Phase………………………………………………………………………………………….. 524
Maintenance and repair………………………………………………………………………………………… 525
Cleaning and Care…………………………………………………………………………………………. 525
Inspection……………………………………………………………………………………………….. 526
Maintenance………………………………………………………………………………………………. 526
Repair…………………………………………………………………………………………………… 527
Spare Parts………………………………………………………………………………………………. 527
Decommissioning………………………………………………………………………………………………. 528
Removal and replacement……………………………………………………………………………………….. 528
Required Tools……………………………………………………………………………………………. 528
Preparing for Removal……………………………………………………………………………………… 528
Removing the Axial Piston Unit……………………………………………………………………………… 529
Preparing the Components for Storage or Further Use…………………………………………………………… 529
Troubleshooting………………………………………………………………………………………………. 530
How to Proceed for Troubleshooting………………………………………………………………………….. 530
Malfunction Table…………………………………………………………………………………………. 531
Replacing seals and assembly groups…………………………………………………………………………….. 533
Replacing the Shaft Seal…………………………………………………………………………………… 534
Sealing or Replacing the Gear Pump………………………………………………………………………….. 537
Sealing the Cover of the Power Take-off……………………………………………………………………… 539
Sealing the Port Plate with Valve…………………………………………………………………………… 541
Sealing or Replacing the Pressure Reducing Valve……………………………………………………………… 543
Replacing the Angle Position Sensor…………………………………………………………………………. 545
Replacing Sealing Nuts…………………………………………………………………………………….. 547
Tightening torques……………………………………………………………………………………………. 548
Slotted Screws……………………………………………………………………………………………. 548
Threaded Plugs……………………………………………………………………………………………. 549
Sealing Nuts……………………………………………………………………………………………… 550
Gear Pump (Option) SP002457……………………………………………………………………………………….. 551
Safety Instructions…………………………………………………………………………………………… 555
Applicable Models…………………………………………………………………………………………….. 555
Single Gear Pump……………………………………………………………………………………………… 556
Disassembly………………………………………………………………………………………………. 556
Reassembly……………………………………………………………………………………………….. 558
Double Gear Pump……………………………………………………………………………………………… 562
Disassembly………………………………………………………………………………………………. 562
Reassembly……………………………………………………………………………………………….. 564
Fan Motor for Oil Cooler SP002552………………………………………………………………………………….. 569
Safety Instructions…………………………………………………………………………………………… 573
Applicable Models…………………………………………………………………………………………….. 573
Disassembly………………………………………………………………………………………………….. 575
Assembly…………………………………………………………………………………………………….. 578
Preassemble………………………………………………………………………………………………. 578
Assembling……………………………………………………………………………………………….. 579
Fan Pump SP002553………………………………………………………………………………………………… 581
Safety Instructions…………………………………………………………………………………………… 585
Applicable Models…………………………………………………………………………………………….. 585
View………………………………………………………………………………………………………… 587
ED – Valve……………………………………………………………………………………………….. 587
General Repair Guidelines……………………………………………………………………………………… 588
Sealing Driveshaft……………………………………………………………………………………………. 589
Sealing Control Valve…………………………………………………………………………………………. 591
Disassembly………………………………………………………………………………………………….. 592
Overview…………………………………………………………………………………………………. 592
Remove Rotary Group……………………………………………………………………………………….. 595
Remove Control Device……………………………………………………………………………………… 596
Remove Shaft/Bearings……………………………………………………………………………………… 597
Cleaning and Inspection……………………………………………………………………………………….. 598
Pump Assembly………………………………………………………………………………………………… 601
Adjustment of Taper Roller Bearing……………………………………………………………………………… 603
Taper Roller Bearing Pretension…………………………………………………………………………….. 603
Tools/Auxiliary Tools/ Tightening Torques……………………………………………………………………….. 610
Main Control Valve SP002416……………………………………………………………………………………….. 611
Safety Instructions…………………………………………………………………………………………… 615
Applicable Models…………………………………………………………………………………………….. 615
Functional Description………………………………………………………………………………………… 616
PC-control Concept………………………………………………………………………………………… 616
General………………………………………………………………………………………………. 616
Expanding Consumer Sections (Options)……………………………………………………………………. 617
M9-25 Main Control Block…………………………………………………………………………………… 618
General Information……………………………………………………………………………………….. 620
Function…………………………………………………………………………………………………. 621
General………………………………………………………………………………………………. 621
Pump Strategy…………………………………………………………………………………………. 623
Neutral Circulation……………………………………………………………………………………. 623
Tank and Cooler Valves…………………………………………………………………………………. 624
Summing and Cut Valves…………………………………………………………………………………. 625
Straight Travel Valve………………………………………………………………………………….. 626
Individual Operation…………………………………………………………………………………… 628
Additional Functions………………………………………………………………………………………. 650
Primary Pressure Relief Valve…………………………………………………………………………… 651
Primary Pressure Relief Valve with Pressure Connection Step………………………………………………… 652
Tank Line and Cooler Pre-tensioning……………………………………………………………………… 653
Secondary Pressure Relief and Feed Valve…………………………………………………………………. 654
Anticavitation (Feed) Valve…………………………………………………………………………….. 655
Pilot-controlled Check Valve (Antidrift Valve)……………………………………………………………. 656
Check Function (Supply)………………………………………………………………………………… 657
Shuttle Damping (Optional)……………………………………………………………………………… 659
Part lists…………………………………………………………………………………………………… 660
Control Block M9-1060-00…………………………………………………………………………………… 660
Control Block M9-1060-00 Operation………………………………………………………………………….. 662
Plate MH4WH 25……………………………………………………………………………………………. 663
Combined Relief/Anticavitation Valve, Pilot Operated………………………………………………………….. 664
MHDBN 22 K2-3X/420-380VFC………………………………………………………………………………. 664
MHDBN 22 K2-3X/420-380YVHC-122………………………………………………………………………….. 665
Anticavitation Valve………………………………………………………………………………………. 666
MHSL 02 K10…………………………………………………………………………………………… 666
Specifications……………………………………………………………………………………………….. 667
Troubleshooting, Testing and Adjustment……………………………………………………………………… 667
How to Proceed for Troubleshooting………………………………………………………………………. 667
Malfunction Table……………………………………………………………………………………… 668
Disassembly………………………………………………………………………………………………….. 670
General Repair Instructions………………………………………………………………………………… 670
Repair Instructions……………………………………………………………………………………….. 672
Parts List Control Block……………………………………………………………………………….. 672
Replace Load-holding Valve Spool (Item 130)………………………………………………………………. 672
Replace Plug Screw (Item 132)…………………………………………………………………………… 673
Replace Throttle Check Valve (Item 135, 136) for Semi Priority Boom Vs. Bucket and Swing Vs. Arm……………….. 674
Replace Pilot Control Cartridge MHSL 5.5 (Item 210) for Antidrift-valve Boom and Arm………………………….. 675
Replace Antidrift Valve (Item 140, 141)………………………………………………………………….. 676
Replace Secondary Pressure Relief Valve (Item 202, 208) / Plug Screw (Item 200)………………………………. 677
Replace Load-holding Valve Function Consisting of Poppet (Item 205), Spring (Item 206) and Plug Screw (Item 207)…. 678
Replace Spool Boom Summation (Item 170, Similar With Spool Arm Summation Item 171)……………………………. 679
Replace Main Spool…………………………………………………………………………………….. 680
Replace Pilot Shuttle Valve (Item 163)…………………………………………………………………… 681
Replace Cut Spool (Item 182)……………………………………………………………………………. 683
Replace End Plate (Item 113) and Directional Valve (Item 101)………………………………………………. 684
Replace Inlet Section (Item 220)………………………………………………………………………… 686
Replace Pre-load Valves (Item 20 and 21) for Tank Line and Cooler Back Pressure………………………………. 687
Replace Primary Pressure Relief Valve (Item 222)………………………………………………………….. 688
Replace Check Valves for Primary Pressure Relief (Item 42)…………………………………………………. 689
Replace Straight Travel Valve…………………………………………………………………………… 690
Reassembly…………………………………………………………………………………………………… 691
Unpacking………………………………………………………………………………………………… 693
Coating the Control Block………………………………………………………………………………….. 693
Installation Conditions……………………………………………………………………………………. 694
Required Tools……………………………………………………………………………………………. 694
Assembling the Control Block……………………………………………………………………………….. 694
Mechanically Connecting the Control Block……………………………………………………………………. 695
Hydraulically Connecting the Control Block…………………………………………………………………… 696
Installing the Electrical Supply……………………………………………………………………………. 696
Before First Commissioning…………………………………………………………………………………. 697
Commissioning…………………………………………………………………………………………….. 698
First Commissioning……………………………………………………………………………………. 699
Re-commissioning………………………………………………………………………………………. 700
Operation………………………………………………………………………………………………… 700
Maintenance and Repair…………………………………………………………………………………….. 701
Definition……………………………………………………………………………………………. 703
Inspection and Maintenance……………………………………………………………………………… 703
Repair……………………………………………………………………………………………….. 706
Spare Parts…………………………………………………………………………………………… 706
PRV (Peak Reducing Valve) SP002459…………………………………………………………………………………. 709
Safety Instructions…………………………………………………………………………………………… 713
Applicable Models…………………………………………………………………………………………….. 713
Instruction Manual……………………………………………………………………………………………. 714
General………………………………………………………………………………………………….. 714
Outer Appearance and the Ports of Valve………………………………………………………………….. 714
Principal Components and Functions………………………………………………………………………….. 715
Explanation of Operation……………………………………………………………………………….. 716
Relief Pressure……………………………………………………………………………………….. 716
Adjustment……………………………………………………………………………………………….. 716
Installation……………………………………………………………………………………………… 717
Hydraulic Oil…………………………………………………………………………………………….. 717
Guide for External Oil Leakage……………………………………………………………………………… 717
Repair Manual………………………………………………………………………………………………… 718
Necessary Tools and Jigs…………………………………………………………………………………… 718
Tools………………………………………………………………………………………………… 718
Jigs…………………………………………………………………………………………………. 718
Cautions During Disassembling and Assembling…………………………………………………………………. 719
Cautions for Disassembling……………………………………………………………………………… 719
Cautions for Assembling………………………………………………………………………………… 719
Disassembling Procedure……………………………………………………………………………………. 720
Exchange of O-ring (Surface of Pump Installation)…………………………………………………………. 720
Exchange of O-ring (Surface of Pilot Valve Ass’y Installation)……………………………………………… 721
Exchange of O-ring and Backup Ring (Part of Main Valve Ass’y)………………………………………………. 722
Disassembling Procedure of Pilot Valve Ass’y (Excluding Adjusting Screw Part)………………………………… 723
Assembling Procedure………………………………………………………………………………………. 724
Sensor Block SP002460…………………………………………………………………………………………….. 725
Safety Instructions…………………………………………………………………………………………… 729
Applicable Models…………………………………………………………………………………………….. 729
Instruction Manual……………………………………………………………………………………………. 730
General………………………………………………………………………………………………….. 730
Outer Appearance and the Ports of Valve………………………………………………………………….. 730
Components and Functions…………………………………………………………………………………… 732
Explanation of Operation……………………………………………………………………………….. 732
Installation……………………………………………………………………………………………… 733
Hydraulic Oil…………………………………………………………………………………………….. 733
Guide for External Oil Leakage……………………………………………………………………………… 733
Repair Manual………………………………………………………………………………………………… 734
Necessary Tools and Jigs…………………………………………………………………………………… 734
Tools………………………………………………………………………………………………… 734
Cautions during Disassembling and Assembling…………………………………………………………………. 734
Cautions for Disassembling……………………………………………………………………………… 734
Cautions for Assembling………………………………………………………………………………… 734
Disassembling Procedure (Shuttle Valve Parts)………………………………………………………………… 735
Assembling Procedure………………………………………………………………………………………. 735
Remote Control Valve (Work Lever / Joystick) SP002450………………………………………………………………… 737
Safety Instructions…………………………………………………………………………………………… 741
Applicable Models…………………………………………………………………………………………….. 741
General Description…………………………………………………………………………………………… 743
Theory of Operation……………………………………………………………………………………….. 743
Structure…………………………………………………………………………………………….. 743
Function……………………………………………………………………………………………… 743
Parts List……………………………………………………………………………………………….. 744
Specifications……………………………………………………………………………………………. 746
Performance…………………………………………………………………………………………… 746
Torques………………………………………………………………………………………………….. 746
Tools and Materials…………………………………………………………………………………………… 746
Disassembly………………………………………………………………………………………………….. 747
Reassembly…………………………………………………………………………………………………… 750
Start-up Procedures…………………………………………………………………………………………… 758
Travel Control Valve (with Damper) SP002381…………………………………………………………………………. 759
Safety Instructions…………………………………………………………………………………………… 763
Applicable Models…………………………………………………………………………………………….. 763
General Description…………………………………………………………………………………………… 764
Theory of Operation……………………………………………………………………………………….. 764
Pressure Reducing Valve……………………………………………………………………………………. 765
Operating Theory of Damper Mechanism………………………………………………………………………… 766
Causes of Faults and Measures………………………………………………………………………………….. 767
Parts List……………………………………………………………………………………………….. 768
Specification…………………………………………………………………………………………….. 770
Torques………………………………………………………………………………………………….. 770
Removal……………………………………………………………………………………………………… 771
Disassembly………………………………………………………………………………………………….. 774
Cleaning and Inspection (Wear Limits and Tolerances)……………………………………………………………… 776
Reassembly…………………………………………………………………………………………………… 777
Installation…………………………………………………………………………………………………. 782
Start-up Procedures…………………………………………………………………………………………… 785
Solenoid Valve Assembly SP002406…………………………………………………………………………………… 787
Safety Instructions…………………………………………………………………………………………… 791
Applicable Models…………………………………………………………………………………………….. 791
5-Solenoid Valve……………………………………………………………………………………………… 792
Parts List……………………………………………………………………………………………….. 792
Functions of 5-Solenoid Valve Assembly………………………………………………………………………. 793
Assembly Diagram and Tools Required…………………………………………………………………………. 794
Cautions During Disassembly and Reassembly…………………………………………………………………… 795
Solenoid Valve Diagram…………………………………………………………………………………….. 796
Check Points and Solutions for Problems……………………………………………………………………… 797
Breaker EPPR Valve (Option) SP002458……………………………………………………………………………….. 799
Safety Instructions…………………………………………………………………………………………… 803
Applicable Models…………………………………………………………………………………………….. 803
Structure……………………………………………………………………………………………………. 804
Parts List……………………………………………………………………………………………….. 804
Functions and Operation……………………………………………………………………………………….. 805
Cautions for Operation………………………………………………………………………………………… 805
Maintenance Instructions………………………………………………………………………………………. 806
Maintenance………………………………………………………………………………………………. 806
Disassembly………………………………………………………………………………………………. 807
Assembly…………………………………………………………………………………………………. 808
Hydraulic Schematic SP002417………………………………………………………………………………………. 811
Safety Instructions…………………………………………………………………………………………… 815
Applicable Models…………………………………………………………………………………………….. 815
DX340LC-3/DX350LC-3/DX380LC-3………………………………………………………………………………….. 817
Electrical System……………………………………………………………………………………………………. 819
Electrical System SP002418………………………………………………………………………………………… 821
Safety Instructions…………………………………………………………………………………………… 827
Applicable Models…………………………………………………………………………………………….. 827
Introduction…………………………………………………………………………………………………. 828
Electrical Wire Color……………………………………………………………………………………… 828
Electrical Supply System………………………………………………………………………………………. 830
Engine Starting Circuit……………………………………………………………………………………….. 832
Start Operation…………………………………………………………………………………………… 832
After Start………………………………………………………………………………………………. 834
Operation of the Start Circuit (2) – Immediately After Start……………………………………………….. 835
Engine Preheating System………………………………………………………………………………………. 836
Engine Stop………………………………………………………………………………………………….. 838
Charging System………………………………………………………………………………………………. 840
Monitoring System…………………………………………………………………………………………….. 841
Instrument Panel………………………………………………………………………………………….. 842
Functional Check………………………………………………………………………………………….. 842
Monitoring System Schematic………………………………………………………………………………… 844
Operation……………………………………………………………………………………………………. 846
Instruments………………………………………………………………………………………………. 846
Warning and Indicator Lights…………………………………………………………………………………… 848
Indication of Warning Lights……………………………………………………………………………….. 848
Indication of Multifunction Gauge…………………………………………………………………………… 851
Initial Operation…………………………………………………………………………………………….. 853
Graphic Information Area Display……………………………………………………………………………….. 854
Overview…………………………………………………………………………………………………. 854
Main Menus for the Graphic Display Area……………………………………………………………………… 854
Menu Selector Buttons……………………………………………………………………………………… 854
User Menu……………………………………………………………………………………………………. 855
User Menu – Access and Escape Methods……………………………………………………………………….. 855
Access Method…………………………………………………………………………………………. 855
Escape Method…………………………………………………………………………………………. 855
User Menu…………………………………………………………………………………………….. 855
Special Menu…………………………………………………………………………………………………. 887
Entering/Accessing and Exiting/Escaping Menus………………………………………………………………… 887
Entering/Accessing Menus……………………………………………………………………………….. 887
Exiting/Escaping Menus…………………………………………………………………………………. 888
Special Menu Selections……………………………………………………………………………………. 888
Monitoring……………………………………………………………………………………………. 888
Graph………………………………………………………………………………………………… 895
Failure Information……………………………………………………………………………………. 896
FMIs (Failure Mode Identifier)………………………………………………………………………….. 906
Information of Machine Operation………………………………………………………………………… 907
Vehicle Configuration………………………………………………………………………………….. 910
Electronic Hydraulic Control System (e-EPOS)…………………………………………………………………….. 914
Control System Schematic…………………………………………………………………………………… 914
Power Plus Mode Control……………………………………………………………………………………….. 916
Operation………………………………………………………………………………………………… 918
1. Power Plus Mode…………………………………………………………………………………….. 918
2. Power Mode, Standard Mode, Economy Mode……………………………………………………………….. 919
Power Mode Control – Circuit Diagram……………………………………………………………………………. 920
Engine Control System…………………………………………………………………………………………. 922
Engine Control Dial…………………………………………………………………………………………… 923
Engine Control Circuit Diagram…………………………………………………………………………………. 924
Automatic Deceleration Control (Auto Idle Control)……………………………………………………………….. 926
Engine Overheat Protection System………………………………………………………………………………. 928
Power Boost Mode……………………………………………………………………………………………… 930
Operation………………………………………………………………………………………………… 930
Power Boost Control – Circuit Diagram……………………………………………………………………….. 932
Automatic Travel Speed Control…………………………………………………………………………………. 934
Automatic Travel Speed Control – Circuit Diagram……………………………………………………………… 936
Self-diagnostic Function………………………………………………………………………………………. 937
e-EPOS Controller…………………………………………………………………………………………. 937
Air Conditioner System………………………………………………………………………………………… 939
Outline………………………………………………………………………………………………….. 939
Internal and External Filters………………………………………………………………………………. 940
How to Check Internal Air Filter………………………………………………………………………… 940
How to Check External Air Filter………………………………………………………………………… 940
Air-Conditioning System Layout……………………………………………………………………………… 942
Air Conditioner/heater Circuit Diagram………………………………………………………………………. 943
Air Conditioner/heater Unit………………………………………………………………………………… 944
Airflow Diagram……………………………………………………………………………………….. 944
Door Open by Vent Modes………………………………………………………………………………… 945
Main Components……………………………………………………………………………………….. 945
Actuator – Airflow Direction Control…………………………………………………………………….. 946
Actuator – Temperature Control………………………………………………………………………….. 946
Actuator – Internal/External Air Exchange………………………………………………………………… 947
Airflow Control Module…………………………………………………………………………………. 947
Ambient Air Temperature Sensor……………………………………………………………………………… 949
Sun Sensor……………………………………………………………………………………………….. 950
Control Panel…………………………………………………………………………………………….. 950
Appearance and Terminal Arrangement……………………………………………………………………… 950
Terminal Terms………………………………………………………………………………………… 951
Control Logic…………………………………………………………………………………………. 952
Self Diagnosis………………………………………………………………………………………… 956
Ambient Temperature Display…………………………………………………………………………….. 957
Compressor……………………………………………………………………………………………….. 958
Receiver Dryer……………………………………………………………………………………………. 958
Troubleshooting………………………………………………………………………………………………. 959
Refrigerant Pressure Check…………………………………………………………………………………. 959
Weight of R134a Gas Used In Machines……………………………………………………………………………. 961
Refrigerant System Repairs…………………………………………………………………………………….. 962
Refrigerant Safe Handling Procedures………………………………………………………………………… 962
Repair and Replacement Procedure……………………………………………………………………………. 963
Refrigerant Recovery………………………………………………………………………………………. 965
Vacuuming Refrigerant System……………………………………………………………………………….. 965
Leakage Check…………………………………………………………………………………………….. 967
Refrigerant Charging………………………………………………………………………………………. 967
Inspecting System For Leakage………………………………………………………………………………. 969
Wiper System…………………………………………………………………………………………………. 970
Wiper Circuit…………………………………………………………………………………………….. 970
Wiper operation…………………………………………………………………………………………… 971
Continuous operation…………………………………………………………………………………… 971
Intermittent operation…………………………………………………………………………………. 971
Lighting System………………………………………………………………………………………………. 974
Lighting System Circuit Diagram…………………………………………………………………………….. 974
Kind of Light…………………………………………………………………………………………….. 975
Operation………………………………………………………………………………………………… 975
Overload Warning Device……………………………………………………………………………………….. 976
Overload Warning Device Circuit Diagram……………………………………………………………………… 976
Audio Controller……………………………………………………………………………………………… 977
Audio Controller Circuit Diagram……………………………………………………………………………. 977
Operations Via Audio Control Panel………………………………………………………………………. 977
Electrical Schematic SP002419……………………………………………………………………………………… 979
Safety Instructions…………………………………………………………………………………………… 983
Applicable Models…………………………………………………………………………………………….. 983
DX340LC-3/DX350LC-3/DX380LC-3 (1/2)…………………………………………………………………………….. 985
DX340LC-3/DX350LC-3/DX380LC-3 (2/2)…………………………………………………………………………….. 987
Attachments…………………………………………………………………………………………………………. 989
Boom and Arm SP002420…………………………………………………………………………………………….. 991
Safety Instructions…………………………………………………………………………………………… 995
Applicable Models…………………………………………………………………………………………….. 995
Front Attachment Pin Specifications…………………………………………………………………………….. 996
DX340LC-3/DX350LC-3……………………………………………………………………………………….. 997
Front Attachment – Removal and Installation……………………………………………………………………… 998
Arm Removal Procedure……………………………………………………………………………………… 998
Boom Removal Procedure……………………………………………………………………………………..1000
Installation………………………………………………………………………………………………….1001
Arm Installation Procedure………………………………………………………………………………….1001
Boom Installation Procedure…………………………………………………………………………………1001
Start-up Procedures……………………………………………………………………………………………1002
Bucket SP002421…………………………………………………………………………………………………..1003
Safety Instructions……………………………………………………………………………………………1007
Applicable Models……………………………………………………………………………………………..1007
Bucket Tooth Inspection and Replacement………………………………………………………………………….1008
Bucket O-ring Replacement………………………………………………………………………………………1009
Bucket Shimming Procedures……………………………………………………………………………………..1011
New Bucket Installation…………………………………………………………………………………….1011
Shimming Procedures for Installed Bucket………………………………………………………………….1012
Attachments…………………………………………………………………………………………………..1013
Bucket Replacement and Reversal……………………………………………………………………………..1013
Replacement……………………………………………………………………………………………….1014
Reversal………………………………………………………………………………………………….1015
Quick Coupler Operation (Optional)…………………………………………………………………………..1016
Securing Work Tool……………………………………………………………………………………..1016
Attaching Quick Coupler to Excavator……………………………………………………………………..1016
Releasing the Work Tool…………………………………………………………………………………1018DX340LC-3/DX350LC-3……………………………………………………………………………………………………… 0
Table of Contents……………………………………………………………………………………………………. 7
Safety……………………………………………………………………………………………………………… 9
Track Excavator Maintenance Safety SP002322…………………………………………………………………………. 11
Safety Instructions…………………………………………………………………………………………… 15
Applicable Models…………………………………………………………………………………………….. 15
Safety Messages………………………………………………………………………………………………. 16
Signal Words……………………………………………………………………………………………… 16
Safety Decals………………………………………………………………………………………………… 17
General……………………………………………………………………………………………………… 17
Safe Operation is Operator’s Responsibility………………………………………………………………….. 17
Know Your Machine…………………………………………………………………………………………. 17
Proper Work Tools and Attachments…………………………………………………………………………… 18
Pressurized Fluids………………………………………………………………………………………… 18
Flying or Falling Objects………………………………………………………………………………….. 19
Personal Protective Equipment (PPE)…………………………………………………………………………. 20
Correction of Machine Problems……………………………………………………………………………… 20
Crushing and Cutting………………………………………………………………………………………. 20
Hot Coolant and Oils – Burn Prevention………………………………………………………………………. 21
Fire and Explosion Prevention………………………………………………………………………………. 22
Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)……………………………………………………. 25
Electrical System and Electrical Shock………………………………………………………………………. 25
Rollover Protective Structure (ROPS)………………………………………………………………………… 26
Transportation……………………………………………………………………………………………….. 30
Obey State and Local Over-the-Road Regulations……………………………………………………………….. 30
Loading and Unloading……………………………………………………………………………………… 30
Transporting Machine………………………………………………………………………………………. 31
Operation……………………………………………………………………………………………………. 32
Before Engine Starting…………………………………………………………………………………….. 32
Work Site………………………………………………………………………………………………… 33
Mounting/Dismounting………………………………………………………………………………………. 34
Cleaning…………………………………………………………………………………………………. 35
Operator Station………………………………………………………………………………………….. 35
Seat Belt………………………………………………………………………………………………… 36
Visibility Information…………………………………………………………………………………….. 37
Boost Starting or Charging Engine Batteries………………………………………………………………….. 38
Starting Engine…………………………………………………………………………………………… 39
Swinging or Traveling……………………………………………………………………………………… 40
Lifting and Digging……………………………………………………………………………………….. 42
Operation on Slopes……………………………………………………………………………………….. 43
Towing…………………………………………………………………………………………………… 44
Attachment……………………………………………………………………………………………….. 45
Equipment Lowering with Engine Stopped………………………………………………………………………. 45
Engine Stop………………………………………………………………………………………………. 45
Parking Machine…………………………………………………………………………………………… 46
Preservation/Storing Machine……………………………………………………………………………….. 47
Maintenance………………………………………………………………………………………………….. 49
Warning Tag………………………………………………………………………………………………. 52
Cleaning…………………………………………………………………………………………………. 53
Proper Tools and Clothing………………………………………………………………………………….. 53
Disassembling Precautions………………………………………………………………………………….. 53
Use of Lighting…………………………………………………………………………………………… 54
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………………………………………………………………………………………. 74
Silica Dust Information……………………………………………………………………………………. 75
Disposal of DHazardous Materials……………………………………………………………………………. 75
Sound……………………………………………………………………………………………………. 76
Vibration………………………………………………………………………………………………… 76
Specifications………………………………………………………………………………………………………. 77
Specification for DX340LC-3/ DX350LC-3……………………………………………………………………………… 79
Safety Instructions…………………………………………………………………………………………… 83
Applicable Models…………………………………………………………………………………………….. 83
General Description…………………………………………………………………………………………… 85
Component Locations…………………………………………………………………………………………… 86
General Dimensions……………………………………………………………………………………………. 88
One – Piece Boom………………………………………………………………………………………….. 88
Two – Piece Boom………………………………………………………………………………………….. 89
Working Range………………………………………………………………………………………………… 90
One – Piece Boom………………………………………………………………………………………….. 90
Two – Piece Boom………………………………………………………………………………………….. 92
General Specifications………………………………………………………………………………………… 94
Engine Performance Curves (Per KS-R1004 Standard)………………………………………………………………… 96
Approximate Weight of Workload Materials………………………………………………………………………… 98
Performance Tests…………………………………………………………………………………………….. 100
Excavator Performance Measurements……………………………………………………………………………… 101
Test Conditions…………………………………………………………………………………………… 101
Travel Speed and Travel Motor Balance (Steering Deviation) Tests……………………………………………….. 101
Speed Test……………………………………………………………………………………………. 101
Travel Deviation………………………………………………………………………………………. 103
Swing Speed and Deceleration Force Test……………………………………………………………………… 103
Swing Speed Test………………………………………………………………………………………. 103
Swing Deceleration Force Test…………………………………………………………………………… 104
Cylinder Performance Tests…………………………………………………………………………………. 105
Boom Cylinders Test……………………………………………………………………………………. 105
Arm Cylinder Test……………………………………………………………………………………… 105
Bucket Cylinder Test…………………………………………………………………………………… 105
Hydraulic Cylinder Natural Drop Test…………………………………………………………………….. 105
Travel Motor Jack-up Test………………………………………………………………………………. 105
General Maintenance………………………………………………………………………………………………….. 107
General Maintenance Instructions SP002454…………………………………………………………………………… 109
Safety Instructions…………………………………………………………………………………………… 113
Applicable Models…………………………………………………………………………………………….. 113
Welding Precautions and Instructions……………………………………………………………………………. 114
Hydraulic System – General Precautions………………………………………………………………………….. 115
Maintenance Service and Repair Procedure………………………………………………………………………… 117
General Precautions……………………………………………………………………………………….. 117
Hydraulic System Cleanliness and Oil Leaks………………………………………………………………………. 118
Maintenance Precautions for Hydraulic System Service………………………………………………………….. 118
Oil Leakage Precautions……………………………………………………………………………………. 119
Cleaning and Inspection……………………………………………………………………………………….. 120
General Instructions………………………………………………………………………………………. 120
Bearing Inspection………………………………………………………………………………………… 121
Standard Torques SP002404…………………………………………………………………………………………. 129
Safety Instructions…………………………………………………………………………………………… 133
Applicable Models…………………………………………………………………………………………….. 133
Torque Values for Standard Metric Fasteners……………………………………………………………………… 134
Torque Values for Standard U.S. Fasteners……………………………………………………………………….. 135
Type 8 Phosphate Coated Hardware……………………………………………………………………………….. 137
Torque Values for Hose Clamps………………………………………………………………………………….. 138
ORFS Swivel Nut Recommended Torque……………………………………………………………………………… 138
Torque Values for Split Flanges………………………………………………………………………………… 139
Torque Wrench Extension Tools………………………………………………………………………………….. 140
Torque Multiplication……………………………………………………………………………………… 140
Other Uses for Torque Wrench Extension Tools…………………………………………………………………. 141
Tightening Torque Specifications (Metric)……………………………………………………………………. 142
Upper Structure……………………………………………………………………………………………………… 145
Cabin SP002324…………………………………………………………………………………………………… 147
Safety Instructions…………………………………………………………………………………………… 151
Applicable Models…………………………………………………………………………………………….. 151
Cabin Identification………………………………………………………………………………………….. 152
Rollover Protective Structure (ROPS)………………………………………………………………………… 152
Removal……………………………………………………………………………………………………… 154
Installation…………………………………………………………………………………………………. 158
Counterweight SP002409……………………………………………………………………………………………. 161
Safety Instructions…………………………………………………………………………………………… 165
Applicable Models…………………………………………………………………………………………….. 165
General……………………………………………………………………………………………………… 166
Warning for Counterweight and Front Attachment Removal………………………………………………………… 166
Removal……………………………………………………………………………………………………… 168
Installation…………………………………………………………………………………………………. 169
Fuel Tank SP002410……………………………………………………………………………………………….. 171
Safety Instructions…………………………………………………………………………………………… 175
Applicable Models…………………………………………………………………………………………….. 175
General Description…………………………………………………………………………………………… 176
Parts List……………………………………………………………………………………………….. 176
Specifications……………………………………………………………………………………………. 177
Removal……………………………………………………………………………………………………… 178
Installation…………………………………………………………………………………………………. 182
Start-up Procedures…………………………………………………………………………………………… 185
Fuel Transfer Pump (Option) SP002394……………………………………………………………………………….. 187
Safety Instructions…………………………………………………………………………………………… 191
Applicable Models…………………………………………………………………………………………….. 191
General Description…………………………………………………………………………………………… 192
Theory of Operation……………………………………………………………………………………….. 192
Troubleshooting………………………………………………………………………………………………. 194
Replacement of Rotor and Vane………………………………………………………………………………….. 194
Replacement of Rear Cover……………………………………………………………………………………… 195
Replacement of Armature……………………………………………………………………………………….. 195
Swing Bearing SP002329……………………………………………………………………………………………. 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
Lower Structure and Chassis…………………………………………………………………………………………… 207
Track Assembly SP002330…………………………………………………………………………………………… 209
Safety Instructions…………………………………………………………………………………………… 213
Applicable Models…………………………………………………………………………………………….. 213
General Description…………………………………………………………………………………………… 214
Track Tension………………………………………………………………………………………………… 215
Cleaning and Inspection (Wear Limits and Tolerances)……………………………………………………………… 217
Track Shoe……………………………………………………………………………………………….. 218
Lower Roller……………………………………………………………………………………………… 220
Upper Roller……………………………………………………………………………………………… 221
Front Idler………………………………………………………………………………………………. 222
Track Shoes and Links…………………………………………………………………………………………. 223
Track Removal…………………………………………………………………………………………….. 223
Track Installation………………………………………………………………………………………… 224
Front Idler Roller……………………………………………………………………………………………. 226
Parts List……………………………………………………………………………………………….. 226
Front Idler Roller Disassembly……………………………………………………………………………… 227
Front Idler Roller Reassembly………………………………………………………………………………. 229
Lower Roller…………………………………………………………………………………………………. 230
Parts List……………………………………………………………………………………………….. 230
Lower Roller Removal………………………………………………………………………………………. 231
Lower Roller Disassembly…………………………………………………………………………………… 231
Lower Roller Reassembly……………………………………………………………………………………. 232
Lower Roller Installation………………………………………………………………………………….. 233
Upper Roller…………………………………………………………………………………………………. 234
Parts List……………………………………………………………………………………………….. 234
Upper Roller Removal………………………………………………………………………………………. 235
Upper Roller Disassembly…………………………………………………………………………………… 235
Upper Roller Reassembly……………………………………………………………………………………. 237
Track Spring and Track Adjusting Cylinder……………………………………………………………………….. 238
Parts List……………………………………………………………………………………………….. 238
Engine and Drivetrain………………………………………………………………………………………………… 241
Engine Coolant Heater (Option) SP002328…………………………………………………………………………….. 243
Safety Instructions…………………………………………………………………………………………… 247
Applicable Models…………………………………………………………………………………………….. 247
Disassembly and Assembly………………………………………………………………………………………. 248
Changing the Circulating Pump………………………………………………………………………………. 248
Changing the Temperature Limiter……………………………………………………………………………. 250
Changing the Temperature Sensor…………………………………………………………………………….. 251
Changing the Combustion Air Fan…………………………………………………………………………….. 253
Changing the Burner, Flame Monitor and Glow Plug……………………………………………………………… 255
Changing the Burner Head…………………………………………………………………………………… 257
Changing the Heat Exchanger………………………………………………………………………………… 259
Drive Coupling (Main Pump) SP002411………………………………………………………………………………… 261
Safety Instructions…………………………………………………………………………………………… 265
Applicable Models…………………………………………………………………………………………….. 265
Drive Coupling……………………………………………………………………………………………….. 266
Installation of Drive Coupling…………………………………………………………………………………. 267
Installation Procedure…………………………………………………………………………………….. 267
Hydraulics………………………………………………………………………………………………………….. 269
Hydraulic System Troubleshooting, Testing and Adjustment SP002412……………………………………………………… 271
Safety Instructions…………………………………………………………………………………………… 275
Applicable Models…………………………………………………………………………………………….. 275
Hydraulic System – General Notes……………………………………………………………………………….. 276
Hydraulic Schematic…………………………………………………………………………………………… 277
General Notes…………………………………………………………………………………………….. 277
Operation of Working Components………………………………………………………………………………… 279
Boom Operating Circuit…………………………………………………………………………………….. 279
Boom Up Circuit…………………………………………………………………………………………… 279
Boom Down Circuit…………………………………………………………………………………………. 279
Arm Operating Circuit……………………………………………………………………………………… 280
Arm Crowd Circuit…………………………………………………………………………………………. 280
Arm Dump Circuit………………………………………………………………………………………….. 280
Bucket Operating Circuit…………………………………………………………………………………… 281
Bucket Crowd Circuit………………………………………………………………………………………. 281
Bucket Dump Circuit……………………………………………………………………………………….. 281
Swing Operating Circuit……………………………………………………………………………………. 281
Right Swing Operating Circuit………………………………………………………………………………. 282
Left Swing Operating Circuit……………………………………………………………………………….. 282
Swing Relief Valve and Makeup Valve…………………………………………………………………………. 282
Travel Operating Circuit…………………………………………………………………………………… 282
Forward Travel Circuit…………………………………………………………………………………….. 283
Reverse Travel Circuit…………………………………………………………………………………….. 283
Procedural Troubleshooting Baseline Recommendations………………………………………………………………. 284
Initial Checks and Tests to Establish Operating Condition of the Excavator………………………………………. 284
Troubleshooting Recommendations…………………………………………………………………………. 284
Pilot Pressure……………………………………………………………………………………………….. 285
Adjustment and Testing…………………………………………………………………………………….. 285
Pump Swash Plate……………………………………………………………………………………………… 286
Adjustment and Testing…………………………………………………………………………………….. 286
Pump EPPRV…………………………………………………………………………………………………… 287
Adjustment and Testing…………………………………………………………………………………….. 287
Pump Pressure………………………………………………………………………………………………… 288
Adjustment and Testing…………………………………………………………………………………….. 288
Pump Regulator……………………………………………………………………………………………….. 289
Adjustment and Testing…………………………………………………………………………………….. 289
Installation and Testing of Flow Meter and Flow Meter Kit…………………………………………………………. 291
Installation and Testing Procedures…………………………………………………………………………. 291
Swing System Troubleshooting…………………………………………………………………………………… 292
Precautions/Initial Checks…………………………………………………………………………………. 292
Swing Relief Valve Checking and Adjustment…………………………………………………………………… 293
Troubleshooting – Swing Gearbox………………………………………………………………………………… 295
Troubleshooting – Hydraulic Problems……………………………………………………………………………. 296
Troubleshooting – Main Pump……………………………………………………………………………………. 299
Troubleshooting – Control Valve………………………………………………………………………………… 301
Troubleshooting – Travel Control Valve………………………………………………………………………….. 303
Troubleshooting – Joystick Control Valve………………………………………………………………………… 304
Accumulator SP002455……………………………………………………………………………………………… 305
Safety Instructions…………………………………………………………………………………………… 309
Applicable Models…………………………………………………………………………………………….. 309
General Description…………………………………………………………………………………………… 310
Specifications……………………………………………………………………………………………. 312
Center Joint (Swivel) SP002545…………………………………………………………………………………….. 313
Safety Instructions…………………………………………………………………………………………… 317
Applicable Models…………………………………………………………………………………………….. 317
General Description…………………………………………………………………………………………… 319
Center Joint Disassembly Diagram……………………………………………………………………………. 320
Troubleshooting, Testing and Adjustment…………………………………………………………………………. 321
Inspection……………………………………………………………………………………………….. 321
Testing………………………………………………………………………………………………….. 321
Disassembly………………………………………………………………………………………………….. 322
Reassembly…………………………………………………………………………………………………… 325
Cylinders SP002422……………………………………………………………………………………………….. 329
Safety Instructions…………………………………………………………………………………………… 333
Applicable Models…………………………………………………………………………………………….. 333
General Description…………………………………………………………………………………………… 334
Theory of Operation……………………………………………………………………………………….. 334
Parts List……………………………………………………………………………………………….. 336
Special Tools and Materials……………………………………………………………………………………. 342
Piston Nut……………………………………………………………………………………………….. 342
Piston Jig……………………………………………………………………………………………….. 344
Steel Bushing Jig…………………………………………………………………………………………. 347
Dust Wiper Jig……………………………………………………………………………………………. 350
Slipper Seal Jig………………………………………………………………………………………….. 353
Slipper Seal Straightening Jig……………………………………………………………………………… 356
Disassembly………………………………………………………………………………………………….. 359
Reassembly…………………………………………………………………………………………………… 364
Swing Device SP002413…………………………………………………………………………………………….. 369
Safety Instructions…………………………………………………………………………………………… 373
Applicable Models…………………………………………………………………………………………….. 373
Structure and Principle of Operation………………………………………………………………………… 374
Structure…………………………………………………………………………………………….. 374
Principle of Operation…………………………………………………………………………………. 379
Valve Casing………………………………………………………………………………………….. 380
Brake Part……………………………………………………………………………………………. 383
Cautions for Operation…………………………………………………………………………………….. 384
Inspection……………………………………………………………………………………………. 384
Direction of Rotation………………………………………………………………………………….. 384
External Load at the End of Shaft……………………………………………………………………….. 385
Hydraulic Oil and Temperature Range……………………………………………………………………… 385
Filter……………………………………………………………………………………………….. 386
Installation and Piping………………………………………………………………………………… 386
Oil Filling and Air Ventilation…………………………………………………………………………. 387
Cautions before Start Operation…………………………………………………………………………. 387
Troubleshooting…………………………………………………………………………………………… 388
General Caution……………………………………………………………………………………….. 388
Examination of Hydraulic Motor………………………………………………………………………….. 388
Troubleshooting……………………………………………………………………………………….. 389
Disassembly and Reassembly…………………………………………………………………………………. 392
Tightening Torque of Bolts……………………………………………………………………………… 392
Tools for Disassembly and Reassembly…………………………………………………………………….. 392
Remove and Install Swing Device………………………………………………………………………………… 394
Removal………………………………………………………………………………………………….. 394
Remove Swing Motor…………………………………………………………………………………….. 396
Install Swing Motor……………………………………………………………………………………. 396
Installation……………………………………………………………………………………………… 397
Disassemble Swing Motor………………………………………………………………………………… 399
Reassemble Swing Motor…………………………………………………………………………………. 403
Disassemble the Reduction Gear………………………………………………………………………….. 409
Reassemble the Reduction Gear…………………………………………………………………………… 413
Maintenance Guidelines…………………………………………………………………………………….. 420
Replacement Standard of Worn Parts………………………………………………………………………. 420
Standard of Sliding Surface Correction…………………………………………………………………… 421
Travel Device SP002414……………………………………………………………………………………………. 423
Safety Instructions…………………………………………………………………………………………… 427
Applicable Models…………………………………………………………………………………………….. 427
Basic Structure and Drawings……………………………………………………………………………….. 429
Basic Structure of TM Motor…………………………………………………………………………….. 429
Motor (M)…………………………………………………………………………………………….. 430
Reduction Gear (R)…………………………………………………………………………………….. 432
Operation Principle……………………………………………………………………………………….. 434
Reduction Gear………………………………………………………………………………………… 434
Hydraulic Motor (Brake Valve, Parking Brake, High-Low 2- Stage Switching Mechanism)…………………………… 435
Cautions for Operation…………………………………………………………………………………….. 443
Installation Method (refer to the Outline Drawing)………………………………………………………… 443
Pipeline……………………………………………………………………………………………… 443
Hydraulic Oil…………………………………………………………………………………………. 444
Lubricant…………………………………………………………………………………………….. 445
Maintenance/Service……………………………………………………………………………………. 446
Troubleshooting…………………………………………………………………………………………… 446
Maintenance Instructions…………………………………………………………………………………… 448
Jigs and Tools for Assembly and Disassembly………………………………………………………………. 448
Remove and Install Travel Device……………………………………………………………………………….. 451
Removal………………………………………………………………………………………………….. 451
Disassembly………………………………………………………………………………………………. 452
General Cautions for Maintenance Work……………………………………………………………………. 452
Disassembly Sequence…………………………………………………………………………………… 452
Assembly…………………………………………………………………………………………………. 462
General Cautions for Maintenance Work……………………………………………………………………. 462
Assembly Sequence……………………………………………………………………………………… 462
Installation……………………………………………………………………………………………… 479
Matters to Check after Assembly…………………………………………………………………………….. 480
Performance Test………………………………………………………………………………………….. 480
Main Pump SP002415……………………………………………………………………………………………….. 483
Safety Instructions…………………………………………………………………………………………… 487
Applicable Models…………………………………………………………………………………………….. 487
Product description…………………………………………………………………………………………… 488
Performance Description……………………………………………………………………………………. 488
Device Description………………………………………………………………………………………… 488
Assembly of the Axial Piston Unit……………………………………………………………………….. 489
Functional Description…………………………………………………………………………………. 490
Manual Override…………………………………………………………………………………………… 491
Product Identification…………………………………………………………………………………….. 493
Parts List……………………………………………………………………………………………….. 494
Sectional Drawings…………………………………………………………………………………….. 494
Transport and storage…………………………………………………………………………………………. 496
Transporting the Axial Piston Unit………………………………………………………………………….. 496
Transporting with Lifting Device………………………………………………………………………… 497
Storing the Axial Piston Unit………………………………………………………………………………. 498
Installation…………………………………………………………………………………………………. 501
Unpacking………………………………………………………………………………………………… 501
Installation Conditions……………………………………………………………………………………. 502
Installation Position……………………………………………………………………………………… 504
Below-reservoir Installation (Standard)………………………………………………………………….. 504
Installing the Axial Piston Unit……………………………………………………………………………. 506
Dimensions……………………………………………………………………………………………. 508
General Instructions…………………………………………………………………………………… 508
Installation with Coupling……………………………………………………………………………… 509
Mounting on an Engine………………………………………………………………………………….. 510
Completing Assembly……………………………………………………………………………………. 510
Hydraulically Connecting the Axial Piston Unit……………………………………………………………. 512
Commissioning………………………………………………………………………………………………… 518
Initial Commissioning……………………………………………………………………………………… 519
Filling the Axial Piston Unit…………………………………………………………………………… 520
Testing the Hydraulic Fluid Supply………………………………………………………………………. 522
Performing Functional Test……………………………………………………………………………… 522
Performing Flushing Cycle………………………………………………………………………………. 523
Recommissioning After Standstill……………………………………………………………………………. 524
Running-in Phase………………………………………………………………………………………….. 524
Maintenance and repair………………………………………………………………………………………… 525
Cleaning and Care…………………………………………………………………………………………. 525
Inspection……………………………………………………………………………………………….. 526
Maintenance………………………………………………………………………………………………. 526
Repair…………………………………………………………………………………………………… 527
Spare Parts………………………………………………………………………………………………. 527
Decommissioning………………………………………………………………………………………………. 528
Removal and replacement……………………………………………………………………………………….. 528
Required Tools……………………………………………………………………………………………. 528
Preparing for Removal……………………………………………………………………………………… 528
Removing the Axial Piston Unit……………………………………………………………………………… 529
Preparing the Components for Storage or Further Use…………………………………………………………… 529
Troubleshooting………………………………………………………………………………………………. 530
How to Proceed for Troubleshooting………………………………………………………………………….. 530
Malfunction Table…………………………………………………………………………………………. 531
Replacing seals and assembly groups…………………………………………………………………………….. 533
Replacing the Shaft Seal…………………………………………………………………………………… 534
Sealing or Replacing the Gear Pump………………………………………………………………………….. 537
Sealing the Cover of the Power Take-off……………………………………………………………………… 539
Sealing the Port Plate with Valve…………………………………………………………………………… 541
Sealing or Replacing the Pressure Reducing Valve……………………………………………………………… 543
Replacing the Angle Position Sensor…………………………………………………………………………. 545
Replacing Sealing Nuts…………………………………………………………………………………….. 547
Tightening torques……………………………………………………………………………………………. 548
Slotted Screws……………………………………………………………………………………………. 548
Threaded Plugs……………………………………………………………………………………………. 549
Sealing Nuts……………………………………………………………………………………………… 550
Gear Pump (Option) SP002457……………………………………………………………………………………….. 551
Safety Instructions…………………………………………………………………………………………… 555
Applicable Models…………………………………………………………………………………………….. 555
Single Gear Pump……………………………………………………………………………………………… 556
Disassembly………………………………………………………………………………………………. 556
Reassembly……………………………………………………………………………………………….. 558
Double Gear Pump……………………………………………………………………………………………… 562
Disassembly………………………………………………………………………………………………. 562
Reassembly……………………………………………………………………………………………….. 564
Fan Motor for Oil Cooler SP002552………………………………………………………………………………….. 569
Safety Instructions…………………………………………………………………………………………… 573
Applicable Models…………………………………………………………………………………………….. 573
Disassembly………………………………………………………………………………………………….. 575
Assembly…………………………………………………………………………………………………….. 578
Preassemble………………………………………………………………………………………………. 578
Assembling……………………………………………………………………………………………….. 579
Fan Pump SP002553………………………………………………………………………………………………… 581
Safety Instructions…………………………………………………………………………………………… 585
Applicable Models…………………………………………………………………………………………….. 585
View………………………………………………………………………………………………………… 587
ED – Valve……………………………………………………………………………………………….. 587
General Repair Guidelines……………………………………………………………………………………… 588
Sealing Driveshaft……………………………………………………………………………………………. 589
Sealing Control Valve…………………………………………………………………………………………. 591
Disassembly………………………………………………………………………………………………….. 592
Overview…………………………………………………………………………………………………. 592
Remove Rotary Group……………………………………………………………………………………….. 595
Remove Control Device……………………………………………………………………………………… 596
Remove Shaft/Bearings……………………………………………………………………………………… 597
Cleaning and Inspection……………………………………………………………………………………….. 598
Pump Assembly………………………………………………………………………………………………… 601
Adjustment of Taper Roller Bearing……………………………………………………………………………… 603
Taper Roller Bearing Pretension…………………………………………………………………………….. 603
Tools/Auxiliary Tools/ Tightening Torques……………………………………………………………………….. 610
Main Control Valve SP002416……………………………………………………………………………………….. 611
Safety Instructions…………………………………………………………………………………………… 615
Applicable Models…………………………………………………………………………………………….. 615
Functional Description………………………………………………………………………………………… 616
PC-control Concept………………………………………………………………………………………… 616
General………………………………………………………………………………………………. 616
Expanding Consumer Sections (Options)……………………………………………………………………. 617
M9-25 Main Control Block…………………………………………………………………………………… 618
General Information……………………………………………………………………………………….. 620
Function…………………………………………………………………………………………………. 621
General………………………………………………………………………………………………. 621
Pump Strategy…………………………………………………………………………………………. 623
Neutral Circulation……………………………………………………………………………………. 623
Tank and Cooler Valves…………………………………………………………………………………. 624
Summing and Cut Valves…………………………………………………………………………………. 625
Straight Travel Valve………………………………………………………………………………….. 626
Individual Operation…………………………………………………………………………………… 628
Additional Functions………………………………………………………………………………………. 650
Primary Pressure Relief Valve…………………………………………………………………………… 651
Primary Pressure Relief Valve with Pressure Connection Step………………………………………………… 652
Tank Line and Cooler Pre-tensioning……………………………………………………………………… 653
Secondary Pressure Relief and Feed Valve…………………………………………………………………. 654
Anticavitation (Feed) Valve…………………………………………………………………………….. 655
Pilot-controlled Check Valve (Antidrift Valve)……………………………………………………………. 656
Check Function (Supply)………………………………………………………………………………… 657
Shuttle Damping (Optional)……………………………………………………………………………… 659
Part lists…………………………………………………………………………………………………… 660
Control Block M9-1060-00…………………………………………………………………………………… 660
Control Block M9-1060-00 Operation………………………………………………………………………….. 662
Plate MH4WH 25……………………………………………………………………………………………. 663
Combined Relief/Anticavitation Valve, Pilot Operated………………………………………………………….. 664
MHDBN 22 K2-3X/420-380VFC………………………………………………………………………………. 664
MHDBN 22 K2-3X/420-380YVHC-122………………………………………………………………………….. 665
Anticavitation Valve………………………………………………………………………………………. 666
MHSL 02 K10…………………………………………………………………………………………… 666
Specifications……………………………………………………………………………………………….. 667
Troubleshooting, Testing and Adjustment……………………………………………………………………… 667
How to Proceed for Troubleshooting………………………………………………………………………. 667
Malfunction Table……………………………………………………………………………………… 668
Disassembly………………………………………………………………………………………………….. 670
General Repair Instructions………………………………………………………………………………… 670
Repair Instructions……………………………………………………………………………………….. 672
Parts List Control Block……………………………………………………………………………….. 672
Replace Load-holding Valve Spool (Item 130)………………………………………………………………. 672
Replace Plug Screw (Item 132)…………………………………………………………………………… 673
Replace Throttle Check Valve (Item 135, 136) for Semi Priority Boom Vs. Bucket and Swing Vs. Arm……………….. 674
Replace Pilot Control Cartridge MHSL 5.5 (Item 210) for Antidrift-valve Boom and Arm………………………….. 675
Replace Antidrift Valve (Item 140, 141)………………………………………………………………….. 676
Replace Secondary Pressure Relief Valve (Item 202, 208) / Plug Screw (Item 200)………………………………. 677
Replace Load-holding Valve Function Consisting of Poppet (Item 205), Spring (Item 206) and Plug Screw (Item 207)…. 678
Replace Spool Boom Summation (Item 170, Similar With Spool Arm Summation Item 171)……………………………. 679
Replace Main Spool…………………………………………………………………………………….. 680
Replace Pilot Shuttle Valve (Item 163)…………………………………………………………………… 681
Replace Cut Spool (Item 182)……………………………………………………………………………. 683
Replace End Plate (Item 113) and Directional Valve (Item 101)………………………………………………. 684
Replace Inlet Section (Item 220)………………………………………………………………………… 686
Replace Pre-load Valves (Item 20 and 21) for Tank Line and Cooler Back Pressure………………………………. 687
Replace Primary Pressure Relief Valve (Item 222)………………………………………………………….. 688
Replace Check Valves for Primary Pressure Relief (Item 42)…………………………………………………. 689
Replace Straight Travel Valve…………………………………………………………………………… 690
Reassembly…………………………………………………………………………………………………… 691
Unpacking………………………………………………………………………………………………… 693
Coating the Control Block………………………………………………………………………………….. 693
Installation Conditions……………………………………………………………………………………. 694
Required Tools……………………………………………………………………………………………. 694
Assembling the Control Block……………………………………………………………………………….. 694
Mechanically Connecting the Control Block……………………………………………………………………. 695
Hydraulically Connecting the Control Block…………………………………………………………………… 696
Installing the Electrical Supply……………………………………………………………………………. 696
Before First Commissioning…………………………………………………………………………………. 697
Commissioning…………………………………………………………………………………………….. 698
First Commissioning……………………………………………………………………………………. 699
Re-commissioning………………………………………………………………………………………. 700
Operation………………………………………………………………………………………………… 700
Maintenance and Repair…………………………………………………………………………………….. 701
Definition……………………………………………………………………………………………. 703
Inspection and Maintenance……………………………………………………………………………… 703
Repair……………………………………………………………………………………………….. 706
Spare Parts…………………………………………………………………………………………… 706
PRV (Peak Reducing Valve) SP002459…………………………………………………………………………………. 709
Safety Instructions…………………………………………………………………………………………… 713
Applicable Models…………………………………………………………………………………………….. 713
Instruction Manual……………………………………………………………………………………………. 714
General………………………………………………………………………………………………….. 714
Outer Appearance and the Ports of Valve………………………………………………………………….. 714
Principal Components and Functions………………………………………………………………………….. 715
Explanation of Operation……………………………………………………………………………….. 716
Relief Pressure……………………………………………………………………………………….. 716
Adjustment……………………………………………………………………………………………….. 716
Installation……………………………………………………………………………………………… 717
Hydraulic Oil…………………………………………………………………………………………….. 717
Guide for External Oil Leakage……………………………………………………………………………… 717
Repair Manual………………………………………………………………………………………………… 718
Necessary Tools and Jigs…………………………………………………………………………………… 718
Tools………………………………………………………………………………………………… 718
Jigs…………………………………………………………………………………………………. 718
Cautions During Disassembling and Assembling…………………………………………………………………. 719
Cautions for Disassembling……………………………………………………………………………… 719
Cautions for Assembling………………………………………………………………………………… 719
Disassembling Procedure……………………………………………………………………………………. 720
Exchange of O-ring (Surface of Pump Installation)…………………………………………………………. 720
Exchange of O-ring (Surface of Pilot Valve Ass’y Installation)……………………………………………… 721
Exchange of O-ring and Backup Ring (Part of Main Valve Ass’y)………………………………………………. 722
Disassembling Procedure of Pilot Valve Ass’y (Excluding Adjusting Screw Part)………………………………… 723
Assembling Procedure………………………………………………………………………………………. 724
Sensor Block SP002460…………………………………………………………………………………………….. 725
Safety Instructions…………………………………………………………………………………………… 729
Applicable Models…………………………………………………………………………………………….. 729
Instruction Manual……………………………………………………………………………………………. 730
General………………………………………………………………………………………………….. 730
Outer Appearance and the Ports of Valve………………………………………………………………….. 730
Components and Functions…………………………………………………………………………………… 732
Explanation of Operation……………………………………………………………………………….. 732
Installation……………………………………………………………………………………………… 733
Hydraulic Oil…………………………………………………………………………………………….. 733
Guide for External Oil Leakage……………………………………………………………………………… 733
Repair Manual………………………………………………………………………………………………… 734
Necessary Tools and Jigs…………………………………………………………………………………… 734
Tools………………………………………………………………………………………………… 734
Cautions during Disassembling and Assembling…………………………………………………………………. 734
Cautions for Disassembling……………………………………………………………………………… 734
Cautions for Assembling………………………………………………………………………………… 734
Disassembling Procedure (Shuttle Valve Parts)………………………………………………………………… 735
Assembling Procedure………………………………………………………………………………………. 735
Remote Control Valve (Work Lever / Joystick) SP002450………………………………………………………………… 737
Safety Instructions…………………………………………………………………………………………… 741
Applicable Models…………………………………………………………………………………………….. 741
General Description…………………………………………………………………………………………… 743
Theory of Operation……………………………………………………………………………………….. 743
Structure…………………………………………………………………………………………….. 743
Function……………………………………………………………………………………………… 743
Parts List……………………………………………………………………………………………….. 744
Specifications……………………………………………………………………………………………. 746
Performance…………………………………………………………………………………………… 746
Torques………………………………………………………………………………………………….. 746
Tools and Materials…………………………………………………………………………………………… 746
Disassembly………………………………………………………………………………………………….. 747
Reassembly…………………………………………………………………………………………………… 750
Start-up Procedures…………………………………………………………………………………………… 758
Travel Control Valve (with Damper) SP002381…………………………………………………………………………. 759
Safety Instructions…………………………………………………………………………………………… 763
Applicable Models…………………………………………………………………………………………….. 763
General Description…………………………………………………………………………………………… 764
Theory of Operation……………………………………………………………………………………….. 764
Pressure Reducing Valve……………………………………………………………………………………. 765
Operating Theory of Damper Mechanism………………………………………………………………………… 766
Causes of Faults and Measures………………………………………………………………………………….. 767
Parts List……………………………………………………………………………………………….. 768
Specification…………………………………………………………………………………………….. 770
Torques………………………………………………………………………………………………….. 770
Removal……………………………………………………………………………………………………… 771
Disassembly………………………………………………………………………………………………….. 774
Cleaning and Inspection (Wear Limits and Tolerances)……………………………………………………………… 776
Reassembly…………………………………………………………………………………………………… 777
Installation…………………………………………………………………………………………………. 782
Start-up Procedures…………………………………………………………………………………………… 785
Solenoid Valve Assembly SP002406…………………………………………………………………………………… 787
Safety Instructions…………………………………………………………………………………………… 791
Applicable Models…………………………………………………………………………………………….. 791
5-Solenoid Valve……………………………………………………………………………………………… 792
Parts List……………………………………………………………………………………………….. 792
Functions of 5-Solenoid Valve Assembly………………………………………………………………………. 793
Assembly Diagram and Tools Required…………………………………………………………………………. 794
Cautions During Disassembly and Reassembly…………………………………………………………………… 795
Solenoid Valve Diagram…………………………………………………………………………………….. 796
Check Points and Solutions for Problems……………………………………………………………………… 797
Breaker EPPR Valve (Option) SP002458……………………………………………………………………………….. 799
Safety Instructions…………………………………………………………………………………………… 803
Applicable Models…………………………………………………………………………………………….. 803
Structure……………………………………………………………………………………………………. 804
Parts List……………………………………………………………………………………………….. 804
Functions and Operation……………………………………………………………………………………….. 805
Cautions for Operation………………………………………………………………………………………… 805
Maintenance Instructions………………………………………………………………………………………. 806
Maintenance………………………………………………………………………………………………. 806
Disassembly………………………………………………………………………………………………. 807
Assembly…………………………………………………………………………………………………. 808
Hydraulic Schematic SP002417………………………………………………………………………………………. 811
Safety Instructions…………………………………………………………………………………………… 815
Applicable Models…………………………………………………………………………………………….. 815
DX340LC-3/DX350LC-3/DX380LC-3………………………………………………………………………………….. 817
Electrical System……………………………………………………………………………………………………. 819
Electrical System SP002418………………………………………………………………………………………… 821
Safety Instructions…………………………………………………………………………………………… 827
Applicable Models…………………………………………………………………………………………….. 827
Introduction…………………………………………………………………………………………………. 828
Electrical Wire Color……………………………………………………………………………………… 828
Electrical Supply System………………………………………………………………………………………. 830
Engine Starting Circuit……………………………………………………………………………………….. 832
Start Operation…………………………………………………………………………………………… 832
After Start………………………………………………………………………………………………. 834
Operation of the Start Circuit (2) – Immediately After Start……………………………………………….. 835
Engine Preheating System………………………………………………………………………………………. 836
Engine Stop………………………………………………………………………………………………….. 838
Charging System………………………………………………………………………………………………. 840
Monitoring System…………………………………………………………………………………………….. 841
Instrument Panel………………………………………………………………………………………….. 842
Functional Check………………………………………………………………………………………….. 842
Monitoring System Schematic………………………………………………………………………………… 844
Operation……………………………………………………………………………………………………. 846
Instruments………………………………………………………………………………………………. 846
Warning and Indicator Lights…………………………………………………………………………………… 848
Indication of Warning Lights……………………………………………………………………………….. 848
Indication of Multifunction Gauge…………………………………………………………………………… 851
Initial Operation…………………………………………………………………………………………….. 853
Graphic Information Area Display……………………………………………………………………………….. 854
Overview…………………………………………………………………………………………………. 854
Main Menus for the Graphic Display Area……………………………………………………………………… 854
Menu Selector Buttons……………………………………………………………………………………… 854
User Menu……………………………………………………………………………………………………. 855
User Menu – Access and Escape Methods……………………………………………………………………….. 855
Access Method…………………………………………………………………………………………. 855
Escape Method…………………………………………………………………………………………. 855
User Menu…………………………………………………………………………………………….. 855
Special Menu…………………………………………………………………………………………………. 887
Entering/Accessing and Exiting/Escaping Menus………………………………………………………………… 887
Entering/Accessing Menus……………………………………………………………………………….. 887
Exiting/Escaping Menus…………………………………………………………………………………. 888
Special Menu Selections……………………………………………………………………………………. 888
Monitoring……………………………………………………………………………………………. 888
Graph………………………………………………………………………………………………… 895
Failure Information……………………………………………………………………………………. 896
FMIs (Failure Mode Identifier)………………………………………………………………………….. 906
Information of Machine Operation………………………………………………………………………… 907
Vehicle Configuration………………………………………………………………………………….. 910
Electronic Hydraulic Control System (e-EPOS)…………………………………………………………………….. 914
Control System Schematic…………………………………………………………………………………… 914
Power Plus Mode Control……………………………………………………………………………………….. 916
Operation………………………………………………………………………………………………… 918
1. Power Plus Mode…………………………………………………………………………………….. 918
2. Power Mode, Standard Mode, Economy Mode……………………………………………………………….. 919
Power Mode Control – Circuit Diagram……………………………………………………………………………. 920
Engine Control System…………………………………………………………………………………………. 922
Engine Control Dial…………………………………………………………………………………………… 923
Engine Control Circuit Diagram…………………………………………………………………………………. 924
Automatic Deceleration Control (Auto Idle Control)……………………………………………………………….. 926
Engine Overheat Protection System………………………………………………………………………………. 928
Power Boost Mode……………………………………………………………………………………………… 930
Operation………………………………………………………………………………………………… 930
Power Boost Control – Circuit Diagram……………………………………………………………………….. 932
Automatic Travel Speed Control…………………………………………………………………………………. 934
Automatic Travel Speed Control – Circuit Diagram……………………………………………………………… 936
Self-diagnostic Function………………………………………………………………………………………. 937
e-EPOS Controller…………………………………………………………………………………………. 937
Air Conditioner System………………………………………………………………………………………… 939
Outline………………………………………………………………………………………………….. 939
Internal and External Filters………………………………………………………………………………. 940
How to Check Internal Air Filter………………………………………………………………………… 940
How to Check External Air Filter………………………………………………………………………… 940
Air-Conditioning System Layout……………………………………………………………………………… 942
Air Conditioner/heater Circuit Diagram………………………………………………………………………. 943
Air Conditioner/heater Unit………………………………………………………………………………… 944
Airflow Diagram……………………………………………………………………………………….. 944
Door Open by Vent Modes………………………………………………………………………………… 945
Main Components……………………………………………………………………………………….. 945
Actuator – Airflow Direction Control…………………………………………………………………….. 946
Actuator – Temperature Control………………………………………………………………………….. 946
Actuator – Internal/External Air Exchange………………………………………………………………… 947
Airflow Control Module…………………………………………………………………………………. 947
Ambient Air Temperature Sensor……………………………………………………………………………… 949
Sun Sensor……………………………………………………………………………………………….. 950
Control Panel…………………………………………………………………………………………….. 950
Appearance and Terminal Arrangement……………………………………………………………………… 950
Terminal Terms………………………………………………………………………………………… 951
Control Logic…………………………………………………………………………………………. 952
Self Diagnosis………………………………………………………………………………………… 956
Ambient Temperature Display…………………………………………………………………………….. 957
Compressor……………………………………………………………………………………………….. 958
Receiver Dryer……………………………………………………………………………………………. 958
Troubleshooting………………………………………………………………………………………………. 959
Refrigerant Pressure Check…………………………………………………………………………………. 959
Weight of R134a Gas Used In Machines……………………………………………………………………………. 961
Refrigerant System Repairs…………………………………………………………………………………….. 962
Refrigerant Safe Handling Procedures………………………………………………………………………… 962
Repair and Replacement Procedure……………………………………………………………………………. 963
Refrigerant Recovery………………………………………………………………………………………. 965
Vacuuming Refrigerant System……………………………………………………………………………….. 965
Leakage Check…………………………………………………………………………………………….. 967
Refrigerant Charging………………………………………………………………………………………. 967
Inspecting System For Leakage………………………………………………………………………………. 969
Wiper System…………………………………………………………………………………………………. 970
Wiper Circuit…………………………………………………………………………………………….. 970
Wiper operation…………………………………………………………………………………………… 971
Continuous operation…………………………………………………………………………………… 971
Intermittent operation…………………………………………………………………………………. 971
Lighting System………………………………………………………………………………………………. 974
Lighting System Circuit Diagram…………………………………………………………………………….. 974
Kind of Light…………………………………………………………………………………………….. 975
Operation………………………………………………………………………………………………… 975
Overload Warning Device……………………………………………………………………………………….. 976
Overload Warning Device Circuit Diagram……………………………………………………………………… 976
Audio Controller……………………………………………………………………………………………… 977
Audio Controller Circuit Diagram……………………………………………………………………………. 977
Operations Via Audio Control Panel………………………………………………………………………. 977
Electrical Schematic SP002419……………………………………………………………………………………… 979
Safety Instructions…………………………………………………………………………………………… 983
Applicable Models…………………………………………………………………………………………….. 983
DX340LC-3/DX350LC-3/DX380LC-3 (1/2)…………………………………………………………………………….. 985
DX340LC-3/DX350LC-3/DX380LC-3 (2/2)…………………………………………………………………………….. 987
Attachments…………………………………………………………………………………………………………. 989
Boom and Arm SP002420…………………………………………………………………………………………….. 991
Safety Instructions…………………………………………………………………………………………… 995
Applicable Models…………………………………………………………………………………………….. 995
Front Attachment Pin Specifications…………………………………………………………………………….. 996
DX340LC-3/DX350LC-3……………………………………………………………………………………….. 997
Front Attachment – Removal and Installation……………………………………………………………………… 998
Arm Removal Procedure……………………………………………………………………………………… 998
Boom Removal Procedure……………………………………………………………………………………..1000
Installation………………………………………………………………………………………………….1001
Arm Installation Procedure………………………………………………………………………………….1001
Boom Installation Procedure…………………………………………………………………………………1001
Start-up Procedures……………………………………………………………………………………………1002
Bucket SP002421…………………………………………………………………………………………………..1003
Safety Instructions……………………………………………………………………………………………1007
Applicable Models……………………………………………………………………………………………..1007
Bucket Tooth Inspection and Replacement………………………………………………………………………….1008
Bucket O-ring Replacement………………………………………………………………………………………1009
Bucket Shimming Procedures……………………………………………………………………………………..1011
New Bucket Installation…………………………………………………………………………………….1011
Shimming Procedures for Installed Bucket………………………………………………………………….1012
Attachments…………………………………………………………………………………………………..1013
Bucket Replacement and Reversal……………………………………………………………………………..1013
Replacement……………………………………………………………………………………………….1014
Reversal………………………………………………………………………………………………….1015
Quick Coupler Operation (Optional)…………………………………………………………………………..1016
Securing Work Tool……………………………………………………………………………………..1016
Attaching Quick Coupler to Excavator……………………………………………………………………..1016
Releasing the Work Tool…………………………………………………………………………………1018
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
R.D