Doosan DX62R 3 DX63 3 Excavator Shop Manual – PDF DOWNLOAD
DESCRIPTION:
Doosan DX62R 3 DX63 3 Excavator Shop Manual – PDF DOWNLOAD
August 2015
- Safe Operation is Operator’s Responsibility Only trained and authorized personnel should operate and maintain the machine. Follow all safety rules, regulations and instructions when operating or performing maintenance on machine.
- • Do not operate machine if you are under the influence of drugs or alcohol. An operator who is taking prescription drugs must get medical advice to determine if he or she can safely operate a machine.
- • When working with other personnel on a work site, be sure that all personnel know nature of work and understand all hand signals that are to be used. • Be sure that all guards and shields are installed in their proper location. Have guards and shields repaired or replaced immediately if damaged.
- • Be sure that you understand the use and maintenance of all safety features such as safety lock lever and seat belt. Use them properly.
- • Never remove, modify or disable any safety features. Always keep them in good operating condition.
- • Always check for and know the location of underground and overhead utility lines before excavating.
- • Failure to use and maintain safety features according to instructions in this manual, Safety Manual and Shop Manual can result in death or serious injury.
- Know Your Machine Know how to operate your machine. Know the purpose of all controls, gauges, signals, indicators and monitor displays. Know the rated load capacity, speed range, braking and steering characteristics, turning radius and operating clearances.
- Keep in mind that rain, snow, ice, loose gravel, soft ground, slopes etc., can change operating capabilities of your machine. Track Excavator Maintenance Safety Proper Work Tools and Attachments Only use work tools and attachments that are recommended by DOOSAN for use on DOOSAN machines. When installing and using optional attachments, read instruction manual for attachment, and general information related to attachments in this manual.
- Because DOOSAN cannot anticipate, identify or test all attachments that owners may want to install on their machines, contact DOOSAN for written authorization and approval of attachments, and their compatibility with optional kits. Attachments and attachment control systems that are compatible with the machine are required for safe and reliable machine operation.
- Do not exceed maximum operating weight (machine weight plus attachment) that is listed on ROPS certification plate.
- Make sure that all guards and shields are in place on machine and on work tool. Depending on type or combination of work equipment, there is a potential that work equipment could interfere with the cabin or other parts of machine. Before using unfamiliar work equipment, check if there is any potential of interference, and operate with caution.
- While you are performing any maintenance, testing, or adjustments to attachments, stay clear of the following areas: cutting edges, pinch points, and crushing surfaces. Never use attachment as a work platform or manlift. Contact your DOOSAN distributor about auxiliary hydraulic kits for attachments installation.
- If you are in doubt about compatibility of a particular attachment with a machine, consult your DOOSAN distributor. Pressurized Fluids Pressurized air or fluids can cause debris and/or fluids to be blown out. This could result in death or serious injury.
- Immediately after operations are stopped, coolant, engine oil, and hydraulic oil are at their highest temperatures and the radiator and hydraulic tank are still under pressure. Always wait for temperature to cool down.
- Follow specified procedures when attempting to remove caps, drain oil or coolant, or replacing filters. Always wait for temperature to cool down, and follow specified procedures when performing these operations. Failure to do so can result in death or serious injury.
- When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield. Pressure can be trapped in a hydraulic system and must be relieved before maintenance is started.
- Releasing trapped pressure can cause sudden machine movement or attachment movement. Use caution if you disconnect hydraulic lines or fittings. High-pressure oil that is released can cause a hose to whip or oil to spray. Fluid penetration can result in death or serious injury.
- If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury. Obey all local laws and regulations for disposal of liquids. To prevent hot coolant from spraying out, stop engine and wait for coolant to cool. Using gloves, slowly loosen cap to relieve pressure.
TABLE OF CONTENTS:
Doosan DX62R 3 DX63 3 Excavator Shop Manual – PDF DOWNLOAD
DX62R-3/DX63-3……………………………………………………………………………….. 0
Table of Contents…………………………………………………………………………. 7
Safety…………………………………………………………………………………… 9
Track Excavator Maintenance Safety SP003041………………………………………………. 11
Safety Instructions………………………………………………………………… 15
Applicable Models………………………………………………………………….. 15
Safety Messages……………………………………………………………………. 16
Signal Words…………………………………………………………………… 16
Other Signal Words……………………………………………………………… 17
Safety Decals……………………………………………………………………… 17
General…………………………………………………………………………… 18
Safe Operation is Operator’s Responsibility……………………………………….. 18
Know Your Machine………………………………………………………………. 18
Proper Work Tools and Attachments………………………………………………… 19
Pressurized Fluids……………………………………………………………… 19
Flying or Falling Objects……………………………………………………….. 20
Personal Protective Equipment (PPE)………………………………………………. 21
Correction of Machine Problems…………………………………………………… 21
Crushing and Cutting……………………………………………………………. 21
Hot Coolant and Oils – Burn Prevention……………………………………………. 22
Fire and Explosion Prevention……………………………………………………. 23
Maintenance………………………………………………………………… 23
Operation………………………………………………………………….. 23
Electrical…………………………………………………………………. 24
Hydraulic System……………………………………………………………. 24
Fueling……………………………………………………………………. 25
Never Use Ether Starting Aids………………………………………………… 25
Welding and Grinding………………………………………………………… 25
If a Fire Occurs……………………………………………………………. 26
Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)…………………………. 26
Electrical System and Electrical Shock……………………………………………. 27
Roll-over Protective Structure (ROPS)…………………………………………….. 27
Protecting Cabin from Flying or Falling Objects (Optional)………………………. 29
Emergency Exit from Operator’s Station………………………………………… 30
Transportation…………………………………………………………………….. 31
Obey State and Local Over-the-Road Regulations…………………………………….. 31
Loading and Unloading…………………………………………………………… 31
Transporting Machine……………………………………………………………. 32
Operation…………………………………………………………………………. 33
Before Engine Starting………………………………………………………….. 33
Machine Condition…………………………………………………………… 33
Work Site……………………………………………………………………… 34
Mounting/Dismounting……………………………………………………………. 34
Cleaning………………………………………………………………………. 35
Operator Station……………………………………………………………….. 35
Seat Belt……………………………………………………………………… 36
Visibility Information………………………………………………………….. 37
Work Site Rules…………………………………………………………….. 38
Boost Starting or Charging Battery……………………………………………….. 38
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
Check After Long-term Parking………………………………………………… 48
Maintenance……………………………………………………………………….. 49
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
Waste Hazardous to the Environment……………………………………………. 57
Check List After Fire……………………………………………………….. 57
Welding Repairs………………………………………………………………… 58
Preparation for Electrical Welding On Body Structure……………………………. 59
Warning for Counterweight and Front Attachment Removal……………………………… 60
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
Battery Hazard Prevention……………………………………………………. 64
Environment and Circumstances……………………………………………………….. 66
Work Site Areas Requiring Extra Caution…………………………………………… 66
Digging Under an Overhang……………………………………………………. 66
Deep Digging……………………………………………………………….. 66
Drop-off or Edge……………………………………………………………. 67
Poor Visibility…………………………………………………………….. 67
Loose or Soft Ground………………………………………………………… 67
High-voltage Cables…………………………………………………………….. 68
Underground Operation…………………………………………………………… 69
Working in Water……………………………………………………………….. 69
Working in Contaminated Environment………………………………………………. 69
Operation in Extreme Conditions………………………………………………….. 70
Operation In Extreme Cold……………………………………………………. 70
Operation in Extreme Heat……………………………………………………. 71
Operation In Dusty and Sandy Areas……………………………………………. 72
Operation in Rainy or Humid Conditions………………………………………… 72
Operation in Saltwater Areas…………………………………………………. 73
Operation at High Altitudes………………………………………………….. 73
Operation During Electrical Storms……………………………………………. 73
Exhaust Ventilation…………………………………………………………….. 74
Ventilation for Enclosed Area………………………………………………… 74
Asbestos Information……………………………………………………………. 74
Silica Dust Information…………………………………………………………. 75
Disposal of Hazardous Materials………………………………………………….. 75
Sound…………………………………………………………………………. 76
Vibration……………………………………………………………………… 76
Specifications……………………………………………………………………………. 77
Specification for DX62R-3/DX63-3 SP003042………………………………………………… 79
Safety Instructions………………………………………………………………… 83
Applicable Models………………………………………………………………….. 83
General Description………………………………………………………………… 85
Component Locations………………………………………………………………… 86
DX62R-3/DX63-3 (Europe)…………………………………………………………. 86
DX63-3 (North America)………………………………………………………….. 88
General Dimensions…………………………………………………………………. 90
DX62R-3/DX63-3 (Europe)…………………………………………………………. 90
DX63-3 (North America)………………………………………………………….. 92
Working Range……………………………………………………………………… 94
DX62R-3/DX63-3 (Europe)…………………………………………………………. 94
DX63-3 (North America)………………………………………………………….. 96
General Specifications……………………………………………………………… 98
DX62R-3/DX63-3 (Europe)…………………………………………………………. 98
DX63-3 (North America)………………………………………………………….. 100
Engine Performance Curves (Per DIN 6270 Standard)……………………………………… 102
DX62R-3/DX63-3 (Europe)…………………………………………………………. 102
DX63-3 (North America)………………………………………………………….. 104
Approximate Weight of Workload Materials……………………………………………… 105
Performance Tests………………………………………………………………….. 107
Excavator Performance Standards……………………………………………………… 108
Test Conditions………………………………………………………………… 108
Travel Speed and Travel Motor Balance (Steering Deviation) Tests…………………….. 108
Speed Test…………………………………………………………………. 108
Travel Deviation……………………………………………………………. 109
Swing Speed and Deceleration Force Test…………………………………………… 110
Swing Speed Test……………………………………………………………. 110
Swing Deceleration Force Test………………………………………………… 110
Cylinder Performance Tests………………………………………………………. 111
Hydraulic Cylinder………………………………………………………….. 111
Boom Cylinders Test…………………………………………………………. 111
Arm Cylinder Test…………………………………………………………… 111
Bucket Cylinder Test………………………………………………………… 111
Hydraulic Cylinder Natural Drop Test………………………………………….. 111
Travel Motor Jack-up Test……………………………………………………. 111
General Maintenance……………………………………………………………………….. 113
General Maintenance Instructions SP002454………………………………………………… 115
Safety Instructions………………………………………………………………… 119
Applicable Models………………………………………………………………….. 119
Welding Precautions and Instructions…………………………………………………. 120
Hydraulic System – General Precautions……………………………………………….. 121
Maintenance Service and Repair Procedure……………………………………………… 123
General Precautions…………………………………………………………….. 123
Hydraulic System Cleanliness and Oil Leaks……………………………………………. 124
Maintenance Precautions for Hydraulic System Service……………………………….. 124
Oil Leakage Precautions…………………………………………………………. 125
Cleaning and Inspection…………………………………………………………….. 126
General Instructions……………………………………………………………. 126
Bearing Inspection……………………………………………………………… 127
Standard Torques………………………………………………………………………. 135
Safety Instructions………………………………………………………………… 139
Applicable Models………………………………………………………………….. 139
Torque Values for Standard Metric Fasteners…………………………………………… 140
Torque Values for Standard U.S. Fasteners…………………………………………….. 141
Type 8 Phosphate Coated Hardware…………………………………………………….. 143
Torque Values for Hose Clamps……………………………………………………….. 144
ORFS Swivel Nut Recommended Torque…………………………………………………… 144
Torque Values for Split Flanges……………………………………………………… 145
Torque Wrench Extension Tools……………………………………………………….. 146
Torque Multiplication…………………………………………………………… 146
Other Uses for Torque Wrench Extension Tools………………………………………. 147
Tightening Torque Specifications (Metric)…………………………………………. 148
Upper Structure…………………………………………………………………………… 151
Cabin SP003058………………………………………………………………………… 153
Safety Instructions………………………………………………………………… 157
Applicable Models………………………………………………………………….. 157
Cabin Identification……………………………………………………………….. 158
Roll-over Protective Structure (ROPS)…………………………………………….. 158
Installation………………………………………………………………………. 165
Swing Bearing SP003010…………………………………………………………………. 169
Safety Instructions………………………………………………………………… 173
Applicable Models………………………………………………………………….. 173
Swing Bearing Maintenance…………………………………………………………… 174
Operating Recommendation………………………………………………………… 174
Measuring Swing Bearing Axial Play……………………………………………….. 174
Measuring Bearing Lateral Play…………………………………………………… 174
Swing Bearing Basic Operation……………………………………………………. 175
Disassembly……………………………………………………………………. 175
Assembly………………………………………………………………………. 177
Lower Structure and Chassis………………………………………………………………… 179
Track Assembly SP003043………………………………………………………………… 181
Safety Instructions………………………………………………………………… 185
Applicable Models………………………………………………………………….. 185
Tracks……………………………………………………………………………. 186
Specification and Construction…………………………………………………… 186
Track Tension……………………………………………………………………… 187
Cleaning and Inspection (Wear Limits and Tolerances)…………………………………… 190
Rubber Track…………………………………………………………………… 191
Steel Track……………………………………………………………………. 192
Track Frame Spring……………………………………………………………… 193
Idler…………………………………………………………………………. 194
Lower Roller………………………………………………………………………. 196
Steel Track……………………………………………………………………. 196
Upper Roller…………………………………………………………………… 198
Sprocket………………………………………………………………………. 199
Idler…………………………………………………………………………….. 200
Disassembly……………………………………………………………………. 201
Reassembly…………………………………………………………………….. 201
Lower Roller………………………………………………………………………. 202
Steel Track……………………………………………………………………. 202
Rubber Track…………………………………………………………………… 203
Disassembly……………………………………………………………………. 204
Reassembly…………………………………………………………………….. 204
Upper Roller………………………………………………………………………. 205
Parts List…………………………………………………………………….. 205
Disassembly……………………………………………………………………. 206
Reassembly…………………………………………………………………….. 206
Track Removal and Installation………………………………………………………. 207
Track Removal………………………………………………………………….. 207
Track Installation……………………………………………………………… 208
Replacement of Rubber Tracks with Steel Tracks…………………………………….. 209
Replacement of Steel Tracks with Rubber Tracks…………………………………….. 210
Track Tension Adjusting Cylinder…………………………………………………….. 211
Parts List…………………………………………………………………….. 211
Disassembly……………………………………………………………………. 212
Reassembly…………………………………………………………………….. 212
Sprocket………………………………………………………………………….. 213
Disassembly……………………………………………………………………. 213
Reassembly…………………………………………………………………….. 213
Engine and Drivetrain……………………………………………………………………… 215
Engine (Europe) SP003057……………………………………………………………….. 217
Safety Instructions………………………………………………………………… 223
Applicable Models………………………………………………………………….. 223
General Service Information…………………………………………………………. 225
Component Identification………………………………………………………… 225
Location of Labels……………………………………………………………… 226
Engine Nameplate (Typical)…………………………………………………… 226
Function of Major Engine Components………………………………………………. 227
Diesel Fuel……………………………………………………………………. 228
Diesel Fuel Specifications…………………………………………………… 228
Filling The Fuel Tank……………………………………………………….. 230
Priming the Fuel System……………………………………………………… 231
Engine Oil…………………………………………………………………….. 232
Engine Oil Specifications……………………………………………………. 232
Engine Oil Viscosity………………………………………………………… 233
Checking Engine Oil…………………………………………………………. 233
Adding Engine Oil…………………………………………………………… 233
Engine Coolant…………………………………………………………………. 234
Engine Coolant Specifications………………………………………………… 235
Filling Radiator with Engine Coolant………………………………………….. 235
Engine Coolant Capacity (Typical)…………………………………………….. 236
Specifications…………………………………………………………………. 237
Description of Model Number………………………………………………….. 237
Engine Speed Specifications………………………………………………….. 237
Engine General Specifications………………………………………………… 238
Principal Engine Specifications………………………………………………….. 239
Engine Service Standards………………………………………………………… 240
Tightening Torques for Standard Bolts and Nuts…………………………………….. 241
Periodic Maintenance……………………………………………………………….. 243
Before You Begin Servicing………………………………………………………. 243
Introduction…………………………………………………………………… 243
The Importance of Periodic Maintenance………………………………………… 243
Performing Periodic Maintenance………………………………………………. 243
DOOSAN Replacement Parts…………………………………………………….. 243
Periodic Maintenance Schedule……………………………………………………. 244
Periodic Maintenance Procedures………………………………………………….. 246
After Initial 50 Hours of Operation…………………………………………… 246
Every 50 Hours of Operation………………………………………………….. 250
Every 250 Hours of Operation…………………………………………………. 254
Every 500 Hours of Operation…………………………………………………. 259
Every 1,000 Hours of Operation……………………………………………….. 263
Every 1,500 Hours of Operation……………………………………………….. 266
Every 2,000 Hours of Operation……………………………………………….. 268
Engine……………………………………………………………………………. 269
Before You Begin Servicing………………………………………………………. 269
Introduction…………………………………………………………………… 269
Cylinder Head Specifications…………………………………………………….. 269
Adjustment Specifications……………………………………………………. 269
Cylinder Head………………………………………………………………. 269
Intake/Exhaust Valve and Guide……………………………………………….. 270
Push Rod…………………………………………………………………… 270
Valve Spring……………………………………………………………….. 270
Rocker Arm and Shaft………………………………………………………… 270
Camshaft and Timing Gear Train Specifications……………………………………… 271
Camshaft…………………………………………………………………… 271
Idler Gear Shaft and Bushing…………………………………………………. 271
Timing Gear Backlash………………………………………………………… 271
Crankshaft and Piston Specifications……………………………………………… 272
Crankshaft…………………………………………………………………. 272
Thrust Bearing……………………………………………………………… 272
Piston…………………………………………………………………….. 272
Piston Ring………………………………………………………………… 273
Connecting Rod……………………………………………………………… 273
Tappet…………………………………………………………………….. 274
Cylinder Block Specifications……………………………………………………. 274
Cylinder Block……………………………………………………………… 274
Special Torque Chart……………………………………………………………. 275
Torque for Bolts and Nuts……………………………………………………. 275
Special Service Tools…………………………………………………………… 276
Measuring Instruments…………………………………………………………… 279
2-Valve Cylinder Head…………………………………………………………… 282
2-Valve Cylinder Head Components……………………………………………… 282
Disassembly of 2-Valve Cylinder Head………………………………………….. 284
Cleaning of Cylinder Head Components………………………………………….. 287
Inspection of Cylinder Head Components………………………………………… 288
Reassembly of Cylinder Head………………………………………………….. 293
4-Valve Cylinder Head…………………………………………………………… 298
4-Valve Cylinder Head Components……………………………………………… 298
Disassembly of 4-Valve Cylinder Head………………………………………….. 300
Cleaning of Cylinder Head Components………………………………………….. 304
Inspection of Cylinder Head Components………………………………………… 304
Inspection of Push Rods……………………………………………………… 305
Inspection of Rocker Arm Assembly…………………………………………….. 305
Inspection of Valve Guides…………………………………………………… 306
Inspection of Cylinder Head………………………………………………….. 306
Inspection of Intake and Exhaust Valves……………………………………….. 306
Reassembly of Cylinder Head………………………………………………….. 310
Measuring and Adjusting Valve Clearance…………………………………………… 315
2-Valve Cylinder Heads………………………………………………………. 316
4-Valve Cylinder Heads………………………………………………………. 317
Crankshaft and Camshaft Components……………………………………………….. 320
Disassembly of Engine……………………………………………………….. 322
Disassembly of Camshaft and Timing Components………………………………….. 323
Disassembly of Crankshaft and Piston Components………………………………… 328
Inspection of Crankshaft and Camshaft Components……………………………….. 332
Honing and Boring…………………………………………………………… 338
Reassembly of Crankshaft and Piston Components…………………………………. 339
Reassembly of Camshaft and Timing Components…………………………………… 345
Final Reassembly of Engine…………………………………………………… 348
Fuel System……………………………………………………………………….. 349
Before You Begin Servicing………………………………………………………. 349
Introduction…………………………………………………………………… 349
Fuel Injection Pump…………………………………………………………. 349
Stop Solenoid………………………………………………………………. 350
Cold Start Device…………………………………………………………… 351
Trochoid Fuel Pump………………………………………………………….. 351
Fuel System Specifications………………………………………………………. 352
Special Torque Chart………………………………………………………… 352
Test and Adjustment Specifications……………………………………………. 352
Special Service Tools…………………………………………………………… 352
Measuring Instruments…………………………………………………………… 353
Fuel System Diagram…………………………………………………………….. 354
Fuel System Components………………………………………………………….. 356
2-Valve Cylinder Head……………………………………………………….. 356
4-Valve Cylinder Head……………………………………………………….. 358
Fuel Injection Pump…………………………………………………………….. 360
Removal of Fuel Injection Pump……………………………………………….. 360
Installation of Fuel Injection Pump…………………………………………… 364
Checking and Adjusting Fuel Injection Timing………………………………………. 369
Determining the Fuel Injection Timing Specification…………………………….. 369
Checking Fuel Injection Timing……………………………………………….. 370
Adjusting Fuel Injection Timing………………………………………………. 373
Fuel Injectors…………………………………………………………………. 374
Removal of Fuel Injectors……………………………………………………. 374
Testing of Fuel Injectors……………………………………………………. 376
Disassembly and Inspection of Fuel Injectors…………………………………… 378
Adjusting Fuel Injector Pressure……………………………………………… 379
Reassembly of Fuel Injectors…………………………………………………. 380
Installation of the Fuel Injectors……………………………………………. 380
Cooling System…………………………………………………………………….. 382
Before You Begin Servicing………………………………………………………. 382
Introduction…………………………………………………………………… 382
Cooling System Diagram………………………………………………………….. 383
Engine Coolant Pump Components…………………………………………………… 384
Engine Coolant System Check……………………………………………………… 385
Engine Coolant Pump…………………………………………………………….. 385
Removal of Engine Coolant Pump……………………………………………….. 385
Disassembly of Engine Coolant Pump……………………………………………. 387
Cleaning and Inspection……………………………………………………… 387
Reassembly of Engine Coolant Pump…………………………………………….. 388
Installation of Engine Coolant Pump…………………………………………… 389
Lubrication System…………………………………………………………………. 390
Before You Begin Servicing………………………………………………………. 390
Introduction…………………………………………………………………… 390
Oil Pump Service Information…………………………………………………….. 390
Lubrication System Diagram………………………………………………………. 391
Checking Engine Oil Pressure…………………………………………………….. 392
Trochoid Oil Pump………………………………………………………………. 392
Oil Pump Components…………………………………………………………. 392
Disassembly of Oil Pump……………………………………………………… 393
Cleaning and Inspection……………………………………………………… 394
Reassembly of Oil Pump………………………………………………………. 395
Starter Motor……………………………………………………………………… 396
Before You Begin Servicing………………………………………………………. 396
Introduction…………………………………………………………………… 396
Starter Motor Information……………………………………………………….. 396
Standard and Optional……………………………………………………….. 396
Starter Motor Specifications…………………………………………………….. 397
Starter Motor Troubleshooting……………………………………………………. 398
Starter Motor Components………………………………………………………… 399
Starter Motor………………………………………………………………….. 400
Removal of Starter Motor…………………………………………………….. 400
Disassembly of Starter Motor…………………………………………………. 400
Cleaning and Inspection……………………………………………………… 403
Reassembly of Starter Motor………………………………………………….. 408
Check Pinion Projection Length……………………………………………….. 410
No-Load Test……………………………………………………………….. 411
Installation of Starter Motor………………………………………………… 411
Alternator………………………………………………………………………… 412
Before You Begin Servicing………………………………………………………. 412
Introduction…………………………………………………………………… 412
Dynamo and Alternator Information………………………………………………… 412
Standard and Optional Dynamos………………………………………………… 412
Standard and Optional Alternators…………………………………………….. 412
Alternator Specifications……………………………………………………….. 413
Dynamo Specifications…………………………………………………………… 413
Alternator Troubleshooting………………………………………………………. 414
Alternator Components…………………………………………………………… 416
Alternator Wiring Diagram……………………………………………………….. 418
Alternator Standard Output………………………………………………………. 419
Alternator…………………………………………………………………….. 420
Removal of Alternator……………………………………………………….. 420
Disassembly of Alternator……………………………………………………. 421
Reassembly of Alternator…………………………………………………….. 423
Installation of Alternator…………………………………………………… 425
Dynamo Component Location……………………………………………………….. 426
Dynamo Wiring Diagram…………………………………………………………… 427
Operation of Dynamo…………………………………………………………….. 427
Dynamo Standard Output………………………………………………………….. 428
Testing of Dynamo………………………………………………………………. 429
Testing Stator Coil Continuity……………………………………………….. 429
Testing Stator Coil Short-to-Ground…………………………………………… 429
Testing Dynamo Regulated Output………………………………………………. 429
Dynamo………………………………………………………………………… 430
Removal of Dynamo…………………………………………………………… 430
Disassembly of Dynamo……………………………………………………….. 430
Reassembly of Dynamo………………………………………………………… 431
Installation of Dynamo………………………………………………………. 432
Electrical Wiring………………………………………………………………….. 433
Electrical Wiring Precautions……………………………………………………. 433
Electrical Wire Resistance………………………………………………………. 434
Battery Cable Resistance………………………………………………………… 435
Electrical Wire Sizes – Voltage Drop……………………………………………… 436
Conversion of AWG to European Standards…………………………………………… 437
Troubleshooting……………………………………………………………………. 438
Special Service Tools…………………………………………………………… 438
Troubleshooting by Measuring Compression Pressure………………………………….. 439
Compression Pressure Measurement Method……………………………………….. 439
Standard Compression Pressure (Reference Value)………………………………… 440
Engine Speed and Compression Pressure (Use for Reference)……………………….. 440
Measured Value and Troubleshooting……………………………………………. 441
Quick Reference Table for Troubleshooting…………………………………………. 441
Engine SP003012……………………………………………………………………….. 449
Safety Instructions………………………………………………………………… 455
Applicable Models………………………………………………………………….. 455
General Service Information…………………………………………………………. 457
Component Identification………………………………………………………… 457
Location of Labels……………………………………………………………… 458
Function of Major Engine Components………………………………………………. 459
Main Electronic Control Components and Features……………………………………. 460
Function of Cooling System Components…………………………………………….. 461
Installation Position Of Sensors…………………………………………………. 462
Supply Pump………………………………………………………………… 462
Rail Pressure Sensor………………………………………………………… 463
Crank Rotation Sensor……………………………………………………….. 463
Cam Speed Sensor……………………………………………………………. 464
Water Temperature Sensor…………………………………………………….. 464
New Air Temperature Sensor…………………………………………………… 465
Diesel Particulate Filter (DPF) Intermediate/lnlet, Exhaust Air Temperature Sensor…. 466
Diesel Particulate Filter (DPF) Differential Pressure Sensor…………………….. 467
Intake/Exhaust Pressure Sensor……………………………………………….. 468
Intake Air Temperature Sensor………………………………………………… 468
EGR Gas Temperature Sensor…………………………………………………… 469
EGR Valve………………………………………………………………….. 469
Intake Air Throttles………………………………………………………… 470
Acceleration Sensor (YANMAR Standard)…………………………………………. 471
Diesel Fuel……………………………………………………………………. 472
Diesel Fuel Specifications…………………………………………………… 472
Filling The Fuel Tank……………………………………………………….. 474
Priming the Fuel System……………………………………………………… 475
Engine Oil…………………………………………………………………….. 476
Engine Oil Specifications……………………………………………………. 476
Engine Oil Viscosity………………………………………………………… 477
Checking Engine Oil…………………………………………………………. 477
Adding Engine Oil…………………………………………………………… 477
Engine Coolant…………………………………………………………………. 478
Engine Coolant Specifications………………………………………………… 479
Filling Radiator with Engine Coolant………………………………………….. 479
Engine Coolant Capacity (Typical)…………………………………………….. 480
Specifications…………………………………………………………………. 481
Description of Model Number………………………………………………….. 481
Engine General Specifications………………………………………………… 481
Principal Engine Specifications………………………………………………….. 482
Set Output Listed by Rotation………………………………………………… 482
Engine Service Standards………………………………………………………… 483
Tightening Torques for Standard Bolts and Nuts…………………………………….. 484
Periodic Maintenance……………………………………………………………….. 486
Before You Begin Servicing………………………………………………………. 486
Introduction…………………………………………………………………… 486
The Importance of Periodic Maintenance………………………………………… 486
Performing Periodic Maintenance………………………………………………. 486
DOOSAN Replacement Parts…………………………………………………….. 486
Required EPA/ARB Maintenance – USA Only……………………………………….. 487
EPA/ARB Installation Requirements -USA Only……………………………………. 487
Periodic Maintenance Schedule……………………………………………………. 488
Periodic Maintenance Procedures………………………………………………….. 490
After Initial 50 Hours of Operation…………………………………………… 490
Every 50 Hours of Operation………………………………………………….. 494
Every 250 Hours of Operation…………………………………………………. 498
Every 500 Hours of Operation…………………………………………………. 502
Every 1,000 Hours of Operation……………………………………………….. 506
Every 1,500 Hours of Operation……………………………………………….. 508
Every 2,000 Hours of Operation……………………………………………….. 509
Every 3,000 Hours of Operation……………………………………………….. 510
Engine……………………………………………………………………………. 512
Before You Begin Servicing………………………………………………………. 512
Introduction…………………………………………………………………… 512
Cylinder Head Specifications…………………………………………………….. 512
Adjustment Specifications……………………………………………………. 512
Cylinder Head………………………………………………………………. 512
Intake/Exhaust Valve and Guide……………………………………………….. 513
Push Rod…………………………………………………………………… 513
Valve Spring……………………………………………………………….. 513
Rocker Arm and Shaft………………………………………………………… 513
Camshaft and Timing Gear Train Specifications……………………………………… 514
Camshaft…………………………………………………………………… 514
Idler Gear Shaft and Bushing…………………………………………………. 514
Timing Gear Backlash………………………………………………………… 514
Crankshaft and Piston Specifications……………………………………………… 515
Crankshaft…………………………………………………………………. 515
Thrust Bearing……………………………………………………………… 515
Piston…………………………………………………………………….. 515
Piston Ring………………………………………………………………… 516
Connecting Rod……………………………………………………………… 516
Tappet…………………………………………………………………….. 517
Cylinder Block Specifications……………………………………………………. 517
Cylinder Block……………………………………………………………… 517
Special Torque Chart……………………………………………………………. 518
Torque for Bolts and Nuts……………………………………………………. 518
Special Service Tools…………………………………………………………… 520
Measuring Instruments…………………………………………………………… 523
Cylinder Head………………………………………………………………….. 526
Cylinder Head Components…………………………………………………….. 526
Components of a Cylinder Head………………………………………………… 527
Disassembly of Cylinder Head…………………………………………………. 528
Cleaning of Cylinder Head Components………………………………………….. 532
Inspection of Cylinder Head Components………………………………………… 532
Reassembly of Cylinder Head………………………………………………….. 537
Measuring and Adjusting Valve Clearance…………………………………………… 542
Crankshaft and Camshaft Components……………………………………………….. 544
Disassembly of Engine……………………………………………………….. 546
Disassembly of Camshaft and Timing Components………………………………….. 547
Disassembly of Crankshaft and Piston Components………………………………… 552
Inspection of Crankshaft and Camshaft Components……………………………….. 556
Honing and Boring…………………………………………………………… 562
Reassembly of Crankshaft and Piston Components…………………………………. 563
Reassembly of Camshaft and Timing Components…………………………………… 569
Final Reassembly of Engine…………………………………………………… 573
EGR System…………………………………………………………………….. 574
EGR System…………………………………………………………………. 574
Fuel System……………………………………………………………………….. 581
Before You Begin Servicing………………………………………………………. 581
Fuel System Specifications………………………………………………………. 583
Torque Chart for Major Bolts and Nuts…………………………………………. 583
Fuel System Diagram…………………………………………………………….. 584
Fuel System Components………………………………………………………….. 585
Removal of Common Rail………………………………………………………. 586
Reassembly of Common Rail……………………………………………………. 588
Removal of Injector…………………………………………………………. 589
Reassembly of Injector………………………………………………………. 590
Removal of Supply Pump………………………………………………………. 592
Reassembly of Supply Pump……………………………………………………. 593
Cooling System…………………………………………………………………….. 595
Before You Begin Servicing………………………………………………………. 595
Introduction…………………………………………………………………… 595
Cooling System Diagram………………………………………………………….. 596
Engine Coolant Pump Components…………………………………………………… 597
Engine Coolant System Check……………………………………………………… 598
Engine Coolant Pump…………………………………………………………….. 598
Disassembly of Engine Coolant Pump……………………………………………. 600
Cleaning and Inspection……………………………………………………… 600
Reassembly of Engine Coolant Pump…………………………………………….. 602
Installation of Engine Coolant Pump…………………………………………… 602
Lubrication System…………………………………………………………………. 604
Before You Begin Servicing………………………………………………………. 604
Introduction…………………………………………………………………… 604
Oil Pump Service Information…………………………………………………….. 604
Lubrication System Diagram………………………………………………………. 605
Checking Engine Oil Pressure…………………………………………………….. 606
Trochoid Oil Pump………………………………………………………………. 606
4TNV98C Oil Pump Components………………………………………………….. 606
Disassembly of Oil Pump……………………………………………………… 607
Cleaning and Inspection……………………………………………………… 608
Reassembly of Oil Pump………………………………………………………. 609
Starter Motor……………………………………………………………………… 610
Before You Begin Servicing………………………………………………………. 610
Introduction…………………………………………………………………… 610
Starter Motor Information……………………………………………………….. 610
4TNV98C – Standard and Optional………………………………………………. 610
Starter Motor Specifications…………………………………………………….. 611
Starter Motor Troubleshooting……………………………………………………. 612
Starter Motor Components………………………………………………………… 613
Starter Motor………………………………………………………………….. 614
Removal of Starter Motor…………………………………………………….. 614
Disassembly of Starter Motor…………………………………………………. 614
Cleaning and Inspection……………………………………………………… 617
Reassembly of Starter Motor………………………………………………….. 622
Check Pinion Projection Length……………………………………………….. 624
No-Load Test……………………………………………………………….. 625
Installation of Starter Motor………………………………………………… 625
Alternator………………………………………………………………………… 626
Before You Begin Servicing………………………………………………………. 626
Introduction…………………………………………………………………… 626
Dynamo and Alternator Information………………………………………………… 626
Standard and Optional Dynamos………………………………………………… 626
Standard and Optional Alternators…………………………………………….. 626
Alternator Specifications……………………………………………………….. 627
Dynamo Specifications…………………………………………………………… 627
Alternator Troubleshooting………………………………………………………. 628
Alternator Components…………………………………………………………… 630
Alternator Wiring Diagram……………………………………………………….. 632
Alternator Standard Output………………………………………………………. 633
Alternator…………………………………………………………………….. 634
Removal of Alternator……………………………………………………….. 634
Disassembly of Alternator……………………………………………………. 635
Reassembly of Alternator…………………………………………………….. 637
Installation of Alternator…………………………………………………… 639
Dynamo Component Location……………………………………………………….. 640
Dynamo Wiring Diagram…………………………………………………………… 641
Operation of Dynamo…………………………………………………………….. 641
Dynamo Standard Output………………………………………………………….. 642
Testing of Dynamo………………………………………………………………. 643
Testing Stator Coil Continuity……………………………………………….. 643
Testing Stator Coil Short-to-Ground…………………………………………… 643
Testing Dynamo Regulated Output………………………………………………. 643
Dynamo………………………………………………………………………… 644
Removal of Dynamo…………………………………………………………… 644
Disassembly of Dynamo……………………………………………………….. 644
Reassembly of Dynamo………………………………………………………… 645
Installation of Dynamo………………………………………………………. 646
Electronic Control System…………………………………………………………… 647
Before You Begin Servicing………………………………………………………. 647
Introduction…………………………………………………………………… 647
Electronic Control System……………………………………………………….. 647
Diesel Particulate Filter (DPF)………………………………………………….. 649
Electronic Control Harness Connections……………………………………………. 654
Electrical Wiring………………………………………………………………….. 663
Electrical Wiring Precautions……………………………………………………. 663
Electrical Wire Resistance………………………………………………………. 664
Battery Cable Resistance………………………………………………………… 665
Electrical Wire Sizes – Voltage Drop……………………………………………… 666
Conversion of AWG to European Standards…………………………………………… 667
Troubleshooting……………………………………………………………………. 668
Special Service Tools…………………………………………………………… 668
Measured Value and Troubleshooting……………………………………………….. 668
Quick Reference Table for Troubleshooting…………………………………………. 668
Drive Coupling (Main Pump) SP001627……………………………………………………… 675
Safety Instructions………………………………………………………………… 679
Applicable Models………………………………………………………………….. 679
General Description………………………………………………………………… 680
Installation of Drive Coupling………………………………………………………. 681
Installation Procedure………………………………………………………….. 681
Hydraulics……………………………………………………………………………….. 683
Accumulator SP002455…………………………………………………………………… 685
Safety Instructions………………………………………………………………… 689
Applicable Models………………………………………………………………….. 689
General Description………………………………………………………………… 0
Specifications…………………………………………………………………. 692
Center Joint (Swivel) SP001628………………………………………………………….. 693
Safety Instructions………………………………………………………………… 697
Applicable Models………………………………………………………………….. 697
General Description………………………………………………………………… 698
Parts List…………………………………………………………………….. 698
Disassembly……………………………………………………………………….. 699
Reassembly………………………………………………………………………… 702
Center Joint Assembly………………………………………………………………. 704
Cylinders SP003044…………………………………………………………………….. 705
Safety Instructions………………………………………………………………… 709
Applicable Models………………………………………………………………….. 709
General Description………………………………………………………………… 710
Theory of Operation…………………………………………………………….. 710
Parts List…………………………………………………………………….. 712
Boom Cylinder………………………………………………………………. 712
Arm Cylinder……………………………………………………………….. 714
Bucket Cylinder…………………………………………………………….. 716
Boom Swing Cylinder…………………………………………………………. 718
Dozer Cylinder (NON Check)…………………………………………………… 720
Dozer Cylinder (Check)………………………………………………………. 722
Disassembly……………………………………………………………………….. 730
Reassembly………………………………………………………………………… 735
Swing Device SP001630………………………………………………………………….. 739
Safety Instructions………………………………………………………………… 743
Applicable Models………………………………………………………………….. 743
Indication of Type…………………………………………………………………. 744
Specifications…………………………………………………………………….. 745
Structure and Principle of Operation…………………………………………………. 746
Parts List…………………………………………………………………….. 746
Principle of Operation………………………………………………………….. 748
Hydraulic Motor…………………………………………………………….. 748
Valve Casing……………………………………………………………….. 749
Instructions Before Operation……………………………………………………….. 752
Inspection…………………………………………………………………….. 752
Rotation Direction……………………………………………………………… 752
External Load at the End of Shaft………………………………………………… 753
Hydraulic Oil and Temperature Range………………………………………………. 753
Filter………………………………………………………………………… 754
Installation and Piping…………………………………………………………. 755
Oil Filling and Air Ventilation………………………………………………….. 755
Instructions Before Starting to Operate…………………………………………… 755
Troubleshooting……………………………………………………………………. 756
General Instructions……………………………………………………………. 756
Examination of Hydraulic Motor…………………………………………………… 756
Troubleshooting………………………………………………………………… 757
Disassembling and Assembling………………………………………………………… 759
Tightening Torque of Bolts………………………………………………………. 759
Necessary Tools………………………………………………………………… 759
Disassembly of Motor……………………………………………………………. 761
Assembly of Motor………………………………………………………………. 766
Disassembly of Reduction Gear……………………………………………………. 772
Assembly of Reduction Gear………………………………………………………. 775
Maintenance Instructions………………………………………………………… 779
Part Replacement Standards for Reduction Gear………………………………….. 780
Standard of Sliding Surface Correction………………………………………… 781
Travel Device SP001686…………………………………………………………………. 783
Safety Instructions………………………………………………………………… 787
Applicable Models………………………………………………………………….. 787
General…………………………………………………………………………… 789
Configuration………………………………………………………………….. 789
Features………………………………………………………………………. 789
Structural Diagram of the Traveling System………………………………………… 790
Structural Diagram of the Axial Piston Motor………………………………………. 791
Operating Principle………………………………………………………………… 792
When Traveling…………………………………………………………………. 792
When Counterbalance Operates…………………………………………………….. 793
When Brake Functions……………………………………………………………. 794
Operating Principle of Parking Brake……………………………………………… 795
2 Speed Limiting Function……………………………………………………….. 796
Parts List………………………………………………………………………… 798
Hydraulic Motor………………………………………………………………… 798
Reduction Gear…………………………………………………………………. 800
Special Tools and Materials…………………………………………………………. 802
Standard Tools…………………………………………………………………. 802
Equipment and Materials…………………………………………………………. 803
Measuring Devices………………………………………………………………. 803
Manufacturing Tools…………………………………………………………….. 804
Travel Motor Workbench………………………………………………………. 804
Fixture……………………………………………………………………. 804
Holder (I)…………………………………………………………………. 804
Holder (II)………………………………………………………………… 804
Holder (IV)………………………………………………………………… 805
Steel Rod………………………………………………………………….. 805
Bearing Preload Adjuster…………………………………………………….. 805
Tightening Torque………………………………………………………………. 808
Weight Table…………………………………………………………………… 808
Travel Motor Troubleshooting………………………………………………………… 809
Travel Motor…………………………………………………………………… 809
Counterbalance Valve……………………………………………………………. 809
Relief Valve…………………………………………………………………… 810
2-Speed Change Over…………………………………………………………….. 810
Parking Brake………………………………………………………………….. 810
Disassembly……………………………………………………………………….. 811
Preparations…………………………………………………………………… 811
Workbench Preparations………………………………………………………. 811
Preparation of Tools and Materials……………………………………………. 811
General Suggestions When Working…………………………………………………. 811
Disassembly Procedure…………………………………………………………… 812
Washing GM motor……………………………………………………………. 812
GM Motor Installation……………………………………………………….. 813
Lubricating Oil Extraction…………………………………………………… 813
Cover Removal………………………………………………………………. 814
Input Gear Removal………………………………………………………….. 815
Spur Gear Removal…………………………………………………………… 816
Rear Flange Removal…………………………………………………………. 816
Removing Parts from the Rear Flange…………………………………………… 818
Disassembly of Plugs Inside Rear Flange……………………………………….. 819
Disassembling Valve (For 2-Speed Control)……………………………………… 820
Remove Hexagon Socket Plug…………………………………………………… 821
Disassembling Valve for Parking Brake…………………………………………. 821
Disassembling Parking Brake………………………………………………….. 822
Disassembling Hydraulic Motor………………………………………………… 822
Removal of Spring Inside Cylinder Block……………………………………….. 823
Removal of Swash Plate………………………………………………………. 824
Removing Ball Bearing From Shaft……………………………………………… 825
Removing Hold Flange………………………………………………………… 825
Fixture Removal…………………………………………………………….. 827
Removing Spindle……………………………………………………………. 827
Removal of Ball Bearing, RV Gear Assembly, and Pin……………………………… 827
Ball Bearing Removal………………………………………………………… 828
Disassembling Spindle Fittings……………………………………………….. 828
Disassembling Hold Flange……………………………………………………. 828
Washing……………………………………………………………………. 829
Finish Washing……………………………………………………………… 829
Service Preparations……………………………………………………………….. 830
Seals…………………………………………………………………………. 830
Service Standards for Parts Subject to Wear……………………………………….. 830
Assembly………………………………………………………………………….. 832
Preparation……………………………………………………………………. 832
General Suggestions When Working…………………………………………………. 832
Assembly Procedure……………………………………………………………… 833
Hub Section Assembly………………………………………………………… 833
Spindle Assembly……………………………………………………………. 834
Mount RV Gear Assembly………………………………………………………. 835
Hold Flange Mounting………………………………………………………… 836
Tightening Reamer Bolts and Hex. Socket Bolts………………………………….. 837
Install Retaining Rings……………………………………………………… 838
Spur Gear Assembly………………………………………………………….. 839
Mounting Oil Seal…………………………………………………………… 839
Shaft Assembly……………………………………………………………… 840
Assembly of Cylinder Block Interior…………………………………………… 841
Assembly of Hydraulic Motor Parts…………………………………………….. 841
Assembly of Parking Brake Section…………………………………………….. 842
Assembly of Brake Valve Parts in Rear Flange…………………………………… 843
Assembly of Rear Flange Mounted Parts…………………………………………. 844
Connection of Rear Flange with Spindle………………………………………… 846
Input Gear Assembly…………………………………………………………. 847
Cover Assembly……………………………………………………………… 848
Remove Assembled GM Motor from Workbench………………………………………. 849
Preload Adjustment of Ball Bearing……………………………………………. 850
Adjusting Axial Clearance on Tapered Roller Bearing…………………………….. 851
Performance Confirmation Test……………………………………………………….. 853
Required Measuring Devices………………………………………………………. 853
Test Procedure…………………………………………………………………. 853
Clearance Adjustment Part Dimensions…………………………………………………. 854
Main Pump SP003045…………………………………………………………………….. 855
Safety Instructions………………………………………………………………… 859
Applicable Models………………………………………………………………….. 859
General Description………………………………………………………………… 860
Hydraulic Schematic………………………………………………………………… 861
Ports Description………………………………………………………………….. 862
General Repair Instructions…………………………………………………………. 863
Tools/Auxiliary Tools/Tightening Torques………………………………………….. 887
Tightening Torques………………………………………………………….. 887
Nm (ft lb) = Max. Tightening Torques (Screws Lubricated µ = 0.125)……………….. 887
Main Control Valve SP003046…………………………………………………………….. 891
Safety Instructions………………………………………………………………… 895
Applicable Models………………………………………………………………….. 895
Functional Description, Section……………………………………………………… 896
Assembly………………………………………………………………………….. 898
Abnormal Operation of the Actuators Connected to the Control Block…………………… 899
Abnormal Machine Operation………………………………………………………. 900
Abnormal Control Block Operation…………………………………………………. 900
Visual Defects…………………………………………………………………. 900
Fundamental Rules………………………………………………………………….. 901
General Information Concerning Control Block Connection…………………………….. 901
Removal/Installation of the SX 12 Control block……………………………………….. 902
General Recommendations…………………………………………………………. 902
Removal of the SX 12 Control Block……………………………………………….. 902
Installation of the SX 12 Control Block…………………………………………… 903
Starting, Maximal Pressure Set Up………………………………………………… 903
SX 12 Control Block Repair Procedure…………………………………………………. 904
LS Pressure Relief Valve Replacement……………………………………………… 904
Flow Regulator Replacement………………………………………………………. 905
Secondary Valves Replacement…………………………………………………….. 906
Hydraulic Operator Removal………………………………………………………. 907
Individual Pressure Compensator Removal…………………………………………… 909
Control Block Disassembly/Assembly……………………………………………….. 910
Remote Control Valve (Work Lever/ Joystick) SP003015………………………………………. 911
Safety Instructions………………………………………………………………… 915
Applicable Models………………………………………………………………….. 915
General Description………………………………………………………………… 917
Theory of Operation…………………………………………………………….. 917
Structure………………………………………………………………….. 917
Function…………………………………………………………………… 917
Structure Diagram………………………………………………………………….. 918
Parts List…………………………………………………………………….. 918
Performance Specification…………………………………………………………… 920
Hydraulic Pressure Circuit Diagram…………………………………………………… 920
Torques……………………………………………………………………….. 921
Tools and Materials………………………………………………………………… 921
Disassembly Method…………………………………………………………………. 922
Assembly Method……………………………………………………………………. 925
Travel Control Valve SP003016…………………………………………………………… 929
Safety Instructions………………………………………………………………… 933
Applicable Models………………………………………………………………….. 933
General Description………………………………………………………………… 934
Parts List…………………………………………………………………….. 934
Performance Specification…………………………………………………………… 936
Hydraulic Pressure Circuit Diagram…………………………………………………… 936
Maintenance……………………………………………………………………….. 937
Required Tool and Tightening Torque………………………………………………. 937
Maintenance Standard……………………………………………………………. 938
Disassembly……………………………………………………………………. 939
Preparation………………………………………………………………… 939
General precaution during disassembly…………………………………………. 939
Disassembly procedure……………………………………………………….. 939
Assembly………………………………………………………………………. 944
Preparation………………………………………………………………… 944
General precaution during reassembly………………………………………….. 944
Assembly…………………………………………………………………… 944
Troubleshooting……………………………………………………………………. 950
General Caution………………………………………………………………… 950
Troubleshooting and Resolution…………………………………………………… 950
Dozer Valve SP003056…………………………………………………………………… 951
Safety Instructions………………………………………………………………… 955
Applicable Models………………………………………………………………….. 955
Structure Diagram………………………………………………………………….. 956
Parts List…………………………………………………………………….. 956
Performance Specification…………………………………………………………… 958
Hydraulic Pressure Circuit Diagram…………………………………………………… 958
Disassembly……………………………………………………………………….. 959
Assembly………………………………………………………………………….. 962
Pilot Supply Valve SP003047…………………………………………………………….. 965
Safety Instructions………………………………………………………………… 969
Applicable Models………………………………………………………………….. 969
General Description………………………………………………………………… 970
Part List……………………………………………………………………… 970
Functions and Operations……………………………………………………………. 971
Hydraulic Schematic…………………………………………………………….. 971
Assembly Diagram and Tools Required………………………………………………. 972
Cautions During Disassembly and Reassembly………………………………………… 973
Check Points and Solutions for Problems…………………………………………… 974
EPPR Valve SP003019……………………………………………………………………. 975
Safety Instructions………………………………………………………………… 979
Applicable Models………………………………………………………………….. 979
General Description………………………………………………………………… 980
Part List……………………………………………………………………… 980
Torque and Tools……………………………………………………………. 980
Functions and Operations……………………………………………………………. 981
Hydraulic Schematic…………………………………………………………….. 981
Reducing Pressure vs Current Characteristic……………………………………….. 982
Check Points and Solutions for Problems…………………………………………… 983
2nd Auxiliary Valve (Option) SP003048……………………………………………………. 985
Safety Instructions………………………………………………………………… 989
Applicable Models………………………………………………………………….. 989
General Description………………………………………………………………… 990
Part List……………………………………………………………………… 990
Torque and Tools……………………………………………………………. 991
Functions and Operations……………………………………………………………. 992
Hydraulic Schematic…………………………………………………………….. 992
Quick Coupler Valve (Option) SP003021……………………………………………………. 993
Safety Instructions………………………………………………………………… 997
Applicable Models………………………………………………………………….. 997
General Description………………………………………………………………… 998
Part List……………………………………………………………………… 998
Functions and Operations…………………………………………………………….1000
Hydraulic Schematic……………………………………………………………..1000
Check Points and Solutions for Problems……………………………………………1000
Forced Regeneration Valve SP003022……………………………………………………….1001
Safety Instructions…………………………………………………………………1005
Applicable Models…………………………………………………………………..1005
General Description…………………………………………………………………1006
Part List………………………………………………………………………1006
Functions and Operations…………………………………………………………….1008
Hydraulic Schematic……………………………………………………………..1008
Check Points and Solutions for Problems……………………………………………1008
Hydraulic Schematic SP003049…………………………………………………………….1009
Safety Instructions…………………………………………………………………1013
Applicable Models…………………………………………………………………..1013
Electrical System………………………………………………………………………….1017
Electrical System (Europe) SP003050………………………………………………………1019
Safety Instructions…………………………………………………………………1023
Applicable Models…………………………………………………………………..1023
Overview…………………………………………………………………………..1025
Electrical Wire Color……………………………………………………………1025
Electrical Supply System…………………………………………………………….1026
Engine Starting…………………………………………………………………….1028
Start Operation…………………………………………………………………1028
After Start…………………………………………………………………….1030
Engine Preheating System…………………………………………………………….1032
Engine Stop………………………………………………………………………..1034
Charging System…………………………………………………………………….1036
Instrument System…………………………………………………………………..1037
Instrument Panel………………………………………………………………..1037
Function Check………………………………………………………………….1038
Operation………………………………………………………………………….1039
Gauge………………………………………………………………………….1039
Warning Lights………………………………………………………………….1040
Function Button……………………………………………………………..1042
User Menu………………………………………………………………………….1044
User Menu – Access and Escape Methods……………………………………………..1044
Access Method……………………………………………………………….1044
Escape Method……………………………………………………………….1044
User Menu…………………………………………………………………..1044
Special Menu……………………………………………………………………1052
Check Connector……………………………………………………………..1053
FMI Code……………………………………………………………………1054
Circuit Diagram of Instrument Panel……………………………………………….1056
VCU……………………………………………………………………………1057
Engine Control System……………………………………………………………1058
Engine Control Dial…………………………………………………………………1059
Engine Control Circuit Diagram……………………………………………………1060
Automatic Deceleration Control (Auto Idle Control)………………………………….1061
Engine Overheat Protection System…………………………………………………1062
Hydraulic Oil Overheat Protection System…………………………………………..1063
Engine Control Unit……………………………………………………………..1064
Refrigerant Circulation……………………………………………………………..1065
Air-conditioning System Circuit Diagram……………………………………………1067
Airflow Control…………………………………………………………………1068
Airflow Control Motor……………………………………………………………1069
Blower Motor……………………………………………………………………1069
Coolant Flow Control Valve……………………………………………………….1070
Temperature Level Control and Display……………………………………………..1071
Weight of R134a Gas Used in Machines………………………………………………….1072
Refrigerant System Repairs…………………………………………………………..1073
Refrigerant Safe Handling Procedures………………………………………………1073
Repair and Replacement Procedure………………………………………………….1074
Refrigerant Recovery…………………………………………………………….1076
Vacuuming Refrigerant System……………………………………………………..1076
Leakage Check…………………………………………………………………..1078
Refrigerant Charging…………………………………………………………….1079
Inspecting System for Leakage…………………………………………………….1080
Troubleshooting…………………………………………………………………….1082
Refrigerant Pressure Check……………………………………………………….1082
Electrical System SP003024………………………………………………………………1085
Safety Instructions…………………………………………………………………1089
Applicable Models…………………………………………………………………..1089
Overview…………………………………………………………………………..1091
Electrical Wire Color……………………………………………………………1091
Electrical Supply System…………………………………………………………….1092
Engine Starting…………………………………………………………………….1094
Start Operation…………………………………………………………………1094
After Start…………………………………………………………………….1096
Engine Preheating System…………………………………………………………….1098
Engine Stop………………………………………………………………………..1100
Charging System…………………………………………………………………….1102
Instrument System…………………………………………………………………..1103
Instrument Panel………………………………………………………………..1103
Function Check………………………………………………………………….1104
Operation………………………………………………………………………….1105
Gauge………………………………………………………………………….1105
Warning Lights………………………………………………………………….1106
Function Button……………………………………………………………..1108
User Menu………………………………………………………………………….1110
User Menu – Access and Escape Methods……………………………………………..1110
Access Method……………………………………………………………….1110
Escape Method……………………………………………………………….1110
User Menu…………………………………………………………………..1110
Special Menu……………………………………………………………………1118
Check Connector……………………………………………………………..1119
FMI Code……………………………………………………………………1120
Circuit Diagram of Instrument Panel……………………………………………….1122
VCU……………………………………………………………………………1123
Engine Control System……………………………………………………………1124
Engine Control Dial…………………………………………………………………1125
Engine Control Circuit Diagram……………………………………………………1126
Automatic Deceleration Control (Auto Idle Control)………………………………….1127
Engine Overheat Protection System…………………………………………………1128
Hydraulic Oil Overheat Protection System…………………………………………..1129
Engine Control Unit……………………………………………………………..1130
Refrigerant Circulation……………………………………………………………..1131
Air-conditioning System Circuit Diagram……………………………………………1133
Airflow Control…………………………………………………………………1134
Airflow Control Motor……………………………………………………………1135
Blower Motor……………………………………………………………………1135
Coolant Flow Control Valve……………………………………………………….1136
Temperature Level Control and Display……………………………………………..1137
Weight of R134a Gas Used in Machines………………………………………………….1138
Refrigerant System Repairs…………………………………………………………..1139
Refrigerant Safe Handling Procedures………………………………………………1139
Repair and Replacement Procedure………………………………………………….1140
Refrigerant Recovery…………………………………………………………….1142
Vacuuming Refrigerant System……………………………………………………..1142
Leakage Check…………………………………………………………………..1144
Refrigerant Charging…………………………………………………………….1145
Inspecting System for Leakage…………………………………………………….1146
Troubleshooting…………………………………………………………………….1148
Refrigerant Pressure Check……………………………………………………….1148
Electrical Schematic SP003025……………………………………………………………1151
Safety Instructions…………………………………………………………………1155
Applicable Models…………………………………………………………………..1155
Attachments……………………………………………………………………………….1161
Boom and Arm SP003055…………………………………………………………………..1163
Safety Instructions…………………………………………………………………1167
Applicable Models…………………………………………………………………..1167
Front Attachment Pin Specifications…………………………………………………..1168
Front Attachment – Removal and Installation……………………………………………1170
Arm Removal Procedure……………………………………………………………1171
Boom Removal Procedure…………………………………………………………..1173
Installation……………………………………………………………………….1174
Arm Installation Procedure……………………………………………………….1174
Boom Installation Procedure………………………………………………………1174
Castle Nut Installation Procedure…………………………………………………1175
Start-up Procedures…………………………………………………………………1175
Bucket SP001643………………………………………………………………………..1177
Safety Instructions…………………………………………………………………1181
Applicable Models…………………………………………………………………..1181
Bucket Tooth Replacement…………………………………………………………….1182
Procedures of Bucket Tooth Replacement…………………………………………….1182
Bucket O-ring Replacement……………………………………………………………1184
Bucket Attachment, Removal and Reversal……………………………………………….1185
Detaching the Bucket…………………………………………………………….1185
Attaching the Bucket…………………………………………………………….1186
Reversing the Bucket…………………………………………………………….1186
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