Doosan DX140LC-5 Excavator Shop Manual 950106-01141E – PDF DOWNLOAD
DESCRIPTION:
Doosan DX140LC-5 Excavator Shop Manual 950106-01141E – PDF DOWNLOAD
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 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 toinstructions 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.
TABLE OF CONTENTS:
Doosan DX140LC-5 Excavator Shop Manual 950106-01141E – PDF DOWNLOAD
DX140LC-5…………………………………………………………………………………………………… 0
NOTICE………………………………………………………………………………………………….. 7
Table of Contents………………………………………………………………………………………… 9
Safety………………………………………………………………………………………………….. 11
Track Excavator Maintenance Safety……………………………………………………………………… 13
Safety Instructions……………………………………………………………………………….. 17
Safety Messages…………………………………………………………………………………… 17
General………………………………………………………………………………………….. 18
Safe Operation is Operator’s Responsibility………………………………………………………. 18
Know Your Machine……………………………………………………………………………… 18
Proper Work Tools and Attachments……………………………………………………………….. 19
Pressurized Fluids…………………………………………………………………………….. 19
Flying or Falling Objects………………………………………………………………………. 20
Personal Protective Equipment (PPE)……………………………………………………………… 21
Correction of Machine Problems………………………………………………………………….. 21
Crushing and Cutting…………………………………………………………………………… 21
Hot Coolant and Oils – Burn Prevention…………………………………………………………… 22
Fire and Explosion Prevention…………………………………………………………………… 23
Fire Extinguisher and First-aid Kit (Emergency Medical Kit)………………………………………… 26
Electrical System and Electrical Shock…………………………………………………………… 27
Roll-over Protective Structure (ROPS)……………………………………………………………. 27
Transportation……………………………………………………………………………………. 31
Obey State and Local Over-the-Road Regulations……………………………………………………. 31
Loading and Unloading………………………………………………………………………….. 31
Transporting Machine…………………………………………………………………………… 32
Operation………………………………………………………………………………………… 33
Before Engine Starting…………………………………………………………………………. 33
Work Site…………………………………………………………………………………….. 34
Mounting/Dismounting…………………………………………………………………………… 35
Cleaning……………………………………………………………………………………… 36
Operator Station………………………………………………………………………………. 36
Seat Belt…………………………………………………………………………………….. 37
Visibility Information…………………………………………………………………………. 38
Boost Starting or Charging Engine Batteries………………………………………………………. 39
Swinging or Traveling………………………………………………………………………….. 41
Lifting and Digging……………………………………………………………………………. 43
Operation on Slopes……………………………………………………………………………. 44
Towing……………………………………………………………………………………….. 45
Attachment……………………………………………………………………………………. 46
Equipment Lowering with Engine Stopped…………………………………………………………… 46
Engine Stop…………………………………………………………………………………… 47
Parking Machine……………………………………………………………………………….. 47
Preservation/Storing Machine……………………………………………………………………. 48
Maintenance………………………………………………………………………………………. 50
Cleaning……………………………………………………………………………………… 53
Proper Tools and Clothing………………………………………………………………………. 53
Disassembling Precautions………………………………………………………………………. 53
Use of Lighting……………………………………………………………………………….. 53
Fire and Explosion Prevention…………………………………………………………………… 54
Burn Prevention……………………………………………………………………………….. 55
Rubber That Contains Fluorides………………………………………………………………….. 56
Rubber and Plastics……………………………………………………………………………. 57
Welding Repairs……………………………………………………………………………….. 58
Warning for Counterweight and Front Attachment Removal…………………………………………….. 59
Lock Inspection Covers…………………………………………………………………………. 60
Working on Machine…………………………………………………………………………….. 60
Accumulator…………………………………………………………………………………… 61
Compressed Air………………………………………………………………………………… 61
Track Tension Adjustments………………………………………………………………………. 62
Supports and Blocking for Work Equipment…………………………………………………………. 62
High-pressure Lines, Tubes and Hoses…………………………………………………………….. 63
Battery………………………………………………………………………………………. 64
Environment and Circumstances………………………………………………………………………. 66
Work Site Areas Requiring Extra Caution………………………………………………………….. 66
High-voltage Cables……………………………………………………………………………. 68
Underground Operation………………………………………………………………………….. 69
Working in Water………………………………………………………………………………. 69
Working in Contaminated Environment……………………………………………………………… 69
Operation in Extreme Conditions…………………………………………………………………. 70
Exhaust Ventilation……………………………………………………………………………. 74
Asbestos Information…………………………………………………………………………… 75
Silica Dust Information………………………………………………………………………… 75
Disposal of Hazardous Materials…………………………………………………………………. 76
Sound………………………………………………………………………………………… 76
Vibration Information………………………………………………………………………….. 77
Specifications…………………………………………………………………………………………… 79
Specifications……………………………………………………………………………………….. 81
Safety Instructions……………………………………………………………………………….. 85
General Description……………………………………………………………………………….. 85
Component Locations……………………………………………………………………………….. 86
Overall Dimensions………………………………………………………………………………… 90
One – Piece Boom………………………………………………………………………………. 90
Two – Piece Boom………………………………………………………………………………. 91
Working Range…………………………………………………………………………………….. 92
One – Piece Boom………………………………………………………………………………. 92
Two – Piece Boom………………………………………………………………………………. 94
General Specifications…………………………………………………………………………….. 96
Approximate Weight of Workload Materials…………………………………………………………….. 98
Performance Tests…………………………………………………………………………………. 100
Purpose of Performance Tests……………………………………………………………………. 100
Kinds of Tests………………………………………………………………………………… 100
Performance Standards………………………………………………………………………….. 100
Precautions for Evaluation of Test Data………………………………………………………….. 100
Definition of “Performance Standard”…………………………………………………………….. 100
Preparation for Performance Tests…………………………………………………………………… 101
The Machine…………………………………………………………………………………… 101
Test Area…………………………………………………………………………………….. 101
Precautions…………………………………………………………………………………… 101
Make Precise Measurement……………………………………………………………………….. 101
Operational Performance Standard Table………………………………………………………………. 102
Operational Performance Test……………………………………………………………………….. 104
Hydraulic Cylinder Cycle Time…………………………………………………………………… 104
Travel Speed………………………………………………………………………………….. 106
Track Revolution Speed…………………………………………………………………………. 107
Mistrack Check………………………………………………………………………………… 109
Swing Speed…………………………………………………………………………………… 111
Swing Function Drift Check……………………………………………………………………… 112
General Maintenance………………………………………………………………………………………. 113
General Maintenance Instructions……………………………………………………………………….. 115
Safety Instructions……………………………………………………………………………….. 119
Welding Precautions and Instructions………………………………………………………………… 120
Hydraulic System – General Precautions………………………………………………………………. 121
Maintenance Service and Repair Procedure…………………………………………………………….. 123
General Precautions……………………………………………………………………………. 123
Hydraulic System Cleanliness and Oil Leaks…………………………………………………………… 124
Maintenance Precautions for Hydraulic System Service………………………………………………. 124
Oil Leakage Precautions………………………………………………………………………… 125
Cleaning and Inspection……………………………………………………………………………. 126
General Instructions…………………………………………………………………………… 126
Bearing Inspection…………………………………………………………………………….. 127
Standard Torques……………………………………………………………………………………… 135
Safety Instructions……………………………………………………………………………….. 139
Torque Values for Standard Metric Fasteners………………………………………………………….. 140
Torque Values for Standard U.S. Fasteners……………………………………………………………. 141
Type 8 Phosphate Coated Hardware……………………………………………………………………. 143
Torque Values for Hose Clamps………………………………………………………………………. 144
ORFS Swivel Nut Recommended Torque………………………………………………………………….. 144
Torque Values for Split Flanges…………………………………………………………………….. 145
Torque Wrench Extension Tools………………………………………………………………………. 146
Torque Multiplication………………………………………………………………………….. 146
Other Uses for Torque Wrench Extension Tools……………………………………………………… 147
Tightening Torque Specifications (Metric)………………………………………………………… 148
Engine………………………………………………………………………………………………….. 151
Engine………………………………………………………………………………………………. 153
Safety Instructions……………………………………………………………………………….. 157
Overview…………………………………………………………………………………………. 158
General Information……………………………………………………………………………….. 159
Major Component Location……………………………………………………………………….. 159
Engine Identification………………………………………………………………………….. 164
Engine Lifting………………………………………………………………………………… 166
Maintenance and Storage………………………………………………………………………… 168
Engine Specification………………………………………………………………………………. 171
General Specification………………………………………………………………………….. 171
Engine Performance Curves………………………………………………………………………. 172
Basic Engine……………………………………………………………………………………… 173
Cylinder Block………………………………………………………………………………… 173
Cylinder Head…………………………………………………………………………………. 175
Valve Mechanism Cover………………………………………………………………………….. 187
Crankcase Breather…………………………………………………………………………….. 192
Flywheel and Flywheel Housing…………………………………………………………………… 196
Actuating System………………………………………………………………………………….. 208
Pistons, Rings, and Connecting Rods……………………………………………………………… 208
Crankshaft……………………………………………………………………………………. 223
Gears and Timing Gear Case……………………………………………………………………… 242
Camshaft……………………………………………………………………………………… 265
Rocker Shaft………………………………………………………………………………….. 275
Lubricant System………………………………………………………………………………….. 286
Overview……………………………………………………………………………………… 286
Engine Oil Pump……………………………………………………………………………….. 288
Engine Oil Filter……………………………………………………………………………… 292
Engine Oil Pan………………………………………………………………………………… 294
Engine Oil Pressure – Test……………………………………………………………………… 302
Excessive Bearing Wear – Inspect………………………………………………………………… 302
Excessive Engine Oil Consumption – Inspect……………………………………………………….. 303
Increased Engine Oil Temperature – Inspect……………………………………………………….. 303
Cooling System……………………………………………………………………………………. 304
Overview……………………………………………………………………………………… 304
Water Pump……………………………………………………………………………………. 305
Water Temperature Regulator…………………………………………………………………….. 310
Engine Oil Cooler……………………………………………………………………………… 314
Piston Cooling Jets……………………………………………………………………………. 320
Fuel System………………………………………………………………………………………. 322
Overview……………………………………………………………………………………… 322
High-pressure Fuel System………………………………………………………………………. 323
Water Separator & Pre Fuel Filter (Fuel Prefilter)………………………………………………… 325
Main Fuel Filter………………………………………………………………………………. 329
Fuel Injection Pump……………………………………………………………………………. 331
Fuel Injection Lines…………………………………………………………………………… 339
Fuel Injectors………………………………………………………………………………… 351
Fuel System – Inspect………………………………………………………………………….. 359
Air in Fuel – Test…………………………………………………………………………….. 360
Finding Top Center Position for No. 1 Piston……………………………………………………… 362
Fuel Injection Timing – Check…………………………………………………………………… 363
Fuel Quality – Test……………………………………………………………………………. 364
Fuel System – Prime……………………………………………………………………………. 365
Cleanliness of Fuel System……………………………………………………………………… 366
Air Inlet and Exhaust System……………………………………………………………………….. 368
Exhaust System………………………………………………………………………………… 368
Clean Emissions Module (Diesel Oxidation Catalyst (DOC) and Selective Catalytic Reduction (SCR) System)…. 423
DEF Dosing Control System………………………………………………………………………. 426
Electrical System…………………………………………………………………………………. 447
Electrical Control System………………………………………………………………………. 447
Sensor Locations for the Engine…………………………………………………………………. 450
Sensor Locations for the Clean Emissions Module…………………………………………………… 455
Electronic Control Module (ECM)…………………………………………………………………. 455
Electric Component – Remove and Install………………………………………………………….. 462
Engine Coolant Heater (Option)…………………………………………………………………………. 497
Safety Instructions……………………………………………………………………………….. 501
Disassembly and Assembly…………………………………………………………………………… 501
Changing the Circulating Pump…………………………………………………………………… 501
Changing the Temperature Limiter………………………………………………………………… 503
Changing the Temperature Sensor…………………………………………………………………. 504
Changing the Combustion Air Fan…………………………………………………………………. 506
Changing the Burner, Flame Monitor and Glow Plug………………………………………………….. 508
Changing the Burner Head……………………………………………………………………….. 510
Changing the Heat Exchanger…………………………………………………………………….. 512
Upper Structure………………………………………………………………………………………….. 513
Cabin……………………………………………………………………………………………….. 515
Safety Instructions……………………………………………………………………………….. 519
Cabin Identification………………………………………………………………………………. 519
Roll-over Protective Structure (ROPS)……………………………………………………………. 519
Removal………………………………………………………………………………………….. 521
Installation……………………………………………………………………………………… 527
Completing work…………………………………………………………………………………… 527
Dimensions of Cabin Glass………………………………………………………………………….. 528
Removal and Installation of Cabin Glass……………………………………………………………… 532
Removal of Cabin Glass…………………………………………………………………………. 532
Installation of Cabin Glass…………………………………………………………………….. 534
Installation of Upper Door Glass………………………………………………………………… 539
Installation of Upper Front Glass……………………………………………………………….. 539
Counterweight………………………………………………………………………………………… 541
Safety Instructions……………………………………………………………………………….. 545
General………………………………………………………………………………………….. 546
Warning for Counterweight and Front Attachment Removal…………………………………………….. 546
Removal………………………………………………………………………………………….. 548
Installation……………………………………………………………………………………… 549
Hydraulic Oil Tank……………………………………………………………………………………. 551
Safety Instructions……………………………………………………………………………….. 555
General………………………………………………………………………………………….. 555
Specification…………………………………………………………………………………. 555
Air Breather………………………………………………………………………………….. 558
Removal………………………………………………………………………………………….. 559
Installation……………………………………………………………………………………… 566
Completing Work…………………………………………………………………………………… 567
Fuel Tank……………………………………………………………………………………………. 569
Safety Instructions……………………………………………………………………………….. 573
General………………………………………………………………………………………….. 573
Specification…………………………………………………………………………………. 573
Removal………………………………………………………………………………………….. 576
Completing Work…………………………………………………………………………………… 583
Main Pump……………………………………………………………………………………………. 585
Safety Instructions……………………………………………………………………………….. 589
Axial Piston Pump…………………………………………………………………………………. 589
General Description……………………………………………………………………………. 589
Specifications………………………………………………………………………………… 590
Overview……………………………………………………………………………………… 592
Hydraulic Circuit……………………………………………………………………………… 595
Theory of Operation……………………………………………………………………………. 598
Tools………………………………………………………………………………………… 600
Tightening Torque……………………………………………………………………………… 601
Removal………………………………………………………………………………………. 602
Installation………………………………………………………………………………….. 612
Completing Work……………………………………………………………………………….. 613
Disassembly…………………………………………………………………………………… 614
Reassembly……………………………………………………………………………………. 617
Troubleshooting……………………………………………………………………………….. 620
Maintenance Instructions……………………………………………………………………….. 622
Regulator………………………………………………………………………………………… 624
Parts List……………………………………………………………………………………. 624
Functional Explanation…………………………………………………………………………. 626
Adjustment……………………………………………………………………………………. 633
Section View………………………………………………………………………………….. 636
Pilot Gear Pump…………………………………………………………………………………… 638
Specification…………………………………………………………………………………. 638
Parts List……………………………………………………………………………………. 639
Theory of Operation……………………………………………………………………………. 640
Port and Hydraulic Circuit……………………………………………………………………… 640
Precaution……………………………………………………………………………………. 641
Drive Coupling (Main Pump)…………………………………………………………………………….. 643
Safety Instructions……………………………………………………………………………….. 647
General………………………………………………………………………………………….. 647
Specification…………………………………………………………………………………. 647
Section View……………………………………………………………………………………… 650
Tools………………………………………………………………………………………… 651
Main Control Valve……………………………………………………………………………………. 655
Safety Instructions……………………………………………………………………………….. 659
General………………………………………………………………………………………….. 659
Specification…………………………………………………………………………………. 659
Parts List……………………………………………………………………………………. 666
Theory of Operation……………………………………………………………………………. 668
Cautions for Operation…………………………………………………………………………. 692
Precaution……………………………………………………………………………………….. 693
Removal………………………………………………………………………………………….. 694
Installation……………………………………………………………………………………… 708
Completing Work…………………………………………………………………………………… 708
Disassembly………………………………………………………………………………………. 709
Cautions on Disassembly………………………………………………………………………… 709
Sequence of Disassembly………………………………………………………………………… 710
cleaning and inspection……………………………………………………………………………. 718
Cleaning……………………………………………………………………………………… 718
Inspection……………………………………………………………………………………. 718
Reassembly……………………………………………………………………………………….. 719
Caution on Assembly……………………………………………………………………………. 719
Sequence of Reassembly…………………………………………………………………………. 720
Troubleshooting and adjustment……………………………………………………………………… 730
Troubleshooting……………………………………………………………………………….. 730
Adjusting Relief Valve…………………………………………………………………………. 732
Swing Device…………………………………………………………………………………………. 735
Safety Instructions……………………………………………………………………………….. 739
General………………………………………………………………………………………….. 739
Specification…………………………………………………………………………………. 739
Swing Motor……………………………………………………………………………….. 739
Swing Reduction Gear……………………………………………………………………….. 739
Pinion Gear……………………………………………………………………………….. 739
Parking Brake……………………………………………………………………………… 739
Overview……………………………………………………………………………………… 740
Parts List……………………………………………………………………………………. 742
Swing Motor……………………………………………………………………………….. 742
Swing Reduction Gear……………………………………………………………………….. 744
Theory of Operation……………………………………………………………………………. 746
Hydraulic Motor……………………………………………………………………………. 746
Valve Casing………………………………………………………………………………. 747
Schematic of Operation of Reactionless Valve………………………………………………….. 751
Brake Part………………………………………………………………………………… 752
Cautions for Operation…………………………………………………………………………. 754
Inspection………………………………………………………………………………… 754
Direction of Rotation………………………………………………………………………. 754
External Load at the End of Shaft……………………………………………………………. 755
Hydraulic Oil and Temperature Range………………………………………………………….. 755
Installation and Piping…………………………………………………………………….. 756
Oil Filling and Air Ventilation……………………………………………………………… 756
Instructions before Starting to Operate………………………………………………………. 756
Removal………………………………………………………………………………………….. 757
Installation……………………………………………………………………………………… 762
Completing work…………………………………………………………………………………… 762
Precaution……………………………………………………………………………………….. 763
Tools for Disassembly and Assembly………………………………………………………………. 763
Tightening Torque……………………………………………………………………………… 763
Disassembly………………………………………………………………………………………. 765
Swing Device………………………………………………………………………………….. 765
Swing Motor…………………………………………………………………………………… 766
Swing Reduction Gear…………………………………………………………………………… 771
Reassembly……………………………………………………………………………………….. 775
Swing Motor…………………………………………………………………………………… 775
Swing Reduction Gear…………………………………………………………………………… 780
Troubleshooting…………………………………………………………………………………… 785
General Instructions…………………………………………………………………………… 785
Examination of Hydraulic Motor………………………………………………………………….. 785
Troubleshooting……………………………………………………………………………….. 786
Maintenance Instructions…………………………………………………………………………… 789
Replacement Standard of Worn Parts………………………………………………………………. 789
Standard of Sliding Surface Correction…………………………………………………………… 789
Joystick Valve (Work Lever)……………………………………………………………………………. 791
Safety Instructions……………………………………………………………………………….. 795
General………………………………………………………………………………………….. 795
Specifications………………………………………………………………………………… 795
Overview……………………………………………………………………………………… 796
Parts List……………………………………………………………………………………. 798
Theory of Operation……………………………………………………………………………. 800
Tools and Torques……………………………………………………………………………… 801
Section View……………………………………………………………………………………… 802
Removal………………………………………………………………………………………….. 804
Installation……………………………………………………………………………………… 809
Completing work…………………………………………………………………………………… 810
Tools and Torques…………………………………………………………………………………. 811
Disassembly………………………………………………………………………………………. 811
Reassembly……………………………………………………………………………………….. 815
Dozer Joystick Valve (Option)………………………………………………………………………….. 823
Safety Instructions……………………………………………………………………………….. 827
General………………………………………………………………………………………….. 827
Specifications………………………………………………………………………………… 827
Overview……………………………………………………………………………………… 828
Hydraulic Circuit……………………………………………………………………………… 829
Parts List……………………………………………………………………………………. 830
Theory of Operation……………………………………………………………………………. 831
Tools……………………………………………………………………………………………. 833
Removal………………………………………………………………………………………….. 834
Installation……………………………………………………………………………………… 838
Completing work…………………………………………………………………………………… 839
Disassembly………………………………………………………………………………………. 840
Reassembly……………………………………………………………………………………….. 843
Travel Control Valve (with Damper)……………………………………………………………………… 849
Safety Instructions……………………………………………………………………………….. 853
General………………………………………………………………………………………….. 854
Specification…………………………………………………………………………………. 854
Overview……………………………………………………………………………………… 855
Parts List……………………………………………………………………………………. 856
Theory of Operation……………………………………………………………………………. 858
Section View……………………………………………………………………………………… 860
Removal………………………………………………………………………………………….. 861
Installation……………………………………………………………………………………… 866
Completing Work…………………………………………………………………………………… 867
Disassembly………………………………………………………………………………………. 868
Reassembly……………………………………………………………………………………….. 871
Troubleshooting…………………………………………………………………………………… 876
Solenoid Valve……………………………………………………………………………………….. 877
Safety Instructions……………………………………………………………………………….. 881
General………………………………………………………………………………………….. 881
Specification…………………………………………………………………………………. 881
Overview……………………………………………………………………………………… 882
Parts List……………………………………………………………………………………. 884
Theory of Operation……………………………………………………………………………. 885
Disassembly and Reassembly…………………………………………………………………………. 886
Troubleshooting…………………………………………………………………………………… 887
EPPR Valve (One or Two-way)……………………………………………………………………………. 889
Safety Instructions……………………………………………………………………………….. 893
Specification…………………………………………………………………………………. 893
General………………………………………………………………………………………….. 894
Specification…………………………………………………………………………………. 894
Overview……………………………………………………………………………………… 895
Hydraulic Circuit……………………………………………………………………………… 896
Troubleshooting…………………………………………………………………………………… 896
Accumulator………………………………………………………………………………………….. 897
Safety Instructions……………………………………………………………………………….. 901
General………………………………………………………………………………………….. 901
Specifications………………………………………………………………………………… 903
Gear Pump (Rotation)………………………………………………………………………………….. 905
Safety Instructions……………………………………………………………………………….. 909
General………………………………………………………………………………………….. 909
Specification…………………………………………………………………………………. 909
Overview……………………………………………………………………………………… 910
Location……………………………………………………………………………………… 910
Parts List……………………………………………………………………………………. 911
Single Gear Pump………………………………………………………………………………….. 912
Disassembly…………………………………………………………………………………… 912
Reassembly……………………………………………………………………………………. 914
One Spool Valve(Rotating)……………………………………………………………………………… 919
Safety Instructions……………………………………………………………………………….. 923
General………………………………………………………………………………………….. 923
Specification…………………………………………………………………………………. 923
Overview……………………………………………………………………………………… 924
Port and Hydraulic Circuit………………………………………………………………….. 924
Theory of Operation……………………………………………………………………………. 925
In the Neutral Condition……………………………………………………………………. 925
Spool Operation……………………………………………………………………………. 925
Disassembly and Assembly…………………………………………………………………………… 927
General Cautions………………………………………………………………………………. 927
Replacement of Spool…………………………………………………………………………… 928
Replacement of Main Relief Valve………………………………………………………………… 930
Replacement of Overload Relief Valve…………………………………………………………….. 931
Replacement of Sub-Block……………………………………………………………………….. 933
Lower Structure and Chassis……………………………………………………………………………….. 935
Swing Bearing………………………………………………………………………………………… 937
Safety Instructions……………………………………………………………………………….. 941
General………………………………………………………………………………………….. 942
General Description……………………………………………………………………………. 942
Parts List……………………………………………………………………………………. 942
Maintenance Guidelines…………………………………………………………………………….. 943
Disassembly………………………………………………………………………………………. 944
Reassembly……………………………………………………………………………………….. 946
Center Joint…………………………………………………………………………………………. 947
Safety Instructions……………………………………………………………………………….. 951
General………………………………………………………………………………………….. 951
General Description……………………………………………………………………………. 951
Overview……………………………………………………………………………………… 952
Parts List……………………………………………………………………………………. 953
Section View……………………………………………………………………………………… 954
Removal………………………………………………………………………………………….. 955
Installation……………………………………………………………………………………… 960
Completing Work…………………………………………………………………………………… 960
Reassembly……………………………………………………………………………………….. 964
Troubleshooting, Testing and Adjustment……………………………………………………………… 966
Inspection……………………………………………………………………………………. 966
Testing………………………………………………………………………………………. 966
Center Joint (Dozer)………………………………………………………………………………….. 967
Safety Instructions……………………………………………………………………………….. 971
General………………………………………………………………………………………….. 971
General Description……………………………………………………………………………. 971
Overview……………………………………………………………………………………… 972
Parts List……………………………………………………………………………………. 974
Section View……………………………………………………………………………………… 976
Removal………………………………………………………………………………………….. 977
Installation……………………………………………………………………………………… 982
Completing Work…………………………………………………………………………………… 982
Disassembly………………………………………………………………………………………. 983
Reassembly……………………………………………………………………………………….. 985
Troubleshooting, Testing and Adjustment……………………………………………………………… 987
Inspection……………………………………………………………………………………. 987
Testing………………………………………………………………………………………. 987
Travel Device………………………………………………………………………………………… 989
Safety Instructions……………………………………………………………………………….. 993
General………………………………………………………………………………………….. 993
Specification…………………………………………………………………………………. 993
Overview……………………………………………………………………………………… 994
Parts List……………………………………………………………………………………. 996
Theory of Operation…………………………………………………………………………….1000
Precaution………………………………………………………………………………………..1012
Tools List for Disassembly and Reassembly…………………………………………………………1012
Removal…………………………………………………………………………………………..1013
Installation………………………………………………………………………………………1019
Completing Work……………………………………………………………………………………1019
Section View………………………………………………………………………………………1020
Disassembly……………………………………………………………………………………….1022
General Precautions…………………………………………………………………………….1022
Disassembly Procedure…………………………………………………………………………..1023
Reassembly………………………………………………………………………………………..1035
General Precautions…………………………………………………………………………….1035
Reassembly Procedure……………………………………………………………………………1035
Performance Test…………………………………………………………………………………..1046
Summary of Seal Information…………………………………………………………………………1047
Troubleshooting……………………………………………………………………………………1048
Track Assembly………………………………………………………………………………………..1051
Safety Instructions………………………………………………………………………………..1055
General…………………………………………………………………………………………..1055
Track Tension……………………………………………………………………………………..1056
Track Shoes and Links………………………………………………………………………………1058
Parts List…………………………………………………………………………………….1058
Track Removal………………………………………………………………………………….1059
Track Installation……………………………………………………………………………..1061
Wear Limits and Tolerances………………………………………………………………………1062
Sprocket………………………………………………………………………………………….1064
Wear Limits and Tolerances………………………………………………………………………1064
Front Idler……………………………………………………………………………………….1065
Overview………………………………………………………………………………………1065
Parts List…………………………………………………………………………………….1066
Front Idler Disassembly…………………………………………………………………………1067
Front Idler Reassembly………………………………………………………………………….1068
Wear Limits and Tolerances………………………………………………………………………1070
Upper Roller………………………………………………………………………………………1071
Overview………………………………………………………………………………………1071
Parts List…………………………………………………………………………………….1072
Upper Roller Removal……………………………………………………………………………1073
Upper Roller Disassembly………………………………………………………………………..1073
Upper Roller Reassembly…………………………………………………………………………1075
Wear Limits and Tolerances………………………………………………………………………1076
Lower Roller………………………………………………………………………………………1077
Overview………………………………………………………………………………………1077
Parts List…………………………………………………………………………………….1078
Lower Roller Removal……………………………………………………………………………1079
Lower Roller Installation……………………………………………………………………….1079
Lower Roller Disassembly………………………………………………………………………..1080
Lower Roller Reassembly…………………………………………………………………………1081
Wear Limits and Tolerances………………………………………………………………………1082
Track Adjuster…………………………………………………………………………………….1084
Parts List…………………………………………………………………………………….1084
Disassembly……………………………………………………………………………………1085
Assembly………………………………………………………………………………………1086
Dozer System………………………………………………………………………………………….1089
Safety Instructions………………………………………………………………………………..1093
General Description………………………………………………………………………………..1094
Hydraulic Circuit………………………………………………………………………………….1095
Front……………………………………………………………………………………………………1097
Boom and Arm………………………………………………………………………………………….1099
Safety Instructions………………………………………………………………………………..1103
Specifications…………………………………………………………………………………….1104
One – Piece Boom……………………………………………………………………………….1104
Two – Piece Boom……………………………………………………………………………….1106
Removal…………………………………………………………………………………………..1108
Arm Removal……………………………………………………………………………………1108
Boom Removal…………………………………………………………………………………..1110
Installation………………………………………………………………………………………1111
Arm Installation……………………………………………………………………………….1111
Boom Installation………………………………………………………………………………1111
Completing Work……………………………………………………………………………………1111
Bucket……………………………………………………………………………………………….1113
Safety Instructions………………………………………………………………………………..1117
Bucket Tooth Inspection and Replacement………………………………………………………………1118
Bucket Detaching and Reversal……………………………………………………………………….1121
Detaching……………………………………………………………………………………..1121
Reversal………………………………………………………………………………………1121
Cylinders…………………………………………………………………………………………….1123
Safety Instructions………………………………………………………………………………..1127
General…………………………………………………………………………………………..1127
General Description…………………………………………………………………………….1127
Specification………………………………………………………………………………….1127
Parts List…………………………………………………………………………………….1128
Theory of Operation…………………………………………………………………………….1142
Seal of Cylinder……………………………………………………………………………….1143
Special Tools and Materials………………………………………………………………………… 0
Rod Bushing (DD-bushing) Pushing-in Jig…………………………………………………………..1151
Disassembly……………………………………………………………………………………….1152
Reassembly………………………………………………………………………………………..1157
Troubleshooting……………………………………………………………………………………1161
Hydraulic System………………………………………………………………………………………….1163
Hydraulic System………………………………………………………………………………………1165
Safety Instructions………………………………………………………………………………..1169
Hydraulic System…………………………………………………………………………………..1169
General Description…………………………………………………………………………….1169
Hydraulic Schematic………………………………………………………………………………..1170
General Description…………………………………………………………………………….1170
Hydraulic Component and Oil Flow…………………………………………………………………….1172
Hydraulic Components……………………………………………………………………………1172
Main Oil Circuit……………………………………………………………………………….1174
Pilot Oil Circuit………………………………………………………………………………1175
Return Oil Circuit……………………………………………………………………………..1176
Safety Cutoff Valve Operation……………………………………………………………………….1177
Power Up Valve Operation……………………………………………………………………………1178
Travel High-speed Valve Operation……………………………………………………………………1179
Swing Brake Release Operation……………………………………………………………………….1181
Travel Forward and Backward Operation………………………………………………………………..1183
Boom Up Operation………………………………………………………………………………….1184
Boom Down Operation………………………………………………………………………………..1186
Easy Boom Operation………………………………………………………………………………..1188
Arm Dump Operation…………………………………………………………………………………1190
Arm Crowd Operation………………………………………………………………………………..1192
Bucket Dump Operation………………………………………………………………………………1194
Bucket Crowd Operation……………………………………………………………………………..1196
Combined Bucket Crowd and Boom Up Operation…………………………………………………………..1198
Combined Travel and Boom, Arm, Bucket or Swing Operation……………………………………………….1199
Two Pump Operation…………………………………………………………………………………1200
Hydraulic System Testing and Adjustment………………………………………………………………….1201
Safety Instructions………………………………………………………………………………..1205
Procedural Troubleshooting Baseline Recommendations……………………………………………………1206
Initial Checks and Tests to Establish Operating Condition of the Excavator……………………………1206
Pilot Pressure…………………………………………………………………………………….1208
Adjustment and Testing………………………………………………………………………….1208
Power Mode Valve…………………………………………………………………………………..1209
Current Signal and Hydraulic Pressure Adjustments………………………………………………….1209
Pressure Up Valve………………………………………………………………………………….1210
Checks and Adjustments………………………………………………………………………….1210
Pump Input Power Control……………………………………………………………………………1212
Pump Regulator Adjustment……………………………………………………………………….1212
Flow Meter and Flow Meter Kit Installation and Testing…………………………………………………1215
Swing System Troubleshooting………………………………………………………………………..1217
Precautions/Initial Checks………………………………………………………………………1217
Swing Relief Valve Checking and Adjustment………………………………………………………..1218
Hydraulic System Troubleshooting………………………………………………………………………..1221
Safety Instructions………………………………………………………………………………..1225
Hydraulic System…………………………………………………………………………………..1225
Unusual Noise Comes Out from Pump Connection………………………………………………………1225
Engine Starts but Machine Does Not Operate………………………………………………………..1226
Hydraulic Oil is Cloudy…………………………………………………………………………1227
Hydraulic Oil Overheated………………………………………………………………………..1227
Hydraulic Pump Cavitation……………………………………………………………………….1228
Hydraulic Oil is Contaminated……………………………………………………………………1228
Boom, Arm, Bucket Speed is Slow………………………………………………………………….1229
Boom, Arm or Bucket Power is Weak………………………………………………………………..1230
Cylinder Moves When Remote Control Valve is in the Neutral Position………………………………….1230
TR (L), TR (R) Swing Does Not Operate When Remote Control Valve Operated……………………………..1231
Swing Speed is Slow…………………………………………………………………………….1232
Does Not Operate Boom Floating…………………………………………………………………..1233
Machine Swings but Does Not Stop…………………………………………………………………1233
One Side Speed is Falls and the Machine Curves…………………………………………………….1234
Machine Does Not Stop on a Slope…………………………………………………………………1235
Travel Motor is Powerless (Travel Only)…………………………………………………………..1235
Machine Makes a Curved Travel, When Travel and Actuator Operation are Executed a the Same Time………….1236
Does Not Travel is 2nd Speed or Auto Speed………………………………………………………..1236
Troubleshooting – Swing Gearbox……………………………………………………………………..1237
Troubleshooting – Hydraulic Problems…………………………………………………………………1238
Troubleshooting – Control Valve……………………………………………………………………..1240
Troubleshooting – Travel Control Valve……………………………………………………………….1241
Troubleshooting – Joystick Control Valve……………………………………………………………..1242
Electrical System…………………………………………………………………………………………1243
Electrical System……………………………………………………………………………………..1245
Safety Instructions………………………………………………………………………………..1251
Introduction………………………………………………………………………………………1251
Electrical Supply System……………………………………………………………………………1252
Engine Starting Circuit…………………………………………………………………………….1254
Start Operation………………………………………………………………………………..1254
After Start……………………………………………………………………………………1256
Engine Stop……………………………………………………………………………………….1258
Monitoring System………………………………………………………………………………….1261
Instrument Panel……………………………………………………………………………….1262
Functional Check……………………………………………………………………………….1262
Monitoring System Schematic……………………………………………………………………..1264
Operation…………………………………………………………………………………………1266
Instruments……………………………………………………………………………………1266
Warning and Indicator Lights……………………………………………………………………….. 0
Indication of Multifunction Gauge………………………………………………………………..1271
Initial Operation………………………………………………………………………………….1273
Graphic Information Area Display…………………………………………………………………….1274
Overview………………………………………………………………………………………1274
Main Menus for the Graphic Display Area…………………………………………………………..1274
Menu Selector Buttons…………………………………………………………………………..1274
User Menu…………………………………………………………………………………………1275
User Menu – Access and Escape Methods…………………………………………………………….1275
Special Menu………………………………………………………………………………………1312
Entering/Accessing and Exiting/Escaping Menus……………………………………………………..1312
Special Menu Selections…………………………………………………………………………1313
Failure Code………………………………………………………………………………………1329
Failure Code at Machine…………………………………………………………………………1329
Failure Code at Engine Side……………………………………………………………………..1332
FMIs (Failure Mode Identifier)…………………………………………………………………..1340
Electronic Hydraulic Control System (EPOS)……………………………………………………………1342
Control System Schematic………………………………………………………………………..1342
Power Plus Mode Control…………………………………………………………………………….1344
Operation……………………………………………………………………………………..1346
Power Mode Control…………………………………………………………………………………1348
Smart Power Control (SPC)…………………………………………………………………………..1350
Operation……………………………………………………………………………………..1350
Engine Control System………………………………………………………………………………1353
Engine Control Dial………………………………………………………………………………..1354
Engine Control…………………………………………………………………………………….1356
Automatic Deceleration Control (Auto Idle Control)…………………………………………………….1358
Engine Overheat Protection System……………………………………………………………………1360
Power Boost Mode…………………………………………………………………………………..1363
Operation……………………………………………………………………………………..1363
Power Boost Control…………………………………………………………………………….1364
Automatic Travel Speed Control………………………………………………………………………1366
Water in Fuel Warning System………………………………………………………………………..1369
Operation……………………………………………………………………………………..1369
Self-diagnostic Function……………………………………………………………………………1370
EPOS Controller………………………………………………………………………………..1370
Air Conditioner System……………………………………………………………………………..1372
Outline……………………………………………………………………………………….1372
Internal and External Filters……………………………………………………………………1373
Air-Conditioning System Layout…………………………………………………………………..1374
Air Conditioner/Heater Unit……………………………………………………………………..1378
Ambient Air Temperature Sensor…………………………………………………………………..1383
Receiver Dryer…………………………………………………………………………………1392
Troubleshooting……………………………………………………………………………………1393
Refrigerant System Repairs………………………………………………………………………….1395
Refrigerant Safe Handling Procedures……………………………………………………………..1395
Repair and Replacement Procedure…………………………………………………………………1396
Refrigerant Recovery……………………………………………………………………………1398
Vacuuming Refrigerant System…………………………………………………………………….1398
Leakage Check………………………………………………………………………………….1400
Refrigerant Charging……………………………………………………………………………1400
Inspecting System For Leakage……………………………………………………………………1402
Wiper System……………………………………………………………………………………… 0
Wiper Operation………………………………………………………………………………..1404
Lighting System…………………………………………………………………………………… 0
Kind of Light………………………………………………………………………………….1407
Operation……………………………………………………………………………………..1407
Overload Warning Device…………………………………………………………………………….1408
Overload Warning Device Circuit Diagram…………………………………………………………..1408
Options………………………………………………………………………………………………….1411
One Way………………………………………………………………………………………………1413
Safety Instructions………………………………………………………………………………..1417
General…………………………………………………………………………………………..1417
General Description…………………………………………………………………………….1417
Theory of Operation…………………………………………………………………………….1417
Hydraulic Circuit………………………………………………………………………………1418
Caution for Installation………………………………………………………………………..1419
Installation Procedure……………………………………………………………………………..1420
Main Piping – One and Two-way……………………………………………………………………1420
Main Piping – One Way…………………………………………………………………………..1422
Boom Piping – One and Two-way……………………………………………………………………1427
Arm Piping – One or Two-way……………………………………………………………………..1428
After Installation Precautions…………………………………………………………………..1429
Air Bleeding…………………………………………………………………………………..1429
Completing Work……………………………………………………………………………………1430
Two-way………………………………………………………………………………………………1431
Safety Instructions………………………………………………………………………………..1435
General…………………………………………………………………………………………..1435
General Description…………………………………………………………………………….1435
Theory of Operation…………………………………………………………………………….1435
Structure……………………………………………………………………………………..1436
Hydraulic Circuit………………………………………………………………………………1437
Caution for Installation………………………………………………………………………..1439
Installation Procedure……………………………………………………………………………..1440
Main Piping – One and Two-way……………………………………………………………………1440
Main Piping – Two-way…………………………………………………………………………..1442
Pilot Piping – Two-way………………………………………………………………………….1446
Boom Piping – One and Two-way……………………………………………………………………1450
Arm Piping – One or Two-way……………………………………………………………………..1452
After Installation Precautions…………………………………………………………………..1453
Air Bleeding…………………………………………………………………………………..1453
Completing Work……………………………………………………………………………………1454
Rotating……………………………………………………………………………………………..1455
Safety Instructions………………………………………………………………………………..1459
General…………………………………………………………………………………………..1459
General Description…………………………………………………………………………….1459
Theory of Operation…………………………………………………………………………….1459
Structure……………………………………………………………………………………..1460
Hydraulic Circuit………………………………………………………………………………1461
Caution for Installation………………………………………………………………………..1462
Installation Procedure…………………………………………………………………………….. 0
Pilot Piping – Rotating…………………………………………………………………………1466
Boom Piping – Rotating………………………………………………………………………….1468
Arm Piping – Rotating…………………………………………………………………………..1470
After Installation Precautions…………………………………………………………………..1471
Air Bleeding…………………………………………………………………………………..1471
Completing Work……………………………………………………………………………………1471
Quick Coupler…………………………………………………………………………………………1473
Safety Instructions………………………………………………………………………………..1477
General…………………………………………………………………………………………..1477
General Description…………………………………………………………………………….1477
Theory of Operation…………………………………………………………………………….1477
Hydraulic Circuit………………………………………………………………………………1478
Caution for Installation………………………………………………………………………..1479
Quick Coupler Operation…………………………………………………………………………….1480
Securing Work Tool……………………………………………………………………………..1480
Attaching Quick Coupler to Excavator……………………………………………………………..1480
Releasing the Work Tool…………………………………………………………………………1482
Installation Procedure……………………………………………………………………………..1484
Main Piping – Quick Coupler……………………………………………………………………..1484
Electric Parts – Quick Coupler…………………………………………………………………..1485
Boom Piping – Quick Coupler……………………………………………………………………..1486
Arm Piping – Quick Coupler………………………………………………………………………1488
After Installation Precautions…………………………………………………………………..1489
Air Bleeding…………………………………………………………………………………..1489
Completing Work……………………………………………………………………………………1489
Two Pump……………………………………………………………………………………………..1491
Safety Instructions………………………………………………………………………………..1495
General…………………………………………………………………………………………..1495
General Description…………………………………………………………………………….1495
Theory of Operation…………………………………………………………………………….1495
Hydraulic Circuit………………………………………………………………………………1496
Caution for Installation………………………………………………………………………..1497
Installation Procedure……………………………………………………………………………..1498
Main Piping – Two Pump………………………………………………………………………….1498
Pilot Piping – Two Pump…………………………………………………………………………1500
After Installation Precautions…………………………………………………………………..1501
Air Bleeding…………………………………………………………………………………..1501
Schematic………………………………………………………………………………………………..1503
Hydraulic Schematic/ Electrical Schematic………………………………………………………………..1505
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