Doosan DX190W-3 Excavator Shop Manual 950106-00402E – PDF DOWNLOAD
DESCRIPTION:
950106-00402E
- 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. Wheeled Excavator Maintenance Safety SP002611 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.
TABLE OF CONTENTS:
Doosan DX190W-3 Excavator Shop Manual 950106-00402E – PDF DOWNLOAD
DX190W-3………………………………………………………………………………………………………………………………………………. 0
Table of Contents…………………………………………………………………………………………………………………………………… 7
Safety…………………………………………………………………………………………………………………………………………….. 9
Wheeled Excavator Maintenance Safety SP002611………………………………………………………………………………………………………. 11
Safety Instructions………………………………………………………………………………………………………………………….. 15
Applicable Models……………………………………………………………………………………………………………………………. 15
Safety Messages……………………………………………………………………………………………………………………………… 17
Signal Words…………………………………………………………………………………………………………………………….. 17
Other Signal Words……………………………………………………………………………………………………………………….. 18
Safety Decals……………………………………………………………………………………………………………………………….. 18
General…………………………………………………………………………………………………………………………………….. 19
Safe Operation is Operator’s Responsibility…………………………………………………………………………………………………. 19
Know Your Machine………………………………………………………………………………………………………………………… 19
Proper Work Tools and Attachments………………………………………………………………………………………………………….. 20
Pressurized Fluids……………………………………………………………………………………………………………………….. 20
Flying or Falling Objects…………………………………………………………………………………………………………………. 21
Personal Protective Equipment (PPE)………………………………………………………………………………………………………… 22
Correction of Machine Problems…………………………………………………………………………………………………………….. 22
Crushing and Cutting……………………………………………………………………………………………………………………… 22
Hot Coolant and Oils – Burn Prevention……………………………………………………………………………………………………… 23
Fire and Explosion Prevention……………………………………………………………………………………………………………… 24
Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)…………………………………………………………………………………… 27
Electrical System and Electrical Shock……………………………………………………………………………………………………… 28
Rollover Protective Structure (ROPS)……………………………………………………………………………………………………….. 28
Transportation………………………………………………………………………………………………………………………………. 32
Obey State and Local Over-the-Road Regulations………………………………………………………………………………………………. 32
Loading and Unloading…………………………………………………………………………………………………………………….. 32
Transporting Machine……………………………………………………………………………………………………………………… 33
Operation…………………………………………………………………………………………………………………………………… 34
Before Engine Starting……………………………………………………………………………………………………………………. 34
Work Site……………………………………………………………………………………………………………………………….. 35
Mounting/Dismounting……………………………………………………………………………………………………………………… 36
Cleaning………………………………………………………………………………………………………………………………… 37
Operator Station…………………………………………………………………………………………………………………………. 37
Seat Belt……………………………………………………………………………………………………………………………….. 38
Visibility Information……………………………………………………………………………………………………………………. 39
Boost Starting or Charging Engine Batteries…………………………………………………………………………………………………. 40
Starting Engine………………………………………………………………………………………………………………………….. 41
Swinging or Traveling…………………………………………………………………………………………………………………….. 42
Lifting and Digging………………………………………………………………………………………………………………………. 44
Operation on Slopes………………………………………………………………………………………………………………………. 45
Towing………………………………………………………………………………………………………………………………….. 46
Attachment………………………………………………………………………………………………………………………………. 47
Equipment Lowering with Engine Stopped……………………………………………………………………………………………………… 47
Engine Stop……………………………………………………………………………………………………………………………… 47
Parking Machine………………………………………………………………………………………………………………………….. 48
Service Brake……………………………………………………………………………………………………………………………. 49
Preservation/Storing Machine………………………………………………………………………………………………………………. 50
Maintenance…………………………………………………………………………………………………………………………………. 52
Warning Tag……………………………………………………………………………………………………………………………… 55
Cleaning………………………………………………………………………………………………………………………………… 56
Proper Tools and Clothing…………………………………………………………………………………………………………………. 56
Disassembling Precautions…………………………………………………………………………………………………………………. 56
Use of Lighting………………………………………………………………………………………………………………………….. 57
Fire and Explosion Prevention……………………………………………………………………………………………………………… 57
Burn Prevention………………………………………………………………………………………………………………………….. 58
Rubber That Contains Fluorides…………………………………………………………………………………………………………….. 59
Rubber and Plastics………………………………………………………………………………………………………………………. 60
Welding Repairs………………………………………………………………………………………………………………………….. 61
Warning for Counterweight and Front Attachment Removal……………………………………………………………………………………….. 62
Working on Machine……………………………………………………………………………………………………………………….. 63
Lock Inspection Covers……………………………………………………………………………………………………………………. 63
Accumulator……………………………………………………………………………………………………………………………… 64
Compressed Air…………………………………………………………………………………………………………………………… 64
Supports and Blocking for Work Equipment……………………………………………………………………………………………………. 64
High-pressure Lines, Tubes and Hoses……………………………………………………………………………………………………….. 65
Battery…………………………………………………………………………………………………………………………………. 66
Environment and Circumstances…………………………………………………………………………………………………………………. 68
Work Site Areas Requiring Extra Caution…………………………………………………………………………………………………….. 68
High-voltage Cables………………………………………………………………………………………………………………………. 70
Underground Operation…………………………………………………………………………………………………………………….. 71
Working in Water…………………………………………………………………………………………………………………………. 71
Working in Contaminated Environment………………………………………………………………………………………………………… 71
Operation in Extreme Conditions……………………………………………………………………………………………………………. 72
Exhaust Ventilation………………………………………………………………………………………………………………………. 76
Asbestos Information……………………………………………………………………………………………………………………… 76
Silica Dust Information…………………………………………………………………………………………………………………… 77
Disposal of Hazardous Materials……………………………………………………………………………………………………………. 77
Sound…………………………………………………………………………………………………………………………………… 78
Vibration……………………………………………………………………………………………………………………………….. 78
Specifications……………………………………………………………………………………………………………………………………… 79
Specifications for DX190W-3 SP002684………………………………………………………………………………………………………………. 81
Safety Instructions………………………………………………………………………………………………………………………….. 85
Applicable Models……………………………………………………………………………………………………………………………. 85
General Description………………………………………………………………………………………………………………………….. 87
Component Locations………………………………………………………………………………………………………………………….. 88
General Dimensions…………………………………………………………………………………………………………………………… 90
One – Piece Boom…………………………………………………………………………………………………………………………. 90
Two – Piece Boom…………………………………………………………………………………………………………………………. 91
Working Range……………………………………………………………………………………………………………………………….. 92
One – Piece Boom…………………………………………………………………………………………………………………………. 92
Two – Piece Boom…………………………………………………………………………………………………………………………. 94
General Specifications……………………………………………………………………………………………………………………….. 96
Engine Performance Curves (Per KS-R1004 Standard)……………………………………………………………………………………………….. 98
Approximate Weight of Workload Materials……………………………………………………………………………………………………….. 100
Performance Tests……………………………………………………………………………………………………………………………. 102
Excavator Performance Standards……………………………………………………………………………………………………………….. 103
Test Conditions………………………………………………………………………………………………………………………….. 103
Travel Speed Tests……………………………………………………………………………………………………………………….. 104
Swing Speed and Deceleration Force Test…………………………………………………………………………………………………….. 105
Cylinder Performance Tests………………………………………………………………………………………………………………… 107
General Maintenance…………………………………………………………………………………………………………………………………. 109
General Maintenance Instructions SP002454………………………………………………………………………………………………………….. 111
Safety Instructions………………………………………………………………………………………………………………………….. 115
Applicable Models……………………………………………………………………………………………………………………………. 115
Welding Precautions and Instructions…………………………………………………………………………………………………………… 116
Hydraulic System – General Precautions…………………………………………………………………………………………………………. 117
Maintenance Service and Repair Procedure……………………………………………………………………………………………………….. 119
General Precautions………………………………………………………………………………………………………………………. 119
Hydraulic System Cleanliness and Oil Leaks……………………………………………………………………………………………………… 120
Maintenance Precautions for Hydraulic System Service…………………………………………………………………………………………. 120
Oil Leakage Precautions…………………………………………………………………………………………………………………… 121
Cleaning and Inspection………………………………………………………………………………………………………………………. 122
General Instructions……………………………………………………………………………………………………………………… 122
Bearing Inspection……………………………………………………………………………………………………………………….. 123
Standard Torques SP002404………………………………………………………………………………………………………………………… 131
Safety Instructions………………………………………………………………………………………………………………………….. 135
Applicable Models……………………………………………………………………………………………………………………………. 135
Torque Values for Standard Metric Fasteners…………………………………………………………………………………………………….. 136
Torque Values for Standard U.S. Fasteners………………………………………………………………………………………………………. 137
Type 8 Phosphate Coated Hardware………………………………………………………………………………………………………………. 139
Torque Values for Hose Clamps…………………………………………………………………………………………………………………. 140
ORFS Swivel Nut Recommended Torque…………………………………………………………………………………………………………….. 140
Torque Values for Split Flanges……………………………………………………………………………………………………………….. 141
Torque Wrench Extension Tools…………………………………………………………………………………………………………………. 142
Torque Multiplication…………………………………………………………………………………………………………………….. 142
Other Uses for Torque Wrench Extension Tools………………………………………………………………………………………………… 143
Tightening Torque Specifications (Metric)…………………………………………………………………………………………………… 144
Upper Structure…………………………………………………………………………………………………………………………………….. 147
Cabin SP002613………………………………………………………………………………………………………………………………….. 149
Safety Instructions………………………………………………………………………………………………………………………….. 153
Applicable Models……………………………………………………………………………………………………………………………. 153
Cabin Identification…………………………………………………………………………………………………………………………. 154
Rollover Protective Structure (ROPS)……………………………………………………………………………………………………….. 154
Removal…………………………………………………………………………………………………………………………………….. 156
Installation………………………………………………………………………………………………………………………………… 160
Counterweight SP002688…………………………………………………………………………………………………………………………… 163
Safety Instructions………………………………………………………………………………………………………………………….. 167
Applicable Models……………………………………………………………………………………………………………………………. 167
General…………………………………………………………………………………………………………………………………….. 168
Warning for Counterweight and Front Attachment Removal……………………………………………………………………………………….. 168
Removal…………………………………………………………………………………………………………………………………….. 170
Installation………………………………………………………………………………………………………………………………… 171
Fuel Tank SP002687………………………………………………………………………………………………………………………………. 173
Safety Instructions………………………………………………………………………………………………………………………….. 177
Applicable Models……………………………………………………………………………………………………………………………. 177
General Description………………………………………………………………………………………………………………………….. 178
Parts List………………………………………………………………………………………………………………………………. 178
Specifications…………………………………………………………………………………………………………………………… 179
Removal…………………………………………………………………………………………………………………………………….. 180
Installation………………………………………………………………………………………………………………………………… 185
Start-up Procedures………………………………………………………………………………………………………………………….. 188
Fuel Transfer Pump (Option) SP002616………………………………………………………………………………………………………………. 189
Safety Instructions………………………………………………………………………………………………………………………….. 193
Applicable Models……………………………………………………………………………………………………………………………. 193
General Description………………………………………………………………………………………………………………………….. 194
Theory of Operation………………………………………………………………………………………………………………………. 194
Troubleshooting……………………………………………………………………………………………………………………………… 195
Replacement of Rotor and Vane…………………………………………………………………………………………………………………. 195
Replacement of Rear Cover…………………………………………………………………………………………………………………….. 196
Replacement of Armature………………………………………………………………………………………………………………………. 196
Swing Bearing SP002617…………………………………………………………………………………………………………………………… 197
Safety Instructions………………………………………………………………………………………………………………………….. 201
Applicable Models……………………………………………………………………………………………………………………………. 201
Swing Bearing Maintenance…………………………………………………………………………………………………………………….. 202
Operating Recommendation………………………………………………………………………………………………………………….. 202
Measuring Swing Bearing Axial Play…………………………………………………………………………………………………………. 202
Measuring Bearing Lateral Play…………………………………………………………………………………………………………….. 202
Swing Bearing Basic Operation……………………………………………………………………………………………………………… 203
Disassembly……………………………………………………………………………………………………………………………… 203
Assembly………………………………………………………………………………………………………………………………… 205
Air Compressor SP002619………………………………………………………………………………………………………………………….. 207
Safety Instructions………………………………………………………………………………………………………………………….. 211
Applicable Models……………………………………………………………………………………………………………………………. 211
General Description………………………………………………………………………………………………………………………….. 212
Parts List………………………………………………………………………………………………………………………………. 212
Specifications…………………………………………………………………………………………………………………………… 212
Locations of Product Number and Serial Number……………………………………………………………………………………………….. 213
Operation and Inspection……………………………………………………………………………………………………………………… 213
Operating Instructions……………………………………………………………………………………………………………………. 213
Instructions Before Inspection and Maintenance………………………………………………………………………………………………. 214
Maintenance Intervals…………………………………………………………………………………………………………………….. 214
Troubleshooting……………………………………………………………………………………………………………………………… 216
Lower Structure and Chassis………………………………………………………………………………………………………………………….. 217
Ram Lock Valve SP002620………………………………………………………………………………………………………………………….. 219
Safety Instructions………………………………………………………………………………………………………………………….. 223
Applicable Models……………………………………………………………………………………………………………………………. 223
Sectional Drawing and Part Names………………………………………………………………………………………………………………. 224
Hydraulic Circuit……………………………………………………………………………………………………………………………. 224
Operational Principle………………………………………………………………………………………………………………………… 225
In Case of No Pilot Pressure at PI Port…………………………………………………………………………………………………….. 225
In Case of Pilot Pressure (Approx. 20 kg/ cm2) at PI Port…………………………………………………………………………………….. 225
Disassembly and Assembly……………………………………………………………………………………………………………………… 225
General Instructions……………………………………………………………………………………………………………………… 225
Assembly and Disassembly of Chocking Valve………………………………………………………………………………………………….. 226
Performance Test…………………………………………………………………………………………………………………………….. 227
Oil Leakage Test…………………………………………………………………………………………………………………………. 227
Operational Test…………………………………………………………………………………………………………………………. 227
Double Pilot Check Valve SP002621…………………………………………………………………………………………………………………. 229
Safety Instructions………………………………………………………………………………………………………………………….. 233
Applicable Models……………………………………………………………………………………………………………………………. 233
Sectional Drawing and Parts…………………………………………………………………………………………………………………… 234
Hydraulic Diagram……………………………………………………………………………………………………………………………. 234
Operational Principle………………………………………………………………………………………………………………………… 235
A Æ C, D Æ B…………………………………………………………………………………………………………………………….. 235
B Æ D, C Æ A…………………………………………………………………………………………………………………………….. 235
Disassembly and Assembly……………………………………………………………………………………………………………………… 236
General Cautions…………………………………………………………………………………………………………………………. 236
Assembly and Disassembly of Double Pilot Check Valve…………………………………………………………………………………………. 237
Performance Test…………………………………………………………………………………………………………………………….. 238
Cracking Pressure Test for Check Cartridge Assembly………………………………………………………………………………………….. 239
Pilot Cracking Pressure Test………………………………………………………………………………………………………………. 239
Oil Leakage Test…………………………………………………………………………………………………………………………. 239
Solenoid Valve SP002622………………………………………………………………………………………………………………………….. 241
Safety Instructions………………………………………………………………………………………………………………………….. 245
Applicable Models……………………………………………………………………………………………………………………………. 245
Single Solenoid Valve………………………………………………………………………………………………………………………… 246
Function………………………………………………………………………………………………………………………………… 247
Disassembly and Reassembly Diagrams………………………………………………………………………………………………………… 248
Troubleshooting………………………………………………………………………………………………………………………….. 249
Double Solenoid Valve………………………………………………………………………………………………………………………… 250
Function………………………………………………………………………………………………………………………………… 251
Disassembly and Reassembly Diagrams………………………………………………………………………………………………………… 252
Troubleshooting………………………………………………………………………………………………………………………….. 253
Front Axle SP002765……………………………………………………………………………………………………………………………… 255
Safety Instructions………………………………………………………………………………………………………………………….. 259
Applicable Models……………………………………………………………………………………………………………………………. 259
Examples of Gear Tooth-Contact Patterns for the Gleason Gear Tooth System………………………………………………………………………. 260
Lubrication and Maintenance Specifications for Axle MS-E 3050 / 3060 / 3070 and MS-E 3050 II / 3060 II / 3070 II……………………………………….. 262
Oil Grade……………………………………………………………………………………………………………………………….. 262
Oil Change………………………………………………………………………………………………………………………………. 262
Oil Change Interval………………………………………………………………………………………………………………………. 264
Oil Level Check………………………………………………………………………………………………………………………….. 264
Brake…………………………………………………………………………………………………………………………………… 264
Brake Wear Measurement on Axles of MT/MS-E 3050 / 3050 II / 3060 / 3060 II / 3070 / 3070 II Range…………………………………………………….. 265
Lining Wear Measurement of Multidisk Brake………………………………………………………………………………………………….. 266
Disassembly…………………………………………………………………………………………………………………………………. 267
Steering………………………………………………………………………………………………………………………………… 267
Output………………………………………………………………………………………………………………………………….. 271
Planetary Carrier…………………………………………………………………………………………………………………….. 272
Brake/Hub……………………………………………………………………………………………………………………………. 273
Knuckle Housing………………………………………………………………………………………………………………………. 276
Differential – Input……………………………………………………………………………………………………………………… 279
Differential Version “D-500” and “D-750″………………………………………………………………………………………………… 280
Input……………………………………………………………………………………………………………………………….. 282
Pivot Bearing……………………………………………………………………………………………………………………………. 284
Reassembly………………………………………………………………………………………………………………………………….. 285
Input…………………………………………………………………………………………………………………………………… 285
Determine Shim for Pinion Positioning to Obtain An Optimum Contact Pattern of Crown Wheel/pinion – Refer to Contact Pattern Examples, (See page -6)…. 285
Adjust Rolling Moment of Drive Pinion Bearing 1.0 – 2.0 Nm (Without Seal Ring):……………………………………………………………… 287
Differential Version “D-500” and “D-750″………………………………………………………………………………………………… 289
Adjust Backlash of Bevel Gear Set and Bearing Rolling Moment of Differential Bearing…………………………………………………………. 292
Backlash and Contact Pattern Check……………………………………………………………………………………………………… 295
Input Flange…………………………………………………………………………………………………………………………….. 298
Output………………………………………………………………………………………………………………………………….. 299
Preassemble Axle Housing………………………………………………………………………………………………………………. 300
Knuckle Housing………………………………………………………………………………………………………………………. 302
Hub…………………………………………………………………………………………………………………………………. 306
Multidisk Brake………………………………………………………………………………………………………………………. 310
Planetary Carrier…………………………………………………………………………………………………………………….. 316
Pivot Bearing……………………………………………………………………………………………………………………………. 318
Steering………………………………………………………………………………………………………………………………… 319
Steering Setting and Checking………………………………………………………………………………………………………….. 325
Oil Drain-Oil Filler and Oil Control Plugs and Grease Lubrication Points……………………………………………………………………….. 328
Rear Axle SP002766………………………………………………………………………………………………………………………………. 329
Safety Instructions………………………………………………………………………………………………………………………….. 333
Applicable Models……………………………………………………………………………………………………………………………. 333
Examples of Gear Tooth-Contact Patterns for the Gleason Gear Tooth System………………………………………………………………………. 334
Lubrication and Maintenance Specifications for Axle MT-E 3050 / 3060 / 3070 and MT-E 3050 II / 3060 II / 3070 II……………………………………….. 336
Oil Grade……………………………………………………………………………………………………………………………….. 336
Oil Change………………………………………………………………………………………………………………………………. 336
Oil Change Interval………………………………………………………………………………………………………………………. 338
Oil Level Check………………………………………………………………………………………………………………………….. 338
Brake…………………………………………………………………………………………………………………………………… 338
Brake Wear Measurement on Axles of MT/MS-E 3050 / 3050 II / 3060 / 3060 II / 3070 / 3070 II Range…………………………………………………….. 339
Lining Wear Measurement of Multidisk Brake………………………………………………………………………………………………….. 340
Disassembly…………………………………………………………………………………………………………………………………. 341
Reassembly………………………………………………………………………………………………………………………………….. 347
Hub Carrier / Hub………………………………………………………………………………………………………………………… 347
Multidisk Brake………………………………………………………………………………………………………………………….. 351
Take Leakage Test of Multidisk Brake……………………………………………………………………………………………………. 354
Adjust and Check Disk Clearance/Piston Stroke……………………………………………………………………………………………. 355
Planetary Carrier………………………………………………………………………………………………………………………… 356
Assembly of An Output Assembly (Figure 78)………………………………………………………………………………………………….. 358
Disassembly…………………………………………………………………………………………………………………………………. 359
Differential/Input……………………………………………………………………………………………………………………….. 359
Input – HL Transmission…………………………………………………………………………………………………………………… 360
Differential Type “D 500” and “D-750″………………………………………………………………………………………………………. 363
Reassembly………………………………………………………………………………………………………………………………….. 365
Differential/Input……………………………………………………………………………………………………………………….. 365
Differential – Type “D-500” and “D-750″…………………………………………………………………………………………………. 365
Determine Shim for Backlash (Crown Wheel/Drive Pinion)……………………………………………………………………………………. 368
Check Backlash and Contact Pattern……………………………………………………………………………………………………… 372
Reassembly of Output Assembly (Figure 123 – 125)…………………………………………………………………………………………….. 374
Engine and Drivetrain……………………………………………………………………………………………………………………………….. 375
Transmission SP002625……………………………………………………………………………………………………………………………. 377
Safety Instructions………………………………………………………………………………………………………………………….. 381
Applicable Models……………………………………………………………………………………………………………………………. 381
Layout 2 HL 250/270/290 Axle Attachment………………………………………………………………………………………………………… 382
Layout 2 HL 250/270/290 Separate Installation…………………………………………………………………………………………………… 383
Measuring Points and Connections or Installation View 2 HL 250/ 270/290 Layout “Axle Attachment”……………………………………………………… 384
Measuring Points and Connections on the 2 HL 250/270/290 Transmission – Version “Separate Installation”……………………………………………….. 386
Notes to the Required Oil Quality and Oil Filling Capacity……………………………………………………………………………………….. 387
Oil Quality/Oil Grade…………………………………………………………………………………………………………………….. 387
Oil Filling Capacity for Power Shift Transmissions (2 HL-250/270/290)………………………………………………………………………….. 387
For the Version “Axle Attachment”………………………………………………………………………………………………………….. 387
Separate the HL-Transmission from the Axle Casing……………………………………………………………………………………………….. 388
Disassembly – Brake/ Clutch/Planet Carrier……………………………………………………………………………………………………… 389
Lube Oil Pump/Downshift Interlock………………………………………………………………………………………………………….. 389
Version “Lube Oil Pump”……………………………………………………………………………………………………………….. 389
Speed Transmitter………………………………………………………………………………………………………………………… 390
Emergency Release (Parking Brake)………………………………………………………………………………………………………….. 390
Input Housing and Modulation Valve…………………………………………………………………………………………………………. 391
Brake/Clutch…………………………………………………………………………………………………………………………….. 392
Planet Carrier…………………………………………………………………………………………………………………………… 398
Disassembly – Output…………………………………………………………………………………………………………………………. 402
Version – Axle Attachment…………………………………………………………………………………………………………………. 402
Version – “Separate Installation”………………………………………………………………………………………………………….. 406
Reassembly – Output………………………………………………………………………………………………………………………….. 410
Version – Axle Attachment…………………………………………………………………………………………………………………. 410
Determine Adjusting Shim for Pinion Gap…………………………………………………………………………………………………. 412
Determine the Adjusting Ring for Rolling Moment/Pinion Bearing…………………………………………………………………………….. 416
Check the Rolling Moment of the Pinion Bearing…………………………………………………………………………………………… 418
Shaft Seal/Output Flange………………………………………………………………………………………………………………. 418
Check the Pinion Gap………………………………………………………………………………………………………………….. 420
Version Separate Installation………………………………………………………………………………………………………….. 421
Shaft Seal/Output Flange………………………………………………………………………………………………………………. 425
Reassembly – Brake/ Clutch/Planet Carrier………………………………………………………………………………………………………. 428
Planet Carrier…………………………………………………………………………………………………………………………… 428
Brake/Clutch…………………………………………………………………………………………………………………………….. 434
Disk Components Brake and Clutch……………………………………………………………………………………………………….. 436
Adjust and check the Disk Clearance/Piston Stroke of Brake and Clutch………………………………………………………………………. 438
Modulation Valve and Input Housing…………………………………………………………………………………………………………. 447
Emergency Release (Parking Brake)………………………………………………………………………………………………………….. 449
Check the Emergency Release for Leak Tightness…………………………………………………………………………………………… 451
Check the Multidisk Brake and Multidisk Clutch for Leak Tightness and Closing Pressure……………………………………………………….. 453
Speed Transmitter………………………………………………………………………………………………………………………… 454
Lube Oil Pump/Downshift Interlock………………………………………………………………………………………………………….. 455
Disassembly – Lube Oil Pump/Downshift Interlock…………………………………………………………………………………………………. 456
Version “with” Lube Oil Pump………………………………………………………………………………………………………………. 456
Version “with” Hydraulic Downshift Interlock………………………………………………………………………………………………… 459
Version “with” Electric Downshift Interlock- Mounted to Transmission…………………………………………………………………………… 462
Reassembly – Lube Oil Pump/Downshift Interlock………………………………………………………………………………………………….. 463
Version “with” Lube Oil Pump………………………………………………………………………………………………………………. 463
Version “with” Hydraulic Downshift Interlock………………………………………………………………………………………………… 469
Version “with” Electric Downshift Interlock – Mounted to the Transmission………………………………………………………………………. 476
Attach the HL-Transmission to the Axle…………………………………………………………………………………………………………. 477
Drive Coupling (Main Pump) SP002626……………………………………………………………………………………………………………….. 479
Safety Instructions………………………………………………………………………………………………………………………….. 483
Applicable Models……………………………………………………………………………………………………………………………. 483
Drive Coupling………………………………………………………………………………………………………………………………. 484
Special Tools……………………………………………………………………………………………………………………………….. 486
Drive Coupling Installation…………………………………………………………………………………………………………………… 487
Installation Procedure……………………………………………………………………………………………………………………. 489
Hydraulics…………………………………………………………………………………………………………………………………………. 491
Hydraulic System Troubleshooting, Testing and Adjustment SP002722…………………………………………………………………………………….. 493
Hydraulic System – General Notes………………………………………………………………………………………………………………. 498
Hydraulic Schematic………………………………………………………………………………………………………………………….. 499
General Notes……………………………………………………………………………………………………………………………. 499
Operation of Working Components……………………………………………………………………………………………………………….. 501
Boom Operating Circuit……………………………………………………………………………………………………………………. 501
Boom Up Circuit………………………………………………………………………………………………………………………….. 501
Boom Down Circuit………………………………………………………………………………………………………………………… 501
Arm Operating Circuit…………………………………………………………………………………………………………………….. 502
Arm Crowd Circuit………………………………………………………………………………………………………………………… 502
Arm Dump Circuit…………………………………………………………………………………………………………………………. 502
Bucket Operating Circuit………………………………………………………………………………………………………………….. 503
Bucket Crowd Circuit……………………………………………………………………………………………………………………… 503
Bucket Dump Circuit………………………………………………………………………………………………………………………. 503
Swing Operating Circuit…………………………………………………………………………………………………………………… 503
Right Swing Operating Circuit……………………………………………………………………………………………………………… 504
Left Swing Operating Circuit………………………………………………………………………………………………………………. 504
Swing Relief Valve and Makeup Valve………………………………………………………………………………………………………… 504
Travel Operating Circuit………………………………………………………………………………………………………………….. 505
Travel Circuit…………………………………………………………………………………………………………………………… 505
Procedural Troubleshooting Baseline Recommendations……………………………………………………………………………………………… 506
Initial Checks and Tests to Establish Operating Condition of the Excavator……………………………………………………………………… 506
Troubleshooting Summary…………………………………………………………………………………………………………………… 506
Pilot Pressure………………………………………………………………………………………………………………………………. 508
Adjustment and Testing……………………………………………………………………………………………………………………. 508
Power Mode Valve…………………………………………………………………………………………………………………………….. 509
Current Signal and Hydraulic Pressure Adjustments……………………………………………………………………………………………. 509
Pressure Up Valve……………………………………………………………………………………………………………………………. 511
Checks and Adjustments……………………………………………………………………………………………………………………. 511
Pump Input Power Control……………………………………………………………………………………………………………………… 513
Pump Regulator Adjustment…………………………………………………………………………………………………………………. 513
Flow Meter and Flow Meter Kit Installation and Testing…………………………………………………………………………………………… 517
Installation and Testing Procedure…………………………………………………………………………………………………………. 517
Swing System Troubleshooting………………………………………………………………………………………………………………….. 519
Precautions/Initial Checks………………………………………………………………………………………………………………… 519
Swing Relief Valve Checking and Adjustment………………………………………………………………………………………………….. 520
Troubleshooting – Swing Gearbox……………………………………………………………………………………………………………….. 522
Troubleshooting – Hydraulic Problems…………………………………………………………………………………………………………… 523
Troubleshooting – Control Valve……………………………………………………………………………………………………………….. 525
Troubleshooting – Travel Control Valve…………………………………………………………………………………………………………. 526
Troubleshooting – Joystick Control Valve……………………………………………………………………………………………………….. 526
Safety Instructions………………………………………………………………………………………………………………………….. 497
Applicable Models……………………………………………………………………………………………………………………………. 497
Accumulator SP002628…………………………………………………………………………………………………………………………….. 527
Safety Instructions………………………………………………………………………………………………………………………….. 531
Applicable Models……………………………………………………………………………………………………………………………. 531
General Description………………………………………………………………………………………………………………………….. 532
Specifications…………………………………………………………………………………………………………………………… 534
Center Joint (Swivel) SP002629……………………………………………………………………………………………………………………. 535
Safety Instructions………………………………………………………………………………………………………………………….. 539
Applicable Models……………………………………………………………………………………………………………………………. 539
General Description………………………………………………………………………………………………………………………….. 540
Parts List………………………………………………………………………………………………………………………………. 541
Troubleshooting, Testing and Adjustment………………………………………………………………………………………………………… 542
Inspection………………………………………………………………………………………………………………………………. 542
Testing…………………………………………………………………………………………………………………………………. 542
Disassembly…………………………………………………………………………………………………………………………………. 543
Reassembly………………………………………………………………………………………………………………………………….. 547
Cylinders SP002708………………………………………………………………………………………………………………………………. 549
Safety Instructions………………………………………………………………………………………………………………………….. 553
Applicable Models……………………………………………………………………………………………………………………………. 553
General Description………………………………………………………………………………………………………………………….. 554
Theory of Operation………………………………………………………………………………………………………………………. 554
Parts List………………………………………………………………………………………………………………………………. 556
Special Tools and Materials…………………………………………………………………………………………………………………… 562
Piston Nut………………………………………………………………………………………………………………………………. 562
Piston Jig………………………………………………………………………………………………………………………………. 564
Steel Bushing Jig………………………………………………………………………………………………………………………… 567
Dust Wiper Jig…………………………………………………………………………………………………………………………… 570
Slipper Seal Jig…………………………………………………………………………………………………………………………. 573
Slipper Seal Straightening Jig…………………………………………………………………………………………………………….. 576
Disassembly…………………………………………………………………………………………………………………………………. 579
Reassembly………………………………………………………………………………………………………………………………….. 584
Swing Device SP002498……………………………………………………………………………………………………………………………. 589
Safety Instructions………………………………………………………………………………………………………………………….. 593
Applicable Models……………………………………………………………………………………………………………………………. 593
Indication of Type…………………………………………………………………………………………………………………………… 594
Specifications………………………………………………………………………………………………………………………………. 595
Structure and Principle of Operation…………………………………………………………………………………………………………… 596
Structure……………………………………………………………………………………………………………………………….. 596
Principles of Operation…………………………………………………………………………………………………………………… 601
Valve Casing…………………………………………………………………………………………………………………………….. 602
Brake Part………………………………………………………………………………………………………………………………. 605
Operation Instructions……………………………………………………………………………………………………………………….. 606
Inspection………………………………………………………………………………………………………………………………. 606
Direction of Rotation…………………………………………………………………………………………………………………….. 606
External Load at the End of Shaft………………………………………………………………………………………………………….. 607
Hydraulic Oil and Temperature Range………………………………………………………………………………………………………… 607
Filter………………………………………………………………………………………………………………………………….. 608
Installation and Piping…………………………………………………………………………………………………………………… 608
Oil Filling and Air Breather………………………………………………………………………………………………………………. 609
Instructions Before Starting to Operate…………………………………………………………………………………………………….. 609
Troubleshooting……………………………………………………………………………………………………………………………… 610
General Instructions……………………………………………………………………………………………………………………… 610
Examination of Hydraulic Motor…………………………………………………………………………………………………………….. 610
Troubleshooting………………………………………………………………………………………………………………………….. 611
Disassembly and Reassembly……………………………………………………………………………………………………………………. 614
Disassemble Swing Motor…………………………………………………………………………………………………………………… 616
Reassemble Swing Motor……………………………………………………………………………………………………………………. 620
Disassemble the Reduction Gear…………………………………………………………………………………………………………….. 625
Reassemble the Reduction Gear……………………………………………………………………………………………………………… 629
Maintenance Instructions………………………………………………………………………………………………………………….. 637
Main Pump and PTO SP002633……………………………………………………………………………………………………………………….. 639
Safety Instructions………………………………………………………………………………………………………………………….. 643
Applicable Models……………………………………………………………………………………………………………………………. 643
Section…………………………………………………………………………………………………………………………………….. 645
General Repair Guidelines…………………………………………………………………………………………………………………….. 646
Seal Kits and Subassemblies…………………………………………………………………………………………………………………… 647
Disassembly…………………………………………………………………………………………………………………………………. 651
Sealing the Driveshaft……………………………………………………………………………………………………………………. 651
Gear Pump Sealing………………………………………………………………………………………………………………………… 653
Control Housing………………………………………………………………………………………………………………………….. 654
Control Module LR………………………………………………………………………………………………………………………… 657
Control Module H…………………………………………………………………………………………………………………………. 658
Controller………………………………………………………………………………………………………………………………. 659
Rotary Groups……………………………………………………………………………………………………………………………. 661
Intermediate Wheel……………………………………………………………………………………………………………………….. 664
Auxiliary Drive………………………………………………………………………………………………………………………….. 666
Inspection Hints…………………………………………………………………………………………………………………………….. 669
Assembly……………………………………………………………………………………………………………………………………. 674
Rotary Group…………………………………………………………………………………………………………………………….. 674
Pump……………………………………………………………………………………………………………………………………. 675
Assembly Guideline……………………………………………………………………………………………………………………. 677
Hydraulic Component – Measurement “D”………………………………………………………………………………………………………. 678
Control Housing………………………………………………………………………………………………………………………….. 681
Intermediate Wheel……………………………………………………………………………………………………………………….. 684
Gear Pump……………………………………………………………………………………………………………………………….. 685
Cover/Auxiliary Drive…………………………………………………………………………………………………………………….. 686
Assembly Guidelines for Tightening Torques……………………………………………………………………………………………………… 687
Bolts (to N 08.001)………………………………………………………………………………………………………………………. 687
Plugs with Internal Hexagon and Profile Seal Ring (to N 02.009)……………………………………………………………………………….. 688
Seal-Lock – Sealing Nuts (to N 02.100)……………………………………………………………………………………………………… 688
Main Control Valve SP002721………………………………………………………………………………………………………………………. 689
Safety Instructions………………………………………………………………………………………………………………………….. 693
Applicable Models……………………………………………………………………………………………………………………………. 693
Functional Description……………………………………………………………………………………………………………………….. 694
PC-control Concept……………………………………………………………………………………………………………………….. 694
General……………………………………………………………………………………………………………………………… 694
Expanding Consumer Sections (Options)…………………………………………………………………………………………………… 695
M9-25 Main Control Block………………………………………………………………………………………………………………….. 696
General Information………………………………………………………………………………………………………………………. 698
Function………………………………………………………………………………………………………………………………… 699
General……………………………………………………………………………………………………………………………… 699
Pump Strategy………………………………………………………………………………………………………………………… 701
Neutral Circulation…………………………………………………………………………………………………………………… 701
Tank and Cooler Valves………………………………………………………………………………………………………………… 702
Summing and Cut Valves………………………………………………………………………………………………………………… 703
Individual Operation………………………………………………………………………………………………………………….. 705
Additional Functions……………………………………………………………………………………………………………………… 725
Tank Line and Cooler Pre-tensioning…………………………………………………………………………………………………….. 725
Secondary Pressure Relief and Feed Valve………………………………………………………………………………………………… 726
Anticavitation (Feed) Valve……………………………………………………………………………………………………………. 727
Pilot-controlled Check Valve (Antidrift Valve)…………………………………………………………………………………………… 728
Check Function (Supply)……………………………………………………………………………………………………………….. 729
Shuttle Damping (Optional)…………………………………………………………………………………………………………….. 731
Part Lists………………………………………………………………………………………………………………………………….. 732
Control Block M9-1060-00………………………………………………………………………………………………………………….. 732
Control Block M9-1060-00 Operation…………………………………………………………………………………………………………. 734
Plate MH4WH 25…………………………………………………………………………………………………………………………… 735
Combined Relief/Anticavitation Valve, Pilot Operated…………………………………………………………………………………………. 736
MHDBB 22 K9-3X/420/21VFC01…………………………………………………………………………………………………………….. 736
MHDBN 22 K2-3X/420-380VLG……………………………………………………………………………………………………………… 737
MHDBN 22 K2-3X/420-4000VFC…………………………………………………………………………………………………………….. 738
Anticavitation Valve……………………………………………………………………………………………………………………… 739
MHSL 02 K10………………………………………………………………………………………………………………………….. 739
Specifications………………………………………………………………………………………………………………………………. 740
Troubleshooting, Testing and Adjustment…………………………………………………………………………………………………….. 740
How to Proceed for Troubleshooting……………………………………………………………………………………………………… 740
Malfunction Table…………………………………………………………………………………………………………………….. 741
Disassembly…………………………………………………………………………………………………………………………………. 743
General Repair Instructions……………………………………………………………………………………………………………….. 743
Repair Instructions………………………………………………………………………………………………………………………. 745
Parts List Control Block………………………………………………………………………………………………………………. 745
Replace Load-holding Valve Spool (Item 130)……………………………………………………………………………………………… 745
Replace Plug Screw (Item 132)………………………………………………………………………………………………………….. 746
Replace Throttle Check Valve (Item 135, 136) for Semi Priority Boom Vs. Bucket and Swing Vs. Arm………………………………………………. 747
Replace Pilot Control Cartridge MHSL 5.5 (Item 210) for Antidrift-valve Boom and Arm…………………………………………………………. 748
Replace Antidrift Valve (Item 140, 141)…………………………………………………………………………………………………. 749
Replace Secondary Pressure Relief Valve (Item 202, 208) / Plug Screw (Item 200)……………………………………………………………… 750
Replace Load-holding Valve Function Consisting of Poppet (Item 205), Spring (Item 206) and Plug Screw (Item 207)………………………………… 751
Replace Spool Boom Summation (Item 170, Similar With Spool Arm Summation Item 171)…………………………………………………………… 752
Replace Main Spool……………………………………………………………………………………………………………………. 753
Replace Pilot Shuttle Valve (Item 163)………………………………………………………………………………………………….. 754
Replace Cut Spool (Item 182)…………………………………………………………………………………………………………… 756
Replace End Plate (Item 113) and Directional Valve (Item 101)……………………………………………………………………………… 757
Replace Inlet Section (Item 220)……………………………………………………………………………………………………….. 759
Replace Pre-load Valves (Item 20 and 21) for Tank Line and Cooler Back Pressure……………………………………………………………… 760
Replace Primary Pressure Relief Valve (Item 222)…………………………………………………………………………………………. 761
Replace Check Valves for Primary Pressure Relief (Item 42)………………………………………………………………………………… 762
Replace Straight Travel Valve………………………………………………………………………………………………………….. 763
Reassembly………………………………………………………………………………………………………………………………….. 764
Unpacking……………………………………………………………………………………………………………………………….. 766
Coating the Control Block…………………………………………………………………………………………………………………. 766
Installation Conditions…………………………………………………………………………………………………………………… 767
Required Tools…………………………………………………………………………………………………………………………… 767
Assembling the Control Block………………………………………………………………………………………………………………. 767
Mechanically Connecting the Control Block…………………………………………………………………………………………………… 768
Hydraulically Connecting the Control Block………………………………………………………………………………………………….. 769
Installing the Electrical Supply…………………………………………………………………………………………………………… 769
Before First Commissioning………………………………………………………………………………………………………………… 770
Commissioning……………………………………………………………………………………………………………………………. 771
First Commissioning…………………………………………………………………………………………………………………… 772
Re-commissioning……………………………………………………………………………………………………………………… 773
Operation……………………………………………………………………………………………………………………………….. 773
Maintenance and Repair……………………………………………………………………………………………………………………. 774
Definition…………………………………………………………………………………………………………………………… 776
Inspection and Maintenance…………………………………………………………………………………………………………….. 776
Repair………………………………………………………………………………………………………………………………. 779
Spare Parts………………………………………………………………………………………………………………………….. 780
Gear Pump SP002702………………………………………………………………………………………………………………………………. 781
Safety Instructions………………………………………………………………………………………………………………………….. 785
Applicable Models……………………………………………………………………………………………………………………………. 785
Single Gear Pump…………………………………………………………………………………………………………………………….. 787
Disassembly……………………………………………………………………………………………………………………………… 787
Reassembly………………………………………………………………………………………………………………………………. 789
Double Gear Pump…………………………………………………………………………………………………………………………….. 793
Disassembly……………………………………………………………………………………………………………………………… 793
Separation 1st and 2nd Working Bodies…………………………………………………………………………………………………… 793
Mounting Flange………………………………………………………………………………………………………………………. 793
1st Working Section…………………………………………………………………………………………………………………… 794
2nd Working Section…………………………………………………………………………………………………………………… 794
Reassembly………………………………………………………………………………………………………………………………. 795
Pressure Plates for 1st Working Section…………………………………………………………………………………………………. 795
Pressure Plates for 2nd Working Section…………………………………………………………………………………………………. 796
1st Working Body……………………………………………………………………………………………………………………… 796
2nd Working Body……………………………………………………………………………………………………………………… 796
Mounting Flange………………………………………………………………………………………………………………………. 797
Travel Motor SP002724……………………………………………………………………………………………………………………………. 799
Safety Instructions………………………………………………………………………………………………………………………….. 803
Applicable Models……………………………………………………………………………………………………………………………. 803
General Repair Instructions…………………………………………………………………………………………………………………… 806
Seal Kits and Subassemblies…………………………………………………………………………………………………………………… 807
Replace Seal Nut…………………………………………………………………………………………………………………………. 809
Disassembly…………………………………………………………………………………………………………………………………. 809
Sealing the Driveshaft……………………………………………………………………………………………………………………. 809
Seal of the Control Parts…………………………………………………………………………………………………………………. 811
Seal of the Relief Valve / Counterbalance Valve……………………………………………………………………………………………… 813
Spare Parts List…………………………………………………………………………………………………………………………. 815
Counterbalance Valve………………………………………………………………………………………………………………….. 815
Brake Release Valve (Pos.4)……………………………………………………………………………………………………………. 816
Shuttle Valve (Pos.3)…………………………………………………………………………………………………………………. 816
Disassembly of the Port Plate……………………………………………………………………………………………………………… 817
Removal of the Positioning Piston………………………………………………………………………………………………………….. 818
Remove Rotary Group………………………………………………………………………………………………………………………. 820
Exchanging of the Rotary Group…………………………………………………………………………………………………………….. 821
Inspection Notes…………………………………………………………………………………………………………………………. 822
Assembly……………………………………………………………………………………………………………………………………. 825
Rotary Group Assembly…………………………………………………………………………………………………………………….. 825
Rotary Group Adjustment (See Service Information)……………………………………………………………………………………………. 827
Assembly of the Port Plate………………………………………………………………………………………………………………… 829
Tightening Torques…………………………………………………………………………………………………………………………… 831
Shaft Bolts……………………………………………………………………………………………………………………………… 831
Locking Screws VSTI………………………………………………………………………………………………………………………. 831
Seal-Locknuts……………………………………………………………………………………………………………………………. 832
Cross-slotted Lens Head Screws DIN 7985…………………………………………………………………………………………………….. 832
Test Procedure………………………………………………………………………………………………………………………………. 833
Hydraulics Schematic……………………………………………………………………………………………………………………… 835
Counterbalance Valve SP002637…………………………………………………………………………………………………………………….. 837
Safety Instructions………………………………………………………………………………………………………………………….. 841
Applicable Models……………………………………………………………………………………………………………………………. 841
General Description………………………………………………………………………………………………………………………….. 842
While Operating to Run Forward…………………………………………………………………………………………………………….. 842
While Operating to Stop…………………………………………………………………………………………………………………… 842
While Operating to Back…………………………………………………………………………………………………………………… 843
Adjustment of Relief Valve………………………………………………………………………………………………………………… 844
Troubleshooting……………………………………………………………………………………………………………………………… 845
Counterbalance Valve…………………………………………………………………………………………………………………………. 846
Recommended Tools………………………………………………………………………………………………………………………… 846
Disassembly……………………………………………………………………………………………………………………………… 846
Order of Disassembly and Torque Values……………………………………………………………………………………………………… 847
Reassembly………………………………………………………………………………………………………………………………. 848
Service Brake Supply Valve SP002638……………………………………………………………………………………………………………….. 853
Safety Instructions………………………………………………………………………………………………………………………….. 857
Applicable Models……………………………………………………………………………………………………………………………. 857
Diagram of Brake Supply Valve Assembly Package………………………………………………………………………………………………. 858
Functions of Brake Supply Valve Assembly Package…………………………………………………………………………………………….. 859
Functions……………………………………………………………………………………………………………………………. 859
Functions of Each Valve……………………………………………………………………………………………………………….. 859
Detailed Functions and Application of Brake Supply Valve Assembly Package…………………………………………………………………… 859
Exploded View and Tools…………………………………………………………………………………………………………………… 861
Cautions for Disassembly and Reassembly…………………………………………………………………………………………………….. 862
Troubleshooting Guide…………………………………………………………………………………………………………………….. 863
How to Check Brake Pressure……………………………………………………………………………………………………………….. 864
Remote Control Valve (Work Lever / Joystick) SP002744……………………………………………………………………………………………….. 865
Safety Instructions………………………………………………………………………………………………………………………….. 869
Applicable Models……………………………………………………………………………………………………………………………. 869
General Description………………………………………………………………………………………………………………………….. 871
Theory of Operation………………………………………………………………………………………………………………………. 871
Parts List………………………………………………………………………………………………………………………………. 872
Specifications…………………………………………………………………………………………………………………………… 874
Torques…………………………………………………………………………………………………………………………………. 874
Tools and Materials………………………………………………………………………………………………………………………….. 874
Disassembly…………………………………………………………………………………………………………………………………. 875
Reassembly………………………………………………………………………………………………………………………………….. 878
Start-up Procedures………………………………………………………………………………………………………………………….. 886
Steering Valve SP002640………………………………………………………………………………………………………………………….. 887
Safety Instructions………………………………………………………………………………………………………………………….. 891
Applicable Models……………………………………………………………………………………………………………………………. 891
General Description………………………………………………………………………………………………………………………….. 892
Theory of Operation………………………………………………………………………………………………………………………. 893
OSPD……………………………………………………………………………………………………………………………………. 894
Tools………………………………………………………………………………………………………………………………………. 896
Disassembly…………………………………………………………………………………………………………………………………. 897
Assembly……………………………………………………………………………………………………………………………………. 902
Hydraulic Connections…………………………………………………………………………………………………………………….. 906
Max. Tightening Torque……………………………………………………………………………………………………………………. 906
Accelerator Pedal Valve (Hydraulic) SP002641……………………………………………………………………………………………………….. 907
Safety Instructions………………………………………………………………………………………………………………………….. 911
Applicable Models……………………………………………………………………………………………………………………………. 911
Structure…………………………………………………………………………………………………………………………………… 912
Parts List………………………………………………………………………………………………………………………………….. 912
Performance Curve……………………………………………………………………………………………………………………………. 913
Hydraulics Symbol……………………………………………………………………………………………………………………………. 913
Disassembly and Assembly Tools………………………………………………………………………………………………………………… 913
Disassembly…………………………………………………………………………………………………………………………………. 914
Assembly……………………………………………………………………………………………………………………………………. 915
Solenoid Valve Assembly SP002642………………………………………………………………………………………………………………….. 917
Safety Instructions………………………………………………………………………………………………………………………….. 921
Applicable Models……………………………………………………………………………………………………………………………. 921
4-Solenoid Valve…………………………………………………………………………………………………………………………….. 922
Diagram of 4-Solenoid Valve Assembly Package………………………………………………………………………………………………… 922
Functions of 4-Solenoid Valve Assembly Package………………………………………………………………………………………………. 923
Functions……………………………………………………………………………………………………………………………. 923
Application by Function of Each Solenoid Valve…………………………………………………………………………………………… 923
Detailed Functions and Application of Each Solenoid Valve…………………………………………………………………………………. 923
Exploded View and Tools…………………………………………………………………………………………………………………… 925
Disassembly, Re-assembly of Solenoid Valve Package, and Necessary Tools…………………………………………………………………….. 925
Instructions for Disassembly and Re- assembly……………………………………………………………………………………………….. 926
Solenoid Valve Diagram………………………………………………………………………………………………………………… 927
Troubleshooting Guide…………………………………………………………………………………………………………………….. 927
Parts……………………………………………………………………………………………………………………………….. 927
How to Check Pilot Pressure……………………………………………………………………………………………………………. 928
4-Solenoid Valve…………………………………………………………………………………………………………………………….. 929
Diagram of 4-Solenoid Valve Assembly Package………………………………………………………………………………………………… 929
Functions of 4-Solenoid Valve Assembly Package………………………………………………………………………………………………. 930
Functions……………………………………………………………………………………………………………………………. 930
Application by Function of Each Solenoid Valve…………………………………………………………………………………………… 930
Detailed Functions and Application of Each Solenoid Valve…………………………………………………………………………………. 931
Exploded View and Tools…………………………………………………………………………………………………………………… 932
Disassembly, Re-assembly of Solenoid Valve Package, and Necessary Tools…………………………………………………………………….. 932
Instructions for Disassembly and Re- assembly……………………………………………………………………………………………….. 933
Solenoid Valve Diagram………………………………………………………………………………………………………………… 934
Troubleshooting Guide…………………………………………………………………………………………………………………….. 934
Parts……………………………………………………………………………………………………………………………….. 934
How to Check Pilot Pressure……………………………………………………………………………………………………………. 935
3-Solenoid Valve…………………………………………………………………………………………………………………………….. 936
Diagram of 3-Solenoid Valve Assembly Package………………………………………………………………………………………………… 936
Functions of 3-Solenoid Valve Assembly Package………………………………………………………………………………………………. 937
Functions……………………………………………………………………………………………………………………………. 937
Application by Function of Each Solenoid Valve…………………………………………………………………………………………… 937
Detailed Functions and Application of Each Solenoid Valve…………………………………………………………………………………. 938
Exploded View and Tools…………………………………………………………………………………………………………………… 939
Disassembly, Re-assembly of Solenoid Valve Package, and Necessary Tools…………………………………………………………………….. 939
Instructions for Disassembly and Re- assembly……………………………………………………………………………………………….. 940
Solenoid Valve Diagram………………………………………………………………………………………………………………… 941
Troubleshooting Guide…………………………………………………………………………………………………………………….. 941
Parts……………………………………………………………………………………………………………………………….. 941
How to Check Pilot Pressure……………………………………………………………………………………………………………. 942
Breaker EPPR Valve (Option) SP002691………………………………………………………………………………………………………………. 943
Safety Instructions………………………………………………………………………………………………………………………….. 947
Applicable Models……………………………………………………………………………………………………………………………. 947
Structure…………………………………………………………………………………………………………………………………… 948
Parts List………………………………………………………………………………………………………………………………. 948
Functions and Operation………………………………………………………………………………………………………………………. 949
Cautions for Operation……………………………………………………………………………………………………………………….. 949
Maintenance Instructions……………………………………………………………………………………………………………………… 950
Maintenance……………………………………………………………………………………………………………………………… 950
Disassembly……………………………………………………………………………………………………………………………… 951
Assembly………………………………………………………………………………………………………………………………… 952
Intelligent Floating Boom (Option) SP002645………………………………………………………………………………………………………… 955
Safety Instructions………………………………………………………………………………………………………………………….. 959
Applicable Models……………………………………………………………………………………………………………………………. 959
General Description………………………………………………………………………………………………………………………….. 960
Parts List………………………………………………………………………………………………………………………………. 960
Assembly Diagram and Tools Required………………………………………………………………………………………………………… 961
Functions and Operations……………………………………………………………………………………………………………………… 962
Operation Instructions……………………………………………………………………………………………………………………. 962
Disassembly and Reassembly Instructions…………………………………………………………………………………………………….. 963
Quick Fit Valve SP002689…………………………………………………………………………………………………………………………. 965
Safety Instructions………………………………………………………………………………………………………………………….. 969
Applicable Models……………………………………………………………………………………………………………………………. 969
General Description………………………………………………………………………………………………………………………….. 970
Parts List………………………………………………………………………………………………………………………………. 970
Assembly Diagram and Tools Required………………………………………………………………………………………………………… 971
Functions and Operations……………………………………………………………………………………………………………………… 972
Operation Instructions……………………………………………………………………………………………………………………. 972
Disassembly and Reassembly Instructions…………………………………………………………………………………………………….. 973
Logic Valve SP002690…………………………………………………………………………………………………………………………….. 975
Safety Instructions………………………………………………………………………………………………………………………….. 979
Applicable Models……………………………………………………………………………………………………………………………. 979
General Description………………………………………………………………………………………………………………………….. 980
Parts List………………………………………………………………………………………………………………………………. 980
Functions and Operations……………………………………………………………………………………………………………………… 981
Assembly Diagram and Tools Required………………………………………………………………………………………………………… 982
Operation Instructions……………………………………………………………………………………………………………………. 983
Disassembly and Reassembly Instructions…………………………………………………………………………………………………….. 983
Dozer Valve SP002529…………………………………………………………………………………………………………………………….. 985
Safety Instructions………………………………………………………………………………………………………………………….. 989
Applicable Models……………………………………………………………………………………………………………………………. 989
Structure Diagram……………………………………………………………………………………………………………………………. 990
Performance Specification…………………………………………………………………………………………………………………….. 991
Hydraulic Pressure Circuit Diagram…………………………………………………………………………………………………………….. 991
Parts List………………………………………………………………………………………………………………………………….. 992
Disassembly and Assembly Tools………………………………………………………………………………………………………………… 993
Disassembly…………………………………………………………………………………………………………………………………. 993
Assembly Method……………………………………………………………………………………………………………………………… 995
Service Brake Pedal Valve SP002723………………………………………………………………………………………………………………… 999
Safety Instructions…………………………………………………………………………………………………………………………..1003
Applicable Models…………………………………………………………………………………………………………………………….1003
Functions of Brake Pedal………………………………………………………………………………………………………………………1005
Internal Structure and Operation Principles……………………………………………………………………………………………………..1006
Internal Structure………………………………………………………………………………………………………………………..1006
Operation Principles………………………………………………………………………………………………………………………1008
Disassembly………………………………………………………………………………………………………………………………….1009
Reassembly…………………………………………………………………………………………………………………………………..1009
Reassembly of the Lower Part……………………………………………………………………………………………………………….1009
Reassembly of the Upper Part……………………………………………………………………………………………………………….1011
Assembly of Pedal Plate……………………………………………………………………………………………………………………1014
Hydraulic Schematic (DX190W-3) SP002692…………………………………………………………………………………………………………….1021
Safety Instructions…………………………………………………………………………………………………………………………..1025
Applicable Models…………………………………………………………………………………………………………………………….1025
DX190W-3…………………………………………………………………………………………………………………………………….1027
Electrical System……………………………………………………………………………………………………………………………………1029
Electrical System SP002649………………………………………………………………………………………………………………………..1031
Safety Instructions…………………………………………………………………………………………………………………………..1037
Applicable Models…………………………………………………………………………………………………………………………….1037
Introduction…………………………………………………………………………………………………………………………………1039
Electrical Supply System………………………………………………………………………………………………………………………1040
Engine Starting Circuit……………………………………………………………………………………………………………………….1042
Start Operation…………………………………………………………………………………………………………………………..1042
After Start………………………………………………………………………………………………………………………………1044
Engine Preheating System………………………………………………………………………………………………………………………1046
Engine Stop………………………………………………………………………………………………………………………………….1048
Charging System………………………………………………………………………………………………………………………………1050
Monitoring System…………………………………………………………………………………………………………………………….1051
Instrument Panel………………………………………………………………………………………………………………………….1052
Functional Check………………………………………………………………………………………………………………………….1052
Monitoring System Schematic………………………………………………………………………………………………………………..1054
Operation……………………………………………………………………………………………………………………………………1056
Instruments………………………………………………………………………………………………………………………………1056
Warning and Indicator Lights…………………………………………………………………………………………………………………..1058
Indication of Warning Lights……………………………………………………………………………………………………………….1058
Indication of Multifunction Gauge…………………………………………………………………………………………………………..1060
Initial Operation…………………………………………………………………………………………………………………………….1062
Graphic Information Area Display……………………………………………………………………………………………………………….1064
Overview…………………………………………………………………………………………………………………………………1064
Main Menus for the Graphic Display Area……………………………………………………………………………………………………..1064
Menu Selector Buttons……………………………………………………………………………………………………………………..1064
User Menu……………………………………………………………………………………………………………………………………1065
User Menu – Access and Escape Methods……………………………………………………………………………………………………….1065
Special Menu…………………………………………………………………………………………………………………………………1093
Entering/Accessing and Exiting/Escaping Menus………………………………………………………………………………………………..1093
Special Menu Selections……………………………………………………………………………………………………………………1094
Electronic Hydraulic Control System (EPOS)………………………………………………………………………………………………………1120
Control System Schematic…………………………………………………………………………………………………………………..1120
Power Plus Mode Control……………………………………………………………………………………………………………………….1122
Operation………………………………………………………………………………………………………………………………..1124
Power Mode Control – Circuit Diagram……………………………………………………………………………………………………………1126
Engine Control System…………………………………………………………………………………………………………………………1128
Engine Control Dial…………………………………………………………………………………………………………………………..1129
Acceleration pedal……………………………………………………………………………………………………………………………1130
Engine Control Circuit Diagram…………………………………………………………………………………………………………………1132
Automatic Deceleration Control (Auto Idle Control)……………………………………………………………………………………………….1134
Engine Overheat Protection System………………………………………………………………………………………………………………1136
Power Boost Mode……………………………………………………………………………………………………………………………..1138
Operation………………………………………………………………………………………………………………………………..1138
Power Boost Control – Circuit Diagram……………………………………………………………………………………………………….1140
cruise control……………………………………………………………………………………………………………………………….1142
Operation………………………………………………………………………………………………………………………………..1142
Cruise Control Circuit…………………………………………………………………………………………………………………….1144
Self-diagnostic Function………………………………………………………………………………………………………………………1146
EPOS Controller…………………………………………………………………………………………………………………………..1146
Air Conditioner System………………………………………………………………………………………………………………………..1148
Outline………………………………………………………………………………………………………………………………….1148
Internal and External Filters………………………………………………………………………………………………………………1149
Air-Conditioning System Layout……………………………………………………………………………………………………………..1151
Air Conditioner/heater Circuit Diagram………………………………………………………………………………………………………1152
Air Conditioner/heater Unit………………………………………………………………………………………………………………..1153
Ambient Air Temperature Sensor……………………………………………………………………………………………………………..1158
Sun Sensor……………………………………………………………………………………………………………………………….1159
Control Panel…………………………………………………………………………………………………………………………….1159
Compressor……………………………………………………………………………………………………………………………….1167
Receiver Dryer……………………………………………………………………………………………………………………………1167
Wiper System…………………………………………………………………………………………………………………………………1168
Wiper Circuit…………………………………………………………………………………………………………………………….1168
Wiper Operation…………………………………………………………………………………………………………………………..1169
Lighting System………………………………………………………………………………………………………………………………1172
Lighting System Circuit Diagram…………………………………………………………………………………………………………….1172
Type…………………………………………………………………………………………………………………………………….1173
Operation………………………………………………………………………………………………………………………………..1173
Overload Warning Device……………………………………………………………………………………………………………………….1174
Overload Warning Device Circuit Diagram……………………………………………………………………………………………………..1174
Audio Controller……………………………………………………………………………………………………………………………..1175
Audio Controller Circuit Diagram……………………………………………………………………………………………………………1175
ram lock device………………………………………………………………………………………………………………………………1176
Ram Lock Control Circuit…………………………………………………………………………………………………………………..1176
Electrical Schematic SP002650……………………………………………………………………………………………………………………..1177
Safety Instructions…………………………………………………………………………………………………………………………..1181
Applicable Models…………………………………………………………………………………………………………………………….1181
DX140W-3/DX160W-3/DX170W-3/DX190W-3…………………………………………………………………………………………………………….1183
Attachments…………………………………………………………………………………………………………………………………………1185
Boom and Arm SP002710…………………………………………………………………………………………………………………………….1187
Safety Instructions…………………………………………………………………………………………………………………………..1191
Applicable Models…………………………………………………………………………………………………………………………….1191
Front Attachment Pin Specifications…………………………………………………………………………………………………………….1192
DX190W-3…………………………………………………………………………………………………………………………………1193
Front Attachment – Removal and Installation……………………………………………………………………………………………………..1194
Arm Removal Procedure……………………………………………………………………………………………………………………..1194
Boom Removal Procedure…………………………………………………………………………………………………………………….1196
Installation…………………………………………………………………………………………………………………………………1197
Arm Installation Procedure…………………………………………………………………………………………………………………1197
Boom Installation Procedure………………………………………………………………………………………………………………..1197
Start-up Procedures…………………………………………………………………………………………………………………………..1198
Bucket SP002506………………………………………………………………………………………………………………………………….1199
Safety Instructions…………………………………………………………………………………………………………………………..1203
Applicable Models…………………………………………………………………………………………………………………………….1203
Bucket Tooth Inspection and Replacement…………………………………………………………………………………………………………1204
Bucket O-ring Replacement……………………………………………………………………………………………………………………..1205
Attachments………………………………………………………………………………………………………………………………….1207
Bucket Replacement and Reversal…………………………………………………………………………………………………………….1207
Replacement………………………………………………………………………………………………………………………………1208
Reversal…………………………………………………………………………………………………………………………………1209
Quick Coupler Operation (Optional)………………………………………………………………………………………………………….1210
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