Daewoo Solar 300LC-V Manual Download

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S0309000

Page 3

Standard Torques

TORQUE VALUES FOR STANDARD METRIC
FASTENERS

NOTE:

The units for the torque values are kg•m (ft lb).

Dia. x

Pitch (mm)

Grade

3.6

(4A)

4.6

(4D)

4.8

(4S)

5.6

(5D)

5.8

(5S)

6.6

(6D)

6.8

(6S)

6.9

(6G)

8.8

(8G)

10.9

(10K)

12.9

(12K)

M5 x Std.

0.15

(1.08)

0.16

(1.15)

0.25

(1.80)

0.22

(1.59)

0.31

(2.24)

0.28

(2.02)

0.43

(3.11)

0.48

(3.47)

0.50

(3.61)

0.75

(5.42)

0.90

(6.50)

M6 x Std.

0.28

(2.02)

0.30

(2.16)

0.45

(3.25)

0.40

(2.89)

0.55

(3.97)

0.47

(3.39)

0.77

(5.56)

0.85

(6.14)

0.90

(6.50)

1.25

(9.04)

1.50

(10.84)

M7 x Std.

0.43

(3.11)

0.46

(3.32)

0.70

(5.06)

0.63

(4.55)

0.83

(6.00)

0.78

(5.64)

1.20

(8.67)

1.30

(9.40)

1.40

(10.12)

1.95

(14.10)

2.35

(16.99)

M8 x Std.

0.70

(5.06)

0.75

(5.42)

1.10

(7.95)

1.00

(7.23)

1.40

(10.12)

1.25

(9.04)

1.90

(13.74)

2.10

(15.18)

2.20

(15.91)

3.10

(22.42)

3.80

(27.48)

M8 x 1

0.73

(5.28)

0.80

(5.78)

1.20

(8.67)

1.00

(7.23)

1.50

(10.84)

1.35

(9.76)

2.10

(15.18)

2.30

(16.63)

2.40

(17.35)

3.35

(24.23)

4.10

(29.65)

M10 x Std.

1.35

(9.76)

1.40

(10.12)

2.20

(15.91)

1.90

(13.74)

2.70

(19.52)

2.35

(19.99)

3.70

(26.76)

4.20

(30.37)

4.40

(31.18)

6.20

(44.84)

7.20

(52.07)

M10 x 1

1.50

(10.84)

1.60

(11.57)

2.50

(18.08)

2.10

(15.18)

3.10

(22.42)

2.80

(20.25)

4.30

(31.10)

4.90

(35.44)

5.00

(36.16)

7.00

(50.63)

8.40

(60.75)

M12 x Std.

2.40

(17.35)

2.50

(18.08)

3.70

(26.76)

3.30

(23.86)

4.70

(33.99)

4.20

(30.37)

6.30

(45.56)

7.20

(52.07)

7.50

(54.24)

10.50

(75.94)

12.50

(90.41)

M12 x 1.5

2.55

(18.44)

2.70

(19.52)

4.00

(28.93)

3.50

(25.31)

5.00

(36.16)

4.50

(32.54)

6.80

(49.18)

7.70

(55.69)

8.00

(57.86)

11.20

(81.00)

13.40

(96.92)

M14 x Std.

3.70

(26.76)

3.90

(28.20)

6.00

(13.23)

5.20

(37.61)

7.50

(54.24)

7.00

(50.63)

10.00

(72.33)

11.50

(83.17)

12.00

(86.79)

17.00

(122.96)

20.00

(144.66)

M14 x 1.5

4.10

(29.65)

4.30

(31.10)

6.60

(47.73)

5.70

(41.22)

8.30

(60.03)

7.50

(54.24)

11.10

(80.28)

12.50

(90.41)

13.00

(94.02)

18.50

(11.26)

22.00

(158.12)

M16 x Std.

5.60

(40.50)

6.00

(43.39)

9.00

(65.09)

8.00

(57.86)

11.50

(83.17)

10.50

(75.94)

15.50

(112.11)

17.90

(129.47)

18.50

(133.81)

26.00

(188.05)

31.00

(224.22)

M16 x 1.5

6.20

(44.84)

6.50

(47.01)

9.70

(70.16)

8.60

(62.20)

12.50

(90.41)

11.30

(81.73)

17.00

(122.96)

19.50

(141.04)

20.00

(144.66)

28.00

(202.52)

35.50

(256.77)

M18 x Std.

7.80

(56.41)

8.30

(60.03)

12.50

(90.41)

11.00

(79.56)

16.00

(115.72)

14.50

(104.87)

21.00

(151.89)

27.50

(198.90)

28.50

(206.14)

41.00

(296.55)

43.00

(311.01)

M18 x 1.5

9.10

(65.82)

9.50

(68.71)

14.40

(104.15)

12.50

(90.41)

18.50

(133.81)

16.70

(120.79)

24.50

(177.20)

27.50

(198.90)

28.50

(206.14)

41.00

(296.55)

49.00

(354.41)

M20 x Std.

11.50

(83.17)

12.00

(86.79)

18.00

(130.19)

16.00

(115.72)

22.00

(159.12)

19.00

(137.42)

31.50

(227.83)

35.00

(253.15)

36.00

(260.38)

51.00

(368.88)

60.00

(433.98)

M20 x 1.5

12.80

(92.58)

13.50

(97.64)

20.50

(148.27)

18.00

(130.19)

25.00

(180.82)

22.50

(162.74)

35.00

(253.15)

39.50

(285.70)

41.00

(296.55)

58.00

(419.51)

68.00

(491.84)

M22 x Std.

15.50

(112.11)

16.00

(115.72)

24.50

(177.20)

21.00

(151.89)

30.00

(216.99)

26.00

(188.05)

42.00

(303.78)

46.00

(332.71)

49.00

(354.41)

67.00

(484.61)

75.00

(542.47)

M22 x 1.5

17.00

(122.96)

18.50

(133.81)

28.00

(202.52)

24.00

(173.59)

34.00

(245.92)

29.00

(209.75)

47.00

(339.95)

52.00

(44.76)

56.00

(405.04)

75.00

(542.47)

85.00

(614.80)

M24 x Std.

20.50

(148.27)

21.50

(155.50)

33.00

(238.68)

27.00

(195.29)

40.00

(289.32)

34.00

(245.92)

55.00

(397.81)

58.00

(419.51)

63.00

(455.67)

82.00

(593.10)

92.00

(655.43)

M24 x 1.5

23.00

(166.35)

35.00

(253.15)

37.00

(267.62)

31.00

(224.22)

45.00

(325.48)

38.00

(202.52)

61.00

(441.21)

67.00

(484.61)

74.00

(535.24)

93.00

(672.66)

103.00

(744.99)

Summary of Contents for Solar 300LC-V

Page 1: ...nsumers periodically contact their distributors for recent documentation on purchased equipment This documentation may include attachments and optional equipment that is not available in your machine...

Page 2: ......

Page 3: ...Product Label Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine Solar 300LC V Serial Number 1001 and Up Pub No 023 00043E Pub No 023 00043E...

Page 4: ......

Page 5: ...Structure Cab S0402040K Counterweight S0403050K Fuel Tank S0405110K Fuel Transfer Pump S0405500 Swing Bearing S0407000 Swing Reduction Gear S0408070K Lower Structure and Chassis Track Assembly S050500...

Page 6: ...i S0708315K Main Control Valve Kayaba S0709401K Pilot Control Valve Work Lever Joystick S0709451K Travel Control Valve With Damper S0709820K Hydraulic Schematic S300LC V S0792160K Electrical System El...

Page 7: ...1SAFETY...

Page 8: ......

Page 9: ...ng equipment capable of safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE Solar 130LC V 0001 and Up Solar 170LC V 1001 and Up Solar 220...

Page 10: ...l Safety Essentials 6 Location of Safety Labels 6 Summary of Safety Precautions for Lifting in Digging Mode 7 Unauthorized Modifications 8 General Hazard Information 8 Before Starting Engine 16 Machin...

Page 11: ...Mode on page 7 4 Unauthorized Modifications on page 8 5 General Hazard Information on page 8 6 Before Starting Engine on page 16 7 Machine Operation on page 19 8 Maintenance on page 26 9 Battery on p...

Page 12: ...ions given in this manual apply only to intended uses of the machine If you use your machine for any unintended uses that are not specifically prohibited you must be sure that it is safe for any other...

Page 13: ...out the safety of some procedures contact a DAEWOO distributor SAFETY ALERT SYMBOL Be Prepared Get To Know All Operating and Safety Instructions This is the Safety Alert Symbol Wherever it appears in...

Page 14: ...firm supporting surface with hooks and slings attached in approved configuration Loads must be balanced and supported evenly Use taglines to keep the load steady if wind conditions and large surface...

Page 15: ...work DANGER Unsafe use of the excavator while making rated lifts could cause serious potentially fatal injuries or extensive damage to the machine or nearby property Do not let anyone operate the mac...

Page 16: ...feeling well if you are taking medication that makes you feel sleepy if you have been drinking or if you are suffering from emotional problems These problems will interfere with your sense of judgemen...

Page 17: ...hine There is danger that this may lead to a serious accident When operating the machine do not put your hands or head out of the window When standing up from the operator s seat always place safety l...

Page 18: ...rious injury When getting on or off the machine always face the machine and maintain three point contact both feet and one hand or one foot and both hands with the handrails steps and track shoes to e...

Page 19: ...the fuel nozzle in constant contact with the neck of the fuel filling nozzle to provide a ground Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secure...

Page 20: ...ible Always observe any rules and regulations related to the work site and working environment INJURY FROM WORK EQUIPMENT Do not enter or put your hand arm or any other part of your body between movab...

Page 21: ...the machine catches fire it may lead to serious personal injury or death If a fire occurs during operation escape from the machine as follows Turn the starter switch OFF and stop the engine If there i...

Page 22: ...e one way single acting and two way double acting piping valving auxiliary control kits Because Daewoo cannot anticipate identify or test all of the attachments that owners may wish to install on thei...

Page 23: ...windows doors or ductwork into which exhaust may be carried or blown by the wind exposing others to danger EMERGENCY EXIT This machine is equipped with a glass breaking tool It is behind the operator...

Page 24: ...and take other steps to prevent people from coming close to or entering the work site If people come close to a moving machine they may be hit or caught by the machine and this may lead to serious per...

Page 25: ...the head guard FOPS if working in areas where there is danger of falling rocks CHECKS BEFORE STARTING ENGINE Every day before starting the engine for the first time carry out the following checks If...

Page 26: ...after starting the engine it may result in a delay in discovering abnormalities in the machine and this may lead to personal injury or damage to the machine Carry out the checks in an open area where...

Page 27: ...of travel Sound the horn to warn people in the area Check that there is no one in the area around the machine There are blind spots behind the machine so if necessary swing the upper structure to che...

Page 28: ...ope or obstacle that causes the machine to tilt 10 degrees or more to the right or left or 30 degrees or more from front to rear Do not operate the steering suddenly The work equipment may hit the gro...

Page 29: ...r the bucket to the ground to help stop the machine Do not travel on grass fallen leaves or wet steel plates Even slight slopes may cause the machine to slip to the side so travel at low speed and mak...

Page 30: ...en terrain can cause dangerous side load conditions and possible tipover and injury Travel without a load or a balanced load may also be hazardous Never relay on lift jacks or other inadequate support...

Page 31: ...poor such as in fog mist snow and rain Wait for the visibility to improve to a level which causes no problems for the operation To avoid hitting the work equipment always do the following When workin...

Page 32: ...TE CAREFULLY ON SNOW ICE AND IN VERY COLD TEMPERATURES In icy cold weather avoid sudden travel movements and stay away from even slight slopes The machine could skid off to one side very easily Snow a...

Page 33: ...l water accumulation or runoff If parking on inclines is unavoidable block the crawler tracks to prevent movement Lower the bucket or other working attachment completely to the ground or to an overnig...

Page 34: ...o there is danger that you may get dirt or mud in your eyes or that you may slip and injure yourself When washing the machine do the following Wear shoes with non slip soles to prevent yourself from s...

Page 35: ...or fuel that is spilled onto hot surfaces or onto electrical components can cause a fire Store all fuels and all lubricants in properly marked containers and away from all unauthorized persons Store...

Page 36: ...to cool before you drain the cooling system Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Remove the hydraulic tank filter plug only...

Page 37: ...cut on pipes or on tubes that contain flammable fluids Before you weld on pipes or on tubes or before you flame cut on pipes or on tubes clean the pipes or tubes thoroughly with a nonflammable solvent...

Page 38: ...following Do not spill oil or grease Do not leave tools laying about Watch your step when walking Never jump down from the machine When getting on or off the machine use the steps and handrails and m...

Page 39: ...The loose retainer pin can injure personnel Make sure that the area is clear of people when you strike a retainer pin To avoid injury to your eyes wear protective glasses when you strike a retainer pi...

Page 40: ...om hydraulic hoses or pressurized components can be difficult to see but pressurized oil has enough force to pierce the skin and cause serious injury Always use a piece of wood or cardboard to check f...

Page 41: ...taminant and may only be disposed of at approved collection facilities To prevent pollution of the environment always do the following Never dump waste oil in a sewer system rivers etc Always put oil...

Page 42: ...ties of water and see a doctor at once If you accidentally drink battery electrolyte drink a large quantity of water or milk raw egg or vegetable oil Call a doctor or poison prevention center immediat...

Page 43: ...series connected twelve volt batteries have a cable connecting one positive terminal on one of the 12 volt batteries to a negative terminal on the other battery Booster or charger cable connections m...

Page 44: ...ng rope to the left and right hooks and secure in position If the engine on the problem machine will not start or there is a failure in the brake system always contact your Daewoo distributor Never go...

Page 45: ...mation on partial disassembly Refer to the Transportation and Shipping section of this Operation and Maintenance Manual for information on loading unloading and towing LIFTING WITH SLING 1 Refer to Sp...

Page 46: ...S0102000 Page 38 Track Excavator Safety...

Page 47: ...1SPECIFICATIONS...

Page 48: ......

Page 49: ...and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capa...

Page 50: ...ange 8 General Specifications 10 Engine Performance Curves Per DIN 6270 Standard 12 Approximate Weight of Workload Materials 14 Performance Tests 17 Excavator Performance Standards 18 Test Conditions...

Page 51: ...AL DESCRIPTION The excavator has three main component sections The Upper Turntable The Lower Undercarriage and Track Frames The Excavator Front end Attachment The following illustration identifies mai...

Page 52: ...S0202080K Page 4 Specifications for Solar 300LC V COMPONENT LOCATIONS Figure 1 1 2 3 4 5 6 11 10 9 7 8 12 13 14 15 16 17 18 19 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 35 ARO0980L...

Page 53: ...AIR CLEANER 11 CONTROL VALVES 12 ARM CYLINDER 13 BOOM 14 BOOM CYLINDER 15 CAB 16 SEAT 17 CENTER JOINT 18 SWING MOTOR 19 PRECLEANER 20 TRAVEL MOTOR 21 LOWER ROLLER 22 UPPER ROLLER 23 TRACK GUIDE 24 TR...

Page 54: ...S0202080K Page 6 Specifications for Solar 300LC V...

Page 55: ...34 10 10 705 mm 35 1 10 700 mm 35 1 B 3 200 mm 10 6 C 7 420 mm 24 4 7 505 mm 24 7 7 500 mm 24 7 D 4 010 mm 13 2 E 4 930 mm 16 2 F 1 175 mm 3 10 G 3 365 mm 11 0 3 515 mm 11 6 3 930 mm 12 11 H 2 960 mm...

Page 56: ...ends on the stability and support provided by ground conditions Digging too far underneath the excavator if soil conditions are wet loose or unstable can collapse ground support which could cause inju...

Page 57: ...22 1 7 980 mm 26 2 D Max Loading Height 7 286 mm 23 11 6 960 mm 22 10 7 475 mm 24 6 F Max Digging Height 10 345 mm 33 11 9 985 mm 32 9 10 520 mm 34 6 G Max Bucket Pin Height 8 890 mm 29 2 8 565 mm 28...

Page 58: ...lb Lower below Swing Bearing 11 050 kg 24 360 lb Digging Forces Bucket Cylinder 177 KN or 18 100 kg 39 900 lb with either 3 100 mm 10 2 or 2 500 mm 8 2 arm Arm Cylinder 131 KN or 13 400 kg 29 500 lb...

Page 59: ...gth standard boom and arm 10 620 mm 34 10 Overall Shipping Width standard shoes 3 200 mm 10 6 Overall Shipping Height to top of cylinder hose 3 365 mm 11 Track Shipping Length 4 930 mm 16 2 Transport...

Page 60: ...2 Specifications for Solar 300LC V ENGINE PERFORMANCE CURVES PER DIN 6270 STANDARD REVOLUTION rpm POWER OUTPUT ps 1000 150 2000 1500 FUEL CONSUMPTION g ps h 170 90 70 TORQUE kg m 160 100 200 80 150 AR...

Page 61: ...arometric Pressure 760 mmHg 20 C 68 F Cooling Fan 711 mm SUCKER 28 in Alternator 24V x 50A Air Cleaner Installed Muffler Installed Performance Standard DIN 6270 Power 200 ps 1 900 rpm 197 hp 1 900 rpm...

Page 62: ...EDIUM WEIGHT OR DENSITY 1 600 KG M3 2 700 LB YD3 OR LESS HIGH WEIGHT OR DENSITY 2 000 KG M3 3 370 LB YD3 OR LESS Charcoal 401 kg m3 695 lb yd3 Coke blast furnace size 433 kg m3 729 lb yd3 Coke foundry...

Page 63: ...mestone graded above 2 1 282 kg m3 2 160 lb yd3 Limestone graded 1 1 2 or 2 1 362 kg m3 2 295 lb yd3 Limestone crushed 1 522 kg m3 2 565 lb yd3 Limestone fine 1 602 kg m3 2 705 lb yd3 Phosphate rock 1...

Page 64: ...hale broken 1 362 kg m3 2 295 lb yd3 Sulphur broken 529 kg m3 1 620 lb yd3 MATERIAL LOW WEIGHT OR DENSITY 1 100 KG M3 1 850 LB YD3 OR LESS MEDIUM WEIGHT OR DENSITY 1 600 KG M3 2 700 LB YD3 OR LESS HIG...

Page 65: ...4 2 0 4 3 5 0 4 Down sec 2 8 0 4 2 7 0 4 Arm Dump sec 3 1 0 4 2 8 0 4 Crowd sec 4 5 0 4 3 8 0 4 Bucket Dump sec 3 1 0 4 2 6 0 4 Crowd sec 3 8 0 4 3 5 0 4 Swing 3 Revolutions sec 19 5 1 0 16 5 1 0 Jack...

Page 66: ...ts with the engine speed control set to maximum RPM 5 Repeat tests with Power Mode engine control settings at both Standard Mode standard work mode and Power Mode high speed mode Travel speed tests sh...

Page 67: ...ormity Deviation distance should always be measured at the 20 m 65 7 1 2 finish line Repeat the test in reverse to measure in both directions with starting point becoming the finish line and vice vers...

Page 68: ...t With the boom arm and bucket in the same position as for the swing speed test rotate the turntable so that the boom is evenly centered between the side frames pointing straight ahead Locate the 90 r...

Page 69: ...d performance standard for new cylinders put a full load of dirt in the bucket and move the attachment cylinders so that the arm cylinder is extended 20 50 mm 1 2 and boom cylinders are retracted the...

Page 70: ...S0202080K Page 22 Specifications for Solar 300LC V...

Page 71: ...1GENERAL MAINTENANCE...

Page 72: ......

Page 73: ...recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoistin...

Page 74: ...ns and Guidelines 3 Hydraulic System General Precautions 4 Maintenance Service and Repair Procedure 5 General Precautions 5 Hydraulic System Cleanliness and Oil Leaks 6 Maintenance Precautions for Hyd...

Page 75: ...repairs on these types of steel are performed with the proper procedures and equipment If repairs are performed incorrectly structural weakening or other damage to the machine that is not always readi...

Page 76: ...fluid is recommended Vibration irregular or difficult movement or unusual noise from any part of the hydraulic system could be an indication of air in the system and many other types of problems As a...

Page 77: ...tion of air leaking into the circuit Refer to the appropriate Troubleshooting section for component or unit for procedures or it may be evidence of a defective pump The gear type pilot pump could be d...

Page 78: ...of flanges manifolds and piping Do not allow cleaning solvents or other fluids to mix with the oil in the system Use clean oil to flush any traces of solvent or other residue before reassembly If met...

Page 79: ...across bearing to avoid spinning bearings that are not lubricated DO NOT SPIN BEARINGS WHEN DRYING bearings may be rotated slowly by hand to facilitate drying process 3 Carefully inspect all bearing r...

Page 80: ...always carefully examine the condition of the bearings and all of its components for wear and damage Once the bearing is removed clean all parts thoroughly using a suitable cleaning solution If the be...

Page 81: ...h even surfaces with no discoloration or marks Bent Cage Cage damage due to improper handling or tool usage Replace bearing Galling Metal smears on roller ends due to overheat lubricant failure or ove...

Page 82: ...ay or grayish black in color with related etching away of material usually at roller spacing Replace bearings check seals and check for proper lubrication Misalignment Outer race misalignment due to f...

Page 83: ...der impact loading or vibration while the bearing is not rotating Replace bearing if rough or noisy Cage Wear Wear around outside diameter of cage and roller pockets caused by abrasive material and in...

Page 84: ...e if leaking Smears Smearing of metal due to slippage caused by poor fitting lubrication overheating overloads or handling damage Replace bearings clean related parts and check for proper fit and lubr...

Page 85: ...made A file drawn over a tempered part will grab and cut metal whereas a file drawn over a hard part will glide readily with no metal cutting Replace bearing if over heating damage is indicated Check...

Page 86: ...S0302000 Page 14 General Maintenance Procedures Return to Master Table of Contents...

Page 87: ...s outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling...

Page 88: ...3 Torque Values for Standard U S Fasteners 4 Type 8 Phosphate Coated Hardware 6 Torque Values for Hose Clamps 7 Torque Values for Split Flanges 8 Torque Wrench Extension Tools 9 Torque Multiplication...

Page 89: ...00 86 79 17 00 122 96 20 00 144 66 M14 x 1 5 4 10 29 65 4 30 31 10 6 60 47 73 5 70 41 22 8 30 60 03 7 50 54 24 11 10 80 28 12 50 90 41 13 00 94 02 18 50 11 26 22 00 158 12 M16 x Std 5 60 40 50 6 00 4...

Page 90: ...ed 0 70 when Molykote white lead or similar mixtures are used as lubricants 0 75 when parkerized bolts or nuts are used 0 85 when cadmium plated bolts or nuts and zinc bolts w waxed zinc nuts are used...

Page 91: ...OT POUNDS ft lb NEWTON METER Nm FOOT POUNDS ft lb NEWTON METER Nm 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7 16 14 7 16 20 1 2 13 1 2 20 9 16 12 9 16 18 5 8 11 5 8 18 3 4 10 3 4 16 7 8 9 7 8 14 1 8...

Page 92: ...es shown below also apply to the following 1 Phosphate coated bolts used in tapped holes in steel or gray iron 2 Phosphate coated bolts used with phosphate coated prevailing torque nuts nuts with dist...

Page 93: ...boots hydraulic system etc CLAMP TYPE AND SIZE TORQUE RADIATOR AIR CLEANER BOOTS ETC HYDRAULIC SYSTEM KILOGRAM METER kg m INCH POUNDS in lb KILOGRAM METER kg m INCH POUNDS in lb T Bolt Any Diameter Wo...

Page 94: ...bolts will damage the flanges and or bolts which may cause leakage Inside diameter of flange on end of hydraulic tube or hose fitting NOTE Values stated in chart are for Standard Pressure Series Code...

Page 95: ...e end of the torque wrench doubles the tightening force on the bolt It also halves the indicated reading on the scale or dial of the torque wrench To accurately adjust or convert indicated scale or di...

Page 96: ...on and accuracy To allow the assembly or mechanism to accept a torque wrench welding a nut or other adapter on the end of a linkage shaft or other leverage point will allow turning the shaft or assemb...

Page 97: ...500 F Remove HOT 210 Product Application Color Removal Required Setup 545 No filler non clog formula for high pressure hydraulic systems Over application will not restrict or foul system components P...

Page 98: ...cold temperature applications 620 For high temperatures to 232 C 450 F Green Same as 609 above 680 For high strength bonds and tight clearance gaps to 0 00008 mm 0 002 Green Same as 609 above Product...

Page 99: ...1UPPER STRUCTURE...

Page 100: ......

Page 101: ...ction Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsibilit...

Page 102: ...S0402040K Page 2 Cab TABLE OF CONTENTS Removal 3 Installation 6...

Page 103: ...disconnecting wiring connectors for A Cab interior lighting B External light wiring C Radio antenna and connections D Wiper washer connections NOTE Control console wiring harnesses and hydraulic pipi...

Page 104: ...located at right side of cab Disconnect duct wiring connector before removing duct 2 17 Disconnect washer hose located at floor plate bottom 18 Remove cover 5 Figure 4 on left side dash cover 3 and bo...

Page 105: ...ng a suitable lifting device attach slings to four lift points on top of cab Figure 7 NOTE Cab weighs approximately 290 kg 639 lb 28 Lift cab from 25 50 mm 1 2 above deck height Check that all electri...

Page 106: ...ll four hex bolts 3 Figure 9 in door side of cabin floor 5 Install two hex bolts 1 Figure 9 in right side of cabin floor and one bolt 4 in front of cab floor 6 Once cab is mounted to floor unhook lift...

Page 107: ...th bolts 1 Figure 10 Install two rubbers 2 Figure 11 12 Install cover 5 Figure 11 on left side dash cover 3 NOTE Connect speaker wire before installing cover 13 Connect washer hose located at floor pl...

Page 108: ...ness Install cover 3 Connect hour meter connector and cigar lighter connect of cover 2 17 Install cover 2 Figure 13 18 Install operator s seat 1 Figure 13 NOTE Be careful not to damage seat covering 1...

Page 109: ...r those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is...

Page 110: ...S0403050K Page 2 Counterweight Return to Master Table of Contents TABLE OF CONTENTS General 3 Removal 5 Installation 7...

Page 111: ...o warns any user that the removal of the counterweight from the machine front attachment or any other part may affect the stability of the machine This could cause unexpected movement resulting in dea...

Page 112: ...the swing lock if equipped to hold the deck in place and always go backwards up the loading ramp The counterweight end of the deck has to get on the trailer first while the cab is still going up the r...

Page 113: ...in all directions to relieve pressure from accumulators 7 Set safety lever on LOCK position 8 Turn key to OFF position and remove from starter switch 9 Hang maintenance warning tag on controls 10 Dis...

Page 114: ...lts 4 Stop lifting with assist crane as soon as lifting slings are taut 15 Remove four bolts 4 Figure 4 and washers 5 from counterweight 2 NOTE Heat bolts if necessary to free them 16 When bolts 4 Fig...

Page 115: ...mounting holes 3 Slide washers 5 Figure 5 onto bolts 4 Apply Loctite 242 to mounting bolt threads 4 Install four bolts 4 Figure 5 with washers 5 into counterweight until washers contact support frame...

Page 116: ...S0403050K Page 8 Counterweight Return to Master Table of Contents...

Page 117: ...of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ulti...

Page 118: ...S0405110K Page 2 Fuel Tank TABLE OF CONTENTS General Description 3 Parts List 4 Specifications 5 Removal 6 Installation 10 Start up Procedures 12...

Page 119: ...Fuel Tank GENERAL DESCRIPTION WARNING Engine fuel is highly flammable and potentially explosive To prevent possible injury and or damage to equipment extinguish or move to a safe distance all potenti...

Page 120: ...S0405110K Page 4 Fuel Tank PARTS LIST 3 7 5 6 4 10 9 23 8 12 11 1 13 16 19 20 14 34 33 ARS1660L Figure 1...

Page 121: ...S gal Reference Number Description 1 Fuel Tank 3 O ring 4 Cover 5 Bolt M10x1 5x25 6 Spring Washer M10 7 Drain Valve 8 Bolt 9 Shim 10 Shim 11 Fuel Filter 12 Cap 2188 9004 13 Plug SP 14 Level Gauge 16...

Page 122: ...representing 10 percent of total fuel supply Also look at level gauge on side of tank to estimate volume of fuel left in tank NOTE If possible work excavator until available fuel supply in tank has be...

Page 123: ...et safety lever on LOCK position 9 Turn key to OFF position and remove from starter switch 10 Hang maintenance warning tag on controls 11 Disconnect negative battery cable leading to frame from batter...

Page 124: ...nd fuel return line 2 from tank 3 and carefully drain remaining fuel from lines 15 Remove clamp 4 Figure 7 holding fuel return line 2 to tank 3 16 Tag and disconnect wires leading to fuel sensor 1 Fig...

Page 125: ...Remove six bolts and washers 4 Figure 12 holding tank 3 to frame Lift tank 25 mm 1 and make sure it is balanced Make sure that there are no other electrical wires or hoses connected to tank Completely...

Page 126: ...ged Be careful of obstacles and wind gusts 3 Install shims 5 Figure 13 as needed to prevent tank 3 from rocking or stress from mounting bolts 4 4 Tighten mounting bolts 4 Figure 13 after shims are ins...

Page 127: ...fuel tank 2 10 Connect as tagged fuel supply line 1 Figure 18 and fuel return line 2 to fuel tank 3 11 Install clamp 4 Figure 18 to hold fuel return line 2 to tank 3 12 Make sure fuel tank drain valve...

Page 128: ...er head 2 Unscrew and pump the hand operated primer pump Figure 21 by the fuel injection pump Pump primer until fuel is present at plug hole in fuel filter head 3 Tighten plug in fuel filter head 4 Co...

Page 129: ...our own personal responsibility MODEL SERIAL NUMBER RANGE Mega 130 0001 and Up Mega 160 0001 and Up Mega 200 III 1001 and Up Mega 200 V 1001 and Up Mega 250 III 1001 and Up Mega 250 V 1001 and Up Mega...

Page 130: ...ment of Rear Cover 5 Replacement of Armature 6 Solar 250LC V 1001 and Up Solar 290LC V 0001 and Up Solar 290LL 1001 and Up Solar 300LC V 1001 and Up Solar 300LL 1001 and Up Solar 330LC V 1001 and Up S...

Page 131: ...EORY OF OPERATION Fuel pump consists of motor pump switch and hose assembly Figure 1 Reference Number Description 1 Motor 2 Pump 2 1 Pump Cover 2 2 Rotor and Vane 3 Inlet Hose 4 Outlet Hose 5 Check Va...

Page 132: ...or very close to zero the motor is bad and must be replaced On units equipped with a toggle switch check the resistance through the toggle switch while the switch is in the ON position If continuity...

Page 133: ...bly and a thermal limiter are installed in the rear cover If you find any damage replace them with new ones Remove the switch cover and screw M5 x L95 from the rear cover Remove cover At reassembly of...

Page 134: ...ver than remove the armature from the housing Remove the pump cover and remove the rotor and vane Insert a new armature into the housing Refer to Replacement of Rear Cover on page 5 for installation o...

Page 135: ...safely handling load Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE Solar 130LC V 0001 and Up Solar 170LC V 1001 and Up Solar 220LC V 0001 and Up Solar 2...

Page 136: ...Swing Bearing TABLE OF CONTENTS Swing Bearing Maintenance 3 Operating Recommendation 3 Measuring Swing Bearing Axial Play 3 Measuring Bearing Lateral Play 3 Swing Bearing Basic Operation 4 Rebuilding...

Page 137: ...nts at 4 points 90 apart around the circumference of the bearing Figure 1 Record and keep all measurements Play in the bearing should increase minimally from one inspection to the next Eventually howe...

Page 138: ...d to the pinion by planetary gears connected to gears on the inner ring which is fixed in the undercarriage Ball bearings turn the outer ring REBUILDING SWING BEARING 1 Remove tip of tapered pin 1 Fig...

Page 139: ...6 to remove steel balls 2 5 Turn inner ring and use wire 1 Figure 7 to remove retainers 2 6 Assemble in reverse order of disassembly and then adjust the gap between the steel balls and retainers using...

Page 140: ...S0407000 Page 6 Swing Bearing...

Page 141: ...tices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely hand...

Page 142: ...rts List 4 Specifications 5 Special Tools and Materials 6 Special Tools 6 Tool A 6 Tool B 6 Tool C 7 Tool D 7 Tool E 7 Tool F 8 Troubleshooting Testing and Adjustment 9 Removal 10 Disassembly 12 Clean...

Page 143: ...and two step output reduction The planetary gear engages with the ring gear The pinion gear is connected with the output shaft and spline The final drive reduces swing motor RPM in order to increase...

Page 144: ...S0408070K Page 4 Swing Reduction Gear PARTS LIST 1 5 7 8 9 10 11 12 21 20 19 18 17 2 4 6 13 14 15 16 22 24 25 27 26 28 3 1 3 2 29 23 ARS2590L Figure 1...

Page 145: ...ring Pin 15 No 2 Planetary Gear 16 No 2 Side Plate 17 Gear Case 18 Lock Ring 19 Pinion Gear 20 Cover 21 Hex Bolt M16x40 22 Collar 23 Seal 24 Plate 25 Bearing 26 Shaft 27 Bearing 28 Lock Wire 29 Spacer...

Page 146: ...90 mm 7 4803 in B 220 mm 8 6614 in C 350 mm 13 7795 in Dimension Measurement A 156 mm 6 1417 in B 130 mm 5 1181 in C 3 mm 0 1299 0 1378 in D 128 mm 5 0394 in E 20 mm 0 7874 in F 120 mm 4 7244 in G 268...

Page 147: ...7559 in B 6 mm 0 2362 in C 6 mm 0 2362 in D 18 mm 0 7087 in Dimension Measurement A 60 mm 2 3622 in B 80 mm 3 1496 in C 150 mm 5 9055 in Dimension Measurement A 108 mm 4 2520 in B 138 mm 5 4331 in C...

Page 148: ...S0408070K Page 8 Swing Reduction Gear Tool F Dimension Measurement A 128 mm 5 0394 in B 158 mm 6 2205 in C 150 mm 5 9055 in ARS2650L A B C Figure 7...

Page 149: ...epair replace broken or drive train faulty assemblies c Pressure at swing motor inlet shows Hydraulic pump or valve broken Troubleshoot hydraulic no increase but without irregular system noises from t...

Page 150: ...icks in all directions to relieve pressure from accumulators 7 Set safety lever on LOCK position 8 Turn key to OFF position and remove from starter switch 9 Hang maintenance warning tag on controls 10...

Page 151: ...e 9 13 Disconnect hose 2 Figure 9 from main frame by loosening nut 3 14 Disconnect grease lubrication line 7 Figure 9 from reduction gearbox 5 15 Remove twelve bolts and washers 4 Figure 9 holding swi...

Page 152: ...duction Gear DISASSEMBLY 1 Drain oil from port A 2 Using a pipe wrench remove oil level gauge 3 1 and pipe 3 2 PT1 4 3 Using L wrench remove socket bolts 2 and motor 1 TANK 1 A 3 2 3 1 ARS2660L Figure...

Page 153: ...socket bolts 4 and cover 5 5 Remove sun gear No 1 6 and carrier assembly No 1 7 Remove thrust plate 10 IMPORTANT Do not remove carrier assembly No 1 7 in field because pin No 1 and carrier No 1 are ca...

Page 154: ...rive spring pin 14 into shaft No 2 13 This will allow shaft to be pressed out of carrier No 2 8 Remove shaft No 2 13 from carrier No 2 12 Remove spring pin 14 from shaft No 2 13 Remove planetary gear...

Page 155: ...0 Remove wire 28 and hex bolt 21 by using socket wrench Remove cover 20 and pinion 19 11 Remove lock ring 18 Put jig D on shaft 26 and press shaft assembly 22 24 25 and 26 out 9 8 ARS2730L Figure 17 2...

Page 156: ...AND TOLERANCES For general cleaning and inspection procedures refer to General Maintenance Procedures section Inspect all components in the assembly Pay particular attention to oil seals lock and spri...

Page 157: ...ing 25 and press bearing 25 on shaft 26 until contact is obtained 2 Install plate 24 on shaft 26 Position Jig A on collar 22 and press collar 22 on shaft 26 until contact is obtained A 25 29 26 Hydaru...

Page 158: ...ith lock wire 28 diagonally NOTE Apply Loctite 262 to bolt threads NOTE Tighten bolt to 2 700 kg cm 195 ft lb 4 Put jig A on pinion gear and press shaft assembly with pinion into case 17 until contact...

Page 159: ...nto shaft assembly until contact is obtained 7 Insert lock pin 9 in case 17 and install ring gear 8 on case 17 NOTE Coat mating faces of case 17 and ring gear 8 with Loctite 609 IMPORTANT When install...

Page 160: ...carrier No 2 12 and shaft No 2 13 9 Install carrier assembly No 2 onto ring gear 8 and shaft assembly Install sun gear No 2 11 in carrier assembly No 2 10 Insert thrust plate 10 in sun gear No 2 11 I...

Page 161: ...00 kg cm 195 ft lb 12 Secure motor 1 onto cover plate 5 with socket bolt 2 Install pipe 3 2 onto cover plate 5 Insert oil level gauge 3 1 into pipe NOTE Coat mating faces of cover plate 5 and motor 1...

Page 162: ...ion gearbox 5 as an assembly on unit 4 Install twelve bolts and washers 4 Figure 34 to secure swing reduction gearbox 5 to frame NOTE Apply Loctite 262 to bolt threads NOTE Tighten bolt to 95 kg m 690...

Page 163: ...rottle at LOW IDLE and swing upper structure slowly two full revolutions to the left and right 4 Shut the engine down and check the hydraulic oil level Fill hydraulic oil tank to H mark on sight gauge...

Page 164: ...S0408070K Page 24 Swing Reduction Gear...

Page 165: ...1LOWER STRUCTURE AND CHASSIS...

Page 166: ......

Page 167: ...manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately...

Page 168: ...ont Idler Roller 12 Parts List 12 Front Idler Roller Disassembly 13 Front Idler Roller Reassembly 15 Lower Roller 16 Parts List 16 Lower Roller Removal 17 Lower Roller Disassembly 17 Lower Roller Reas...

Page 169: ...G Safely measuring track tension requires two people One person must be in the operator s seat running the controls to keep one side frame in the air while the other person makes dimensional checks Ta...

Page 170: ...is hard and full of rocks or gravel 4 The increased clearance recommended for muddy ground conditions is between distance D on below table The clearance should be approximately distance E on below ta...

Page 171: ...adjustment cylinder 2 The longer the adjustment cylinder the greater the pressure on the tension spring pushing the track idler wheel outward 6 If there is not enough slack or clearance in the tracks...

Page 172: ...general recommendations and specific safety precautions before starting any lower travel frame component rebuilding procedure Component Reference Dimensions Reference Normal New Dimension Recommended...

Page 173: ...1 741 42 3 mm 1 665 41 2 mm R 1 622 Master pin Lower roller axle A 75 mm 2 953 74 5 mm 2 933 74 2 mm R 2 921 Lower roller bushing A 75 5 mm 2 972 76 mm R 2 992 Axle bushing clearance 1 0 mm 0 039 1 8...

Page 174: ...r roller axle A 55 mm 2 165 54 5 mm 2 146 54 2 mm R 2 134 Upper roller bushing A 55 5 mm 2 185 56 mm R 2 205 Axle bushing clearance 1 0 mm 0 039 1 8 mm 0 071 Flange thickness bushing B 6 5 mm 0 256 5...

Page 175: ...ont idler bushing A 90 5 mm 3 563 91 mm R 3 583 Axle bushing clearance 1 0 mm 0 039 1 8 mm 0 071 Gap between bushing and side collar Total amount for both sides B 1 0 mm 0 039 1 5 mm 0 059 Front idler...

Page 176: ...o clock from top position on travel reduction gearbox 4 Remove four nuts and bolts 2 Figure 13 holding shoe to link Remove enough shoes to make access to lock pin easier NOTE Support track shoes with...

Page 177: ...aise track frame off blocking 3 With blocking removed lower track frame onto track Make sure all rollers are properly positioned on track 4 Move unit backwards while feeding track up over front idler...

Page 178: ...S0505000 Page 12 Track Assembly FRONT IDLER ROLLER PARTS LIST Figure 18 Reference Number Description 1 Bearing 2 Plug 3 Pin 4 O ring 5 Axle 6 Group Seal 7 Idler 8 Bushing Reference Number Description...

Page 179: ...emove plug 2 Figure 19 and drain oil from roller assembly 1 2 Separate the pin 3 Figure 20 from the bearing 1 3 Use a press to remove the bearing from the axle Separate the O ring 4 Figure 21 from the...

Page 180: ...Detach the group seal 6 Figure 22 from the idler 7 and bearing 1 5 Use a press to separate the axle 5 Figure 23 O ring 4 and bearing 1 6 Remove bushing 8 Figure 24 with the press and special tool ST 1...

Page 181: ...ing 1 Figure 25 and axle 5 holes and pin 3 them together 4 Install group seal 6 Figure 26 inside the idler 7 and bearing 1 NOTE Apply clean engine oil to the joint side of the group seal Apply grease...

Page 182: ...S0505000 Page 16 Track Assembly LOWER ROLLER PARTS LIST Figure 28 Reference Number Description 1 Pin 2 O ring 3 Collar 4 Axle 5 Roller 6 Group Seal 7 Bushing 8 Plug Reference Number Description...

Page 183: ...rame There is an alignment pin on each end of lower roller assembly NOTE To gain access to some rollers the link guard may have to be removed Remove four spring washers and bolts to remove guard NOTE...

Page 184: ...tach collar 3 Figure 32 and O rings 2 from the axle using a press LOWER ROLLER REASSEMBLY 1 Degrease clean and dry all parts before reassembly Insert bushing 7 Figure 33 into roller 2 Apply grease to...

Page 185: ...e inside the roller 6 Install the collar 3 Figure 36 O ring 2 and pin 1 on the remaining side 7 Fill with clean engine oil with approximately 350 cc 3 4 pint LOWER ROLLER INSTALLATION 1 Install four b...

Page 186: ...rack Assembly UPPER ROLLER PARTS LIST Figure 38 Reference Number Description 1 Plug 2 Bolt 3 Cover 4 Bolt 5 Washer 6 Roller 7 Axle 8 Group Seal 9 Bracket 10 Bushing 11 O ring 12 Lock Washer Reference...

Page 187: ...ck on top of track frame and apply pressure to track shoe 3 Remove mounting hardware holding upper roller assembly to track frame UPPER ROLLER DISASSEMBLY 1 Remove the plug 1 Figure 40 from the cover...

Page 188: ...000 Page 22 Track Assembly 4 Separate the group seal 8 Figure 43 from the roller and bracket 9 5 Separate the bushing 10 Figure 44 from the roller with a press and special tool ST 1919 Figure 43 Figur...

Page 189: ...nto the roller 6 and bushing NOTE Apply clean engine oil to the joint side of the group seal Apply grease to the group seal O ring 3 Install the axle washer 5 Figure 47 and bolt 4 4 Attach group seal...

Page 190: ...S0505000 Page 24 Track Assembly 7 Tighten plug 1 Figure 48 Figure 48...

Page 191: ...S0505000 Page 25 Track Assembly TRACK SPRING AND TRACK ADJUSTING CYLINDER PARTS LIST Figure 49...

Page 192: ...mber Description 1 Piston Rod 2 Piston Ring 3 Backup Ring 4 Packing 5 Retaining Ring 6 Rod 7 O ring 8 Cylinder 9 Spring 10 Spacer 11 Flange 12 Nut 13 Valve 14 Bolt 15 Plate 16 Yoke 17 Socket Bolt 18 F...

Page 193: ...1ENGINE AND DRIVE TRAIN...

Page 194: ......

Page 195: ...ned within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own pers...

Page 196: ...ir Discharge According to Path Selection 10 Air conditioning System Circuit Diagram 12 Troubleshooting 14 Weight of R134a Gas Used In Machines 17 Refrigerant System Repairs 18 Refrigerant Safe Handlin...

Page 197: ...air filtration system which filters out dirt and dust particles from air being circulated into operator s cab This filter should be cleaned out every 500 hours NOTE In the event that the unit is being...

Page 198: ...e 3 and inspect for any damage 6 Use compressed air to clean filter element If filter element is very dirty use a mild soap or detergent and water to clean it NOTE If water was used to clean filter be...

Page 199: ...nditioner REFRIGERANT CIRCULATION 1 2 3 4 5 6 HDA6046L Figure 4 Reference Number Description 1 Evaporator 2 Expansion Valve 3 Condenser 4 Condenser Fan 5 Compressor 6 Blower Fan 7 Receiver Dryer Refer...

Page 200: ...ir surrounding the evaporator creating a cooling effect and changes from the gas to the liquid state The refrigerant once again flows into the compressor in the gaseous state and the process is repeat...

Page 201: ...UT CONTROL PANEL OUTPUT A C CONTROL PANEL DISPLAY LOW SPEED RELAY TEMPERATURE SENSOR MID SPEED RELAY HIGH SPEED RELAY BLOWER MOTOR VENT ACTUATOR DEF ACTUATOR INTAKE ACTUATOR COMP RELAY CONDENSER FAN R...

Page 202: ...consists of a 24 step variable selector The display uses 7 Green Red two color LEDs to display the selected temperature Blower Fan Speed Control OFF Switch LOW Switch MID Switch HI Switch Compressor C...

Page 203: ...Green 3 28 V 0 2 8 Red Red Green Green Green Green Green 3 11 V 0 2 9 Red Red Red Green Green Green Green 2 93 V 0 2 10 Red Red Red Green Green Green Green 2 76 V 0 2 11 Red Red Red Green Green Green...

Page 204: ...S0605060K Page 10 Air Conditioner AIR DISCHARGE ACCORDING TO PATH SELECTION Face Rear and Defroster Foot ARS1280L Figure 10 ARS1290L Figure 11...

Page 205: ...S0605060K Page 11 Air Conditioner Face and Defroster ARS1300L Figure 12...

Page 206: ...HRS 26P 14 9 2 7 15 9 26 16 CN5 16 2 1 4 15 4 5 6 1 2 COOL 15 CN5 AMP MIC 13P 13 6 12 11 4 5 10 9 3 7 8 2 1 15 8 M 15 1 87 9 87a 87 M 85 8 87a 7 10 30 BLOWER SPEED TEMP CONTROL RECIRCLE FRESH AIR MOD...

Page 207: ...elay 10 Foot Defrost Control Actuator 11 Receiver Dryer Low High Pressure Cut Off Switch 12 Diode 13 Compressor 14 A C Control Panel 15 A C Unit 15 1 Blower Motor 15 2 Resister 15 3 High Speed Relay 1...

Page 208: ...y 1 Check for traces of refrigerant oil Yes Reassemble using correct tightening torque No Go to next step 2 Using a leak detection device or soapy water check for refrigerant leakage at all major comp...

Page 209: ...3 46 9 psi Yes Moisture in system replace receiver dryer No Contaminated system replace expansion valve Replace evaporator core assembly 5 High Pressure Over 6 18 kg cm2 85 256 psi Low Pressure 500 m...

Page 210: ...r Conditioner 7 High Pressure Over 7 0 11 0 kg cm2 100 156 psi Low Pressure 4 0 6 0 kg cm2 57 85 psi Possible Cause Low refrigerant pressure due to poor compressor compression Inspect and replace comp...

Page 211: ...Solar 170LC V 850 20 grams 30 0 7 oz Solar 170W III 1100 20 grams 38 0 7 oz Solar 200W III 1100 20 grams 38 0 7 oz Solar 200W V 850 20 grams 30 0 7 oz Solar 220LC III 950 20 grams 33 0 7 oz Solar 220L...

Page 212: ...em standards require new tools equipment and parts DO NOT attempt to use equipment use in servicing the old refrigerant system WARNING Always wear protective glasses and gloves when handling refrigera...

Page 213: ...efrigerant system with the engine running do not open the high pressure valve on the manifold gauge as the reverse flow of high pressure refrigerant will rupture the hose 10 When releasing the high pr...

Page 214: ...R AIR LEAKAGE VACUUM SYSTEM OVER 20 MINUTES CHARGE SYSTEM APPROXIMATELY 100 g CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHARGE SYSTEM TO PROPER LEVEL Standard Capacity less Initial Charge CHECK SYSTEM FOR...

Page 215: ...uge dials indicates 0 kg cm2 0 psi VACUUMING REFRIGERANT SYSTEM 1 Vacuuming Procedure NOTE When the A C system has been exposed to the air it must be vacuumed out Perform vacuum process for 30 minutes...

Page 216: ...he mounting disk is in the raised position B Attach the manifold gauge center hose to the valve assembly C Turn the disc in the clockwise direction and securely mount valve onto refrigerant container...

Page 217: ...e engine running When exchanging refrigerant containers press the manifold gauge low side valve to eliminate air from the charging hose 2 Charge the system by opening the manifold gauge low side valve...

Page 218: ...from vehicle WARNING When charging refrigerant system with the engine running Always keep refrigerant supply container in the upright position Never open the high side pressure valve Gauge Dial Stand...

Page 219: ...sor outlet condenser inlet receiver dryer inlet air conditioner unit inlet 2 Low pressure side Compressor inlet air conditioner unit outlet 3 Compressor Compressor shaft area bolt hole area and magnet...

Page 220: ...S0605060K Page 26 Air Conditioner...

Page 221: ...those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is...

Page 222: ...S0609010K Page 2 Drive Coupling Main Pump TABLE OF CONTENTS Drive Coupling 3 Special Tools 4 Drive Coupling Installation 6 Installation Procedure 8...

Page 223: ...it is very important to properly adjust clearance between the face of the coupling hub and end of pump drive shaft Measurement H shown in the following procedure to a specific value Figure 1 thru Fig...

Page 224: ...d Figure 5 This distance will be referred to as Measurement H in the installation instructions that follow NOTE In manufacturing drawings Figure 4 dimension A and B equal the Measurement H The two too...

Page 225: ...Dimension Measurement Models A 6 0 1 mm 0 2362 0 0039 in S300LC V S300LL B 7 0 1 mm 0 2756 0 0039 in S340LC V S420LC V S470LC V C 20 0 mm 0 787 in D 7 0 mm 0 275 in E 18 0 mm 0 708 in Radius F 22 0 m...

Page 226: ...ive coupling for main pump is installed the following mounting dimensions and installation procedures must be observed NOTE If these procedures are not followed noise will occur and or the service lif...

Page 227: ...Pin 4 2 Insert 4 3 Bolt 4 Ta 4 Flywheel 1 5 Spring Pin 8 6 Insert 4 7 Hub 1 8 Bolt 4 Ta 9 Pump shaft 1 10 Clamping screw 2 Tb 11 Element 1 Table 2 Specification for Measurement H and Torque Refer to...

Page 228: ...ews 10 NOTE Tighten clamping screws to value Tb in the tables NOTE Coat clamping screws 10 with Loctite 262 5 Install element 11 between inserts 2 on engine flywheel 4 6 Install main pump and hub 7 by...

Page 229: ...1HYDRAULICS...

Page 230: ......

Page 231: ...safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and...

Page 232: ...rcuit 8 Swing Operating Circuit 8 Right Swing Operating Circuit 9 Left Swing Operating Circuit 9 Swing Relief Valve and Make up Valve 9 Travel Operating Circuit 9 Forward Travel Circuit 10 Reverse Tra...

Page 233: ...and Flow Meter Kit Installation and Testing 21 Swing System Troubleshooting 23 Precautions Initial Checks 23 Swing Relief Valve Checking and Adjustment 23 Troubleshooting Swing Gearbox 25 Troubleshoot...

Page 234: ...ncy The system features an electronically controlled output optimization system which allows the operator to choose between two distinctly different power modes high output rapid cycling maximum speed...

Page 235: ...cuit for these functions the output of both pumps can be combined allowing higher speed operation Boom up arm crowd and dumping functions can operate in any one of the two available power modes the st...

Page 236: ...ondary boom up pilot pressure that is transmitted to the BOOM1 and BOOM2 spools of the control valve simultaneously When secondary pilot pressure reaches 7 9 kg cm2 100 130 psi boom control valve spoo...

Page 237: ...the AM1 and AM2 spools of the control valve simultaneously When secondary pilot pressure reaches 7 9 kg cm2 100 130 psi the arm control valve spools AM1 and AM2 open Output flow from both halves of th...

Page 238: ...ump flows to the bucket cylinder BUCKET DUMP CIRCUIT When the bucket control lever is put in the dump mode the bucket control valve spool in the left half of the control valve opens to supply oil from...

Page 239: ...LVE AND MAKE UP VALVE Whenever the spool is shifted to the neutral mode during swing operation the possibility exists that surge pressure in the circuit caused by inertial momentum of the upper works...

Page 240: ...achine REVERSE TRAVEL CIRCUIT When the right and left travel control levers are pushed backward output from both main pumps is directed through the PR PL TRRR and TRLR ports on the control valve throu...

Page 241: ...t the pump drive flex coupling pull out the electrical tray under the operator s seat to inspect the self diagnostic display If the EPOS trouble code display is clear check hydraulic functions in the...

Page 242: ...tolerance specified in the table adjust gear pump relief pressure by loosening the lock nut and turning the set screw in clockwise to increase pressure or turning it out to decrease it NOTE Be aware t...

Page 243: ...to relieve pressure and connect an in line t style adapter to the valve pressure port Install a 60 bar 1 000 psi test gauge in the adapter Restart the engine and increase engine RPM by turning the sp...

Page 244: ...uid back into the system if excessive fluid was lost To verify operation of the swing priority solenoid valve connect test equipment and begin testing with the work mode switch set to digging the stat...

Page 245: ...Pressure must be 350 bars 5075 psi or up to 10 bars 145 psi higher Because one adjustment can affect the other check low stage main relief pressure by repeating the cylinder stall test without pressu...

Page 246: ...tment NOTE The electrical pressure up power boost solenoid valve located alongside the swing priority solenoid and arm speed control solenoid in compartment rear of the operator s cab must be operatin...

Page 247: ...tently overloaded and engine troubleshooting shows engine performance to be at or above rated output If reduced cylinder speed and diminished work performance provide an indication that rated maximum...

Page 248: ...low 1 and 2 Each one of the adjustment procedures could affect the setting of the others Check and record the arm dump speed performance test before and after input power adjustment whether or not a f...

Page 249: ...horsepower 1 4 turn on the adjusting screw is equal to approximately 17 horsepower NOTE For each full turn of adjustment on the larger diameter screw 2 the square tipped adjusting screw should be turn...

Page 250: ...justing screw 1 Figure 16 affects the delivery rate Q of the pump Tightening the adjusting screw decreases the maximum cut flow as shown in Figure 15 while backing out the screw increases cut flow del...

Page 251: ...te fittings and adapter flanges to guarantee a pressure tight seal NOTE Be sure to maintain even tightening torque on all flange fittings Use Loctite brand PST 545 or an alternate manufacturer s hydra...

Page 252: ...book If test results do not measure up to specified values pump output tests can be repeated using different control levers Recheck front pump operation while stroking the bucket cylinder out lever a...

Page 253: ...Investigate unusual operating noises or vibration Check for loose bolts connections SWING RELIEF VALVE CHECKING AND ADJUSTMENT Make a check of operating pressures through the swing relief valve if Th...

Page 254: ...pressure through the port is at the recommended level the brake release valve should disengage the swing brake allowing the swing motor to rotate the excavator If pressure adjustment to the valve has...

Page 255: ...motor drain rate Replace Repair motor Gear train defective Refer to Swing Gear Troubleshooting procedure Swing functions but only at reduced RPM Causes listed above could also produce dragging swing O...

Page 256: ...al damaged Assembly compound joint sealer old and not sealing bolt not tight or flange warped Replace oil seal Disassemble and check mating surfaces Reapply Loctite torque bolts to specifications Exce...

Page 257: ...valve malfunction Readjust or replace Oil leak at make up valve Clean repair Control valve spool damaged Repair or replace Dirt in control valve spool Clean or replace Actuator joystick foot pedal dam...

Page 258: ...contamination Disassemble clean main poppet Broken or damaged spring Replace Adjusting screw loose Readjust Main poppet sticking Repair replace Clogged orifice in pilot passage to control valve Clean...

Page 259: ...ents worn out past wear limits Replace Problem Possible Causes Remedies Secondary pressure does not increase Low primary pressure Check primary pressure Broken spring Replace spring Spool sticking Cle...

Page 260: ...sembly Secondary pressure too high Dirt other interference between valve parts Clean repair or replace Return line pressure too high Redirect return line Secondary pressure does not hold steady Dirt o...

Page 261: ...thin this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal r...

Page 262: ...S0703010K Page 2 Accumulator TABLE OF CONTENTS General Description 3 Specifications 4...

Page 263: ...and out and an elastic diaphragm to separate the two chambers The flexible diaphragm changes shape to conform to the changing pressures and volumes of the two fluids in the upper and lower chambers T...

Page 264: ...ge pressure the flexible diaphragm begins to retract upward 4 When system oil is at highest working pressure and the accumulator fills to maximum reserve capacity the flexible diaphragm is pushed up i...

Page 265: ...S0703010K Page 5 Accumulator Solar 470LC V S N 1001 thru 1049 Pilot Travel 10 kg cm2 140 psi 320 cc 19 53 in3 S N 1050 and Up 750 cc 45 77 in3 Model Serial Number System Charge Pressure Volume...

Page 266: ...S0703010K Page 6 Accumulator...

Page 267: ...d in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Rem...

Page 268: ...S0704080K Page 2 Center Joint Swivel TABLE OF CONTENTS General Description 3 Parts List 4 Troubleshooting Testing and Adjustment 5 Inspection 5 Testing 5 Disassembly 6 Reassembly 7...

Page 269: ...RIPTION The center joint swivel is designed to allow hydraulic oil from the upper structure to flow to components in the lower structure It is capable of allowing continuous 360 rotation of the upper...

Page 270: ...10E 10H 10I 10J 10C 10C 10C 10B 10K 10G ARS1730L Figure 1 Reference Number Description 10A Body 10B Spindle 10C Seal 10D O ring 10E Thrust Plate 10F Retaining Ring 10G O ring 10H Cover 10I Spring Was...

Page 271: ...of the excavator A high pressure relief valve with a setting pressure 1 5 times maximum system pressure A stop valve A manually operated in line change over valve Install the change over valve upstre...

Page 272: ...or emergency tear down use a thin but rounded tip smooth edge scraper or spatula to remove O rings or seals to avoid causing damage to those that must be reused NOTE The backup ring shown in the asse...

Page 273: ...fill the center swivel with clean hydraulic fluid prior to reassembly of high pressure and drain line piping Clean and pre fill piping line ends to reduce the amount of air in the system Bleed air fro...

Page 274: ...S0704080K Page 8 Center Joint Swivel...

Page 275: ...Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE Solar 130LC V 0001 and Up Solar 130W V 0001 and Up Solar 170LC V 1001 and Up Solar 170W V 1001 and Up Sol...

Page 276: ...TENTS General Description 3 Theory of Operation 3 Parts List 4 Special Tools and Materials 6 Piston Nut 6 Piston Jig 10 Steel bush Jig 14 Dust Wiper Jig 18 Slipper Seal Jig 22 Slipper Seal Straighteni...

Page 277: ...shown as oil path A or to the front of the cylinder oil path B The cylinder rod is extended as oil flow is pumped through the circuit to the back side of the piston The force F1 of the piston stroke c...

Page 278: ...it does to lengthen it Q1 Q2 PARTS LIST The following parts list is a partial listing only for full and complete parts list information refer to the Hydraulic Equipment Component Parts List Cross sect...

Page 279: ...t 8 Retaining Ring 9 Rod Cover 10 O ring 11 O ring 12 Backup Ring 13 Piston Rod 14 Cylinder Tube 15 Cushion Ring 16 Piston 17 Slide Ring 18 Wear Ring 19 Slipper Seal 20 O ring 21 Backup Ring 22 Piston...

Page 280: ...Page 6 Cylinders SPECIAL TOOLS AND MATERIALS PISTON NUT B A D C 0 2 0 1 0 2 0 1 R R15 R20 C3 C5 35 350 ARS4730L 15 4 R 0 5 Through Hole 8 Figure 6 Material SM45C AISI 1045 Rockwell Harden from 22 27 O...

Page 281: ...OM S200N V BUCKET OPTION BOOM OP 125 0 mm 4 92 in 85 0 mm 3 35 in 12 0 mm 0 47 in 5 0 mm 0 20 in S130W V ARM S130LC V SHORT ARM S170W V BUCKET S220LC V BUCKET S220LL BUCKET BUCKET 115 0 mm 4 53 in 75...

Page 282: ...n S470LC V ARM S55W V ARM 106 0 mm 4 17 in 66 0 mm 2 60 in 12 0 mm 0 47 in 5 0 mm 0 20 in S80W II ARM 120 0 mm 4 72 in 79 0 mm 3 11 in 10 0 mm 0 39 in 5 0 mm 0 20 in S70 III ARM S80W II BOOM MEGA 130...

Page 283: ...S0705000 Page 9 Cylinders...

Page 284: ...S0705000 Page 10 Cylinders PISTON JIG C 35 A 30 R R15 20 2 B D R F 2 Through Hole 8 15 ARS4740L 4 R5 Figure 7 Material SM45C AISI 1045 Rockwell Harden from 22 27 Oil Quench...

Page 285: ...BUCKET MEGA 200 III LIFT S290LC V ARM S ARM 120 0 mm 4 72 in 13 0 mm 0 51 in 85 0 mm 3 35 in 150 0 mm 5 91 in S290LL BUCKET BOOM S300LC V ARM S ARM S330LC V BOOM BUCKET S340LC V BUCKET BOOM BUCKET OP...

Page 286: ...S0705000 Page 12 Cylinders P S Power Steering O R Out Rigger MODEL CYLINDER A 0 1 B C D MODEL CYLINDER...

Page 287: ...S0705000 Page 13 Cylinders...

Page 288: ...e 14 Cylinders STEEL BUSH JIG 20 A 20 5 A F 15 1 B 40 E ARS4750L B Figure 8 Material SM45C which is done thermal refining QT Hrc 22 28 Undefined Chamfer C R 0 5 Max Place Finally work to used DNMG Tip...

Page 289: ...4 in S70 III ARM BOOM MEGA 200 III LIFT MEGA 200 III TC H C S220LL ARM 90 0 mm 3 54 in 105 0 mm 4 13 in 40 0 mm 1 58 in 6 5 mm 0 26 in S290LC V S ARM ARM S290LL BOOM BUCKET S300LC V S ARM ARM MEGA 250...

Page 290: ...5 51 in 70 mm 2 76 in 11 mm 0 43 in K C S420LC V BOOM K C S400LC V BOOM K C S55W V BUCKET 50 0 mm 1 97 in 60 0 mm 2 36 in 30 0 mm 1 18 in S55 V ARM BOOM OP BUCKET DOZER 65 0 mm 2 56 in 75 0 mm 2 95 in...

Page 291: ...S0705000 Page 17 Cylinders...

Page 292: ...rs DUST WIPER JIG D C DIA B 40 15 3 C1 5 DIA B DIA A DIA A 20 R0 2 1 ARS4760L Figure 9 Material SM45C which is done thermal refining QT Hrc 22 28 Undefined Chamfer C R 0 5 Max Place Finally work to us...

Page 293: ...0 mm 3 31 in 5 5 mm 0 22 in 6 0 mm 0 24 in S80W III BOOM S130W V BOOM S130LC V BOOM MEGA 160 III BUCKET BUCKET 55 0 mm 2 17 in 69 0 mm 2 72 in 5 0 mm 0 20 in 6 0 mm 0 24 in S55 V ARM BOOM BOOM OP BUC...

Page 294: ...0 mm 0 24 in 7 0 mm 2 28 in S290LC V ARM 105 0 mm 4 13 in 121 0 mm 4 76 in 6 0 mm 0 24 in 7 0 mm 2 28 in S290LC V S ARM S300LC V ARM S ARM S370LC V BOOM S ARM 105 0 mm 4 13 in 121 0 mm 4 76 in 6 0 mm...

Page 295: ...0 20 in 6 0 mm 0 24 in S80W III ARM 65 0 mm 2 56 in 79 0 mm 3 11 in 5 5 mm 0 22 in 6 0 mm 0 24 in BOOM 70 0 mm 2 76 in 84 0 mm 3 31 in 5 5 mm 0 22 in 6 0 mm 0 24 in BUCKET 55 0 mm 2 17 in 69 0 mm 2 7...

Page 296: ...S0705000 Page 22 Cylinders SLIPPER SEAL JIG ARS4770L A 2 A A 14 B B 40 5 R 1 0 R1 1 0 Figure 10...

Page 297: ...OIST S290 V BOOM BUCKET S BUCKET BOOM 130 0 mm 5 12 in 28 5 mm 1 12 in S250LC V BUCKET S290LC V ARM 150 0 mm 5 91 in 28 5 mm 1 12 in S290LL BOOM HOIST BUCKET HEEL S290LC V S ARM S300LC V ARM S ARM S34...

Page 298: ...S0705000 Page 24 Cylinders S200W V BOOM 135 0 mm 5 32 in 28 5 mm 1 12 in S220LC V ARM S220N V ARM OP P S Power Steering MODEL CYLINDER A B MODEL CYLINDER 0 2 0 1 0 2 0 1...

Page 299: ...S0705000 Page 25 Cylinders...

Page 300: ...S0705000 Page 26 Cylinders SLIPPER SEAL STRAIGHTENING JIG ARS4780L 2 R1 50 25 100 A 15 A 2 5 R 2 C 1 Figure 11...

Page 301: ...BUCKET S220LL BOOM HOIST S290 V BOOM BUCKET S BUCKET BOOM 130 0 mm 5 12 in S250 V BUCKET S290LC V ARM 150 0 mm 5 91 in S300LC V ARM S ARM S340LC V BOOM BUCKET BUCKET OP S370LC V BOOM BUCKET BUCKET OP...

Page 302: ...S0705000 Page 28 Cylinders S200W V BOOM 135 0 mm 5 32 in S220LC V ARM S220N V ARM OP P S Power Steering CYLINDER A MODEL CYLINDER 0 2 0 1...

Page 303: ...or other protective material around piston rod to avoid possibility of accidentally scratching or scoring rod surface while fasteners are being loosened and removed Component parts numbered in parenth...

Page 304: ...d of cylinder wall before using a plastic or other soft faced hammer for final disassembly 5 Begin withdrawing piston rod assembly away from cylinder Attach a lifting support when final 1 3 of rod is...

Page 305: ...through end of rod 8 Remove set screw by using a socket wrench 9 Fabricate or purchase a piston nut removal wrench Dimensions are called off at beginning of this procedure This tool may also be ordere...

Page 306: ...er to evenly pull off rod cover 9 from end of piston rod Be careful not to damage rod bushing 6 and dust wiper U packing and other seals 12 Use a dull rounded tip tool to pry off O ring 11 and backup...

Page 307: ...ing 21 from cylinder head 15 During disassembly of cylinder head be careful not to damage buffer seal 5 and U packing 4 16 Disassemble retaining ring 3 and dust wiper 2 Separate retaining ring 8 and r...

Page 308: ...S0705000 Page 34 Cylinders 17 Force out pin bushing 1 from body of cylinder Figure 28...

Page 309: ...nents install the dust wiper 2 and rod bushing 6 to the rod cover 9 Insert retaining rings 3 and 8 IMPORTANT Replace any part that shows evidence of damage or excessive wear Replacement of all O rings...

Page 310: ...inning of this procedure to attach seal Cool seal by pushing a retracting jig against seal for several minutes Apply a strip of clean see through sealing tape around slipper seal to keep it free of du...

Page 311: ...before reassembly 10 Pre apply fastener locking compound Loctite 242 or 243 or an alternate manufacturer s equivalent product to all end cover retaining bolts Wrap a protective cushion around end of r...

Page 312: ...S0705000 Page 38 Cylinders...

Page 313: ...shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of sa...

Page 314: ...s 15 Special Tools 15 Pressing Tool of Inner Ring 2 and Taper Roller Bearing 4 Inner Race 15 Assembly Tool for Oil Seal 3 15 Assembly Tool for Brake Piston 13 15 Troubleshooting Testing and Adjustment...

Page 315: ...of Spring 28 Reassembly of Balance Plate 29 Reassembly of Inner Race 29 Reassembly of O ring 29 Applying Liquid Packing 30 Reassembly of Cover 30 Tightening of Bolt Tightening of Cover 19 and Housing...

Page 316: ...spring 6 to slide on cam plate 7 The strength of scrowave 18 and the hydraulic power which actuates bushing 16 cause the mating surfaces of balance plate 24 and cylinder block 27 to be pressed togethe...

Page 317: ...All nine pistons in the cylinder block have equal bore diameter length and volume They are configured in a concentric layout around the drive shaft as shown in the cross sectional end view in Figure...

Page 318: ...uses pressure c to turn into negative pressure since the motor starts to act like a pump Since the motor is now acting as a pump make up oil is needed to supply oil in c However if pressure at port B...

Page 319: ...a resistance against spring 49 which forces open poppet 48 so that oil can pass through oil passages g and h from port B thus opening make up check 36 and allowing oil to flow into passage c During t...

Page 320: ...mber of check 64 on side A the side A check 64 pushes the side B check 64 to the left until it contacts seat 62 on side A This action closes the bypass passage while reducing speed of the upper struct...

Page 321: ...ver the swing controls are engaged to swing in one direction or the other IMPORTANT Along with the swing brake a 2 position positive swing lock has also been provided It should be secured whenever the...

Page 322: ...spring 16 Figure 4 locks up the friction plate 11 split plate 12 and swing motor casing 301 preventing the motor drive shaft from turning When hydraulic pressure is forced to the back side of the bra...

Page 323: ...rated When pressurized oil flowing into port SH is stopped as in condition 2 spool 73 is pushed to the right side end by spring 77 and closes port PG and PB Pressurized oil from port PB flows out to p...

Page 324: ...S0707270K Page 12 Swing Motor Toshiba MFC200 PARTS LIST Figure 6...

Page 325: ...ston 14 O ring 15 Spring 16 Bush 17 Teflon Ring 18 Scrowave 19 Cover 20 O ring 21 Cap 22 Parallel Pin 23 Piston 24 Balance Plate 25 Needle Bearing 26 Snap Ring 27 Cylinder 28 Housing 29 Plug 30 Bypass...

Page 326: ...77 kg cm 565 psi 100 Release Pressure Allowable Pressure 49 97 kg cm 710 psi Rotating Direction B Port Inflow Clockwise A Port Inflow Counterclockwise Allowable Viscosity Range 10 1000 mm2 s Allowable...

Page 327: ...g Motor Toshiba MFC200 SPECIAL TOOLS AND MATERIALS SPECIAL TOOLS Pressing Tool of Inner Ring 2 and Taper Roller Bearing 4 Inner Race Assembly Tool for Oil Seal 3 Assembly Tool for Brake Piston 13 Figu...

Page 328: ...internal damaged Open inlet and outlet port of motor apply pilot pressure of 3 9 4 9 Mpa to brake release port and then check the turning of output shaft with torque of about 30 40 Nm over one revolu...

Page 329: ...k fluid in tank and motor case Bleed air fully Fastening parts loose Check pipe laying parts fastening part bolts motor fastening bolts and each motor fastening part bolts Fasten suitable tightening t...

Page 330: ...valves or timer This could result in them being deformed and or malfunctioning No INSPECTION PARTS CORRECTION a Wear of sliding part of balance plate 24 Repair or replace parts b Damage of sliding pa...

Page 331: ...nent to cool to 40 C or below Working on this component when it is at higher temperatures can result in burns When disconnecting hoses from component always work after allowing pressurized air and oil...

Page 332: ...ex hole size 17 mm and cover 19 from housing 4 Remove snap ring 26 inner race of needle bearing 25 and balance plate 24 5 Remove piston 23 from balance plate 24 NOTE Be careful not to scratch the slid...

Page 333: ...8 Remove springs 15 from piston 13 NOTE Match mark springs 15 with piston 13 9 Piston 13 will not come out of housing 28 due to sliding resistance of O rings 12 and 14 Remove it using tap holes M6 in...

Page 334: ...4 and oil seal 3 will remain in housing 28 3 Keep the sliding surface A of cylinder 27 covered until installation This will protect it from damage 4 Mark or number piston holes of cylinder 27 and pist...

Page 335: ...ng bearing puller 2 Remove collar 5 from cylinder 27 Remove cam plate 7 return plate 8 and piston assembly 9 from cylinder 27 3 Remove cam plate 7 from sliding surface of piston assembly 9 by sliding...

Page 336: ...each part for damage when disassembling If it is damaged repair it with fine grade oil stone or crocus cloth as necessary Then thoroughly clean it with a suitable cleaning oil and dry it with moistur...

Page 337: ...f return plate 8 3 Install piston assembly 9 and return plate 8 into cylinder 27 NOTE Install piston assembly 9 into holes of cylinder 27 in the original position NOTE When reassembling apply hydrauli...

Page 338: ...to it and press fit inner ring 2 using special tool Install snap ring 1 NOTE Use extreme care not to get Loctite on the rollers of taper roller bearing 4 NOTE Clean off remaining Loctite between inner...

Page 339: ...king spring 6 is inserted in the spot facing of return plate 8 NOTE When installing cylinder assembly as the spline of cylinder 27 is out from the under part of housing 28 put a support of 30 50 mm un...

Page 340: ...and 14 REASSEMBLY OF BRAKE PISTON 1 Apply hydraulic oil to the circumferential sliding surface of piton 13 and install it to housing 28 NOTE Since there is an interference between piston 13 and O rin...

Page 341: ...reassembling direction which was marked before disassembling of balance plate 24 and cover 19 NOTE Fully apply grease to piston 23 and pin 22 for stopping turning of balance plate of cover 19 and inst...

Page 342: ...ing 28 lift cover 19 by hand and install it to housing 28 slowly NOTE Align and install cover 19 to housing 28 according to the installation position marked before disassembling NOTE The clearance bet...

Page 343: ...RMING OF REASSEMBLY 1 Open inlet and outlet port of motor apply pilot pressure of 3 9 4 9 Mpa to brake release port and then check the turning of output shaft with torque of about 30 40 Nm over one re...

Page 344: ...case with hydraulic oil If motor is operated without hydraulic oil it can result in internal parts being damage After fully filling motor with oil operate it at a no load condition and low speed for...

Page 345: ...ctices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely han...

Page 346: ...Troubleshooting Testing and Adjustment 23 Hydraulic Motor 23 General Caution Matters 23 Inspection method of abnormality of hydraulic motor 23 Cause and remedy of trouble 23 Travel Reduction Gear 25 G...

Page 347: ...aring 18 of Housing 1 Part 44 Selection Method of Shim 15 Thickness 45 Reassembling of Floating Seal 19 46 Reassembling of Housing 1 and Shaft Casing 25 46 Reassembling of Stopper 27 46 Reassembling o...

Page 348: ...erating rotating force Cross over relief valve Negative brake Counter balance valve Swash tilting assembly 3 Reduction gear consists of two speed differential gear represented by the following graphic...

Page 349: ...F1 P x A P Supply pressure A Pressure area The force F1 generates perpendicular force N1 and radial force W1 against swash plate 201 which has a tilting angle of W1 generates torque T T W1 x R1 again...

Page 350: ...A poppet A is opened and hydraulic oil flows from chamber A to port B 3 Operation of negative brake Pressurized oil entering through counter balance spool 361 in valve casing forces brake piston 702 t...

Page 351: ...t Oil in chamber N flows through orifice I to chamber Dv drains from port Bv to tank and spool moves to left then oil flows to K to Dv and to Bv Passages of Cv H and P are constructed so that pressure...

Page 352: ...le creating more torque A External pilot pressure Pi 0 Large tilt angle If pilot pressure does not act on tilting valve the position of swash plate 201 is set at a large tilting angle Swash plate 201...

Page 353: ...a small tilt angle Reduction Gear 1 Operation Reduction gear consists of a compound planetary gear assembly The compound gear assembly changes the high speed low torque input from the hydraulic motor...

Page 354: ...ts planetary motion and revolution of gear P1 rotates carrier C1 Rotation of carrier C raises differential motion among gears R1 R2 P1 and P2 and rotates ring gear R1 This ring gear R1 rotates housing...

Page 355: ...S0707315K Page 11 Travel Motor with Gearbox...

Page 356: ...368 367 350 369 366 381 464 485 567 506 572 571 531 533 534 541 543 542 567 568 568 350 464 381 361 364 363 362 369 367 368 365 384 485 383 382 485 567 461 546 401 509 507 568 568 567 567 402 568 384...

Page 357: ...ket Bolt 368 Hex Socket Bolt 369 O ring 381 Plunger C B Valve 382 Stopper Check 383 Backup Ring 384 Spring Check 401 Hex Socket Bolt 402 Hex Socket Bolt 435 Lock Ring 451 Valve Plate Pin 452 Support P...

Page 358: ...S0707315K Page 14 Travel Motor with Gearbox Reduction Gear 19 1 18 27 31 30 29 30 7 8 22 17 6 11 20 16 17 30 29 30 23 24 14 10 10 32 3 32 12 9 4 13 5 21 15 2 28 20 ARS3970L Figure 12...

Page 359: ...al 20 Needle Roller 21 Snap Ring 22 Hex Socket Head Bolt 23 Hex Bolt 24 Plug 27 Stopper 28 Spacer 29 Collar 30 Thrust Washer 31 Hex Head Bolt 32 O ring Reference Number Description Travel Motor Specif...

Page 360: ...S0707315K Page 16 Travel Motor with Gearbox SPECIAL TOOLS AND MATERIALS SPECIAL TOOLS JIG 1 JIG 2 JIG 3 JIG 4 JIG 5 JIG 6 ARS3990L Figure 13...

Page 361: ...S0707315K Page 17 Travel Motor with Gearbox JIG 7 JIG 8 JIG 9 JIG 10 JIG 11 JIG 12 ARS4000L Figure 14...

Page 362: ...S0707315K Page 18 Travel Motor with Gearbox JIG 13 JIG 14 JIG 15 JIG 17 JIG 18 ARS4010L JIG 19 20 JIG 16 Figure 15...

Page 363: ...G 19 Cluster Gear 6 JIG 20 Carrier 9 Tools Applicable Parts Section Name Standard Remark Tool Hex L wrench Nominal dimension 4mm Plug 24 Hex wrench Nominal dimension 17mm Bolt 22 Socket wrench Nominal...

Page 364: ...S0707315K Page 20 Travel Motor with Gearbox Etc Air pressure 6 kg cm2 85 psi Oil bath Heating temperature over 120 C Vacuum cleaner...

Page 365: ...spanner 19 mm Hp Plug 567 27 mm Hp Plug 464 36 mm Relief Valve 350 Snap ring pliers For hole or shaft Stop Ring 107 108 Plastic hammer Also wood hammer is possible Steel bar 7x7x200 Needle Bearing 10...

Page 366: ...mm 750 567 HP Plug PF 1 4 19 mm 370 545 546 Orifice screw NPTF 1 16 4 mm 70 368 Hex socket bolt M12x30L 10 mm 1 000 367 Hex socket bolt M10x30L 8 mm 670 401 Hex socket bolt M16x50L 14 mm 2 400 402 Hex...

Page 367: ...roblem Possible Cause Remedy Travelling device fails to operate Motor pressure does not increase Oil is bypassed at relief valve 350 Replace or repair relief valve Check spring damaged Replace check s...

Page 368: ...parts Brake operation is difficult Brake torque low Friction and separation plate worn Replace worn parts Brake spring damaged Replace brake spring Brake does not operate Parts in brake stuck Replace...

Page 369: ...use Remedy Temperature of reduction gear housing is high Over 60 C of ambient temperature Gear oil is insufficient Lubricating poor due to insufficient gear oil Fill gear oil in rated quantity Bearing...

Page 370: ...nd output side indicates front side 6 Before applying Loctite completely remove oil from mating surfaces using Loctite 587 and uniting them 7 When tightening bolts apply Loctite 262 to bolt threads an...

Page 371: ...and shaft 11 5 Remove calking mark of carrier 9 and pull pin 12 using a pulling tap M6x1 6 Tap and drop shaft 11 under jig 3 by using copper hammer 7 Pull cluster gear 6 and remove thrust washer 30 t...

Page 372: ...B17 11 Remove coupling gear subassembly from shaft casing using bolts 3 ea M10x1 5x70 and pulling tap of coupling gear 5 12 Put it with coupling gear subassembly facing ground by using eye bolts 2 ea...

Page 373: ...f ring gear No 1 3 facing ground 16 Pull out floating seal 19 from housing by using drive and separate O ring and seal 17 Pull out floating seal 19 from shaft casing by using drive and separate O ring...

Page 374: ...05 NOTE Spring 10ea Hole 11ea 6 Remove brake piston 702 from shaft casing 272 7 Remove piston ring 708 278 and 707 252 from brake piston 702 8 Turn disassembling and reassembling jig 90 and set it wit...

Page 375: ...e drive shaft subassembly NOTE Lightly tap and remove cylindrical roller and outer race of bearing 102 by using copper bar and plastic hammer 16 Remove oil seal 491 17 Remove fixing pin 709 from separ...

Page 376: ...rical bush 122 from cylinder block 111 Disassembly of Valve Casing 1 Remove drain HP plug 464 with O ring 485 2 Remove O ring 472 from valve casing 3 Remove swash spool 531 swash spring 533 and O ring...

Page 377: ...ol 361 10 Remove HP plug 567 with O ring 568 NOTE 5 places 11 Remove seat 541 ball 543 stopper 542 and HP plug 567 with O ring 568 12 Remove needle bearing 103 NOTE Use plastic hammer and copper bar 1...

Page 378: ...AR LIMITS AND TOLERANCES For general cleaning and inspection procedures refer to General Maintenance Procedures section MAINTENANCE STANDARD Change parts with standard of the following table If parts...

Page 379: ...spline 49 06 48 46 Over pin diameter 4 5 of spline inside of cylinder and spherical bush 35 25 35 75 Replace Thickness of separate plate 3 3 3 Thickness of friction plate 2 3 2 1 Free length of brake...

Page 380: ...h Gearbox 1 Clearance between piston and cylinder bore D d 2 Thickness of shoe t 3 Vibration of vertical direction of piston and shoe 4 Height difference of spherical bush and pressure plate H h Figur...

Page 381: ...Ring gear No 2 Coupling gear 0 200 0 608 1 30 Coupling Sun gear spline 0 1 0 2 0 5 OPD Ring gear No 1 386 106 368 514 Ring gear No 2 337 482 337 678 Base tangent length Cluster gear No 1 63 259 63 344...

Page 382: ...n heater to heat fit of cylindrical roller bearing and adjust temperature to about 100 C NOTE Be careful not to damage oil seal contacting part of drive shaft 2 Install stopper ring 107 by using plier...

Page 383: ...der and direction of seat and stopper NOTE Tightening torque 370 kg cm 27 ft lb 5 Install HP plug 567 with O ring 568 NOTE Five places NOTE Tightening torque 370 kg cm 27 ft lb 6 Tighten orifice screw...

Page 384: ...12 1 000 kg cm 72 ft lb M10 670 kg cm 48 ft lb 10 After tighten plug 571 with O ring 572 to proper torque insert swash spool 531 swash spring 533 and O ring 509 NOTE Tightening torque 750 kg cm 54 ft...

Page 385: ...er torque NOTE After winding seal tape and applying Loctite to plug install it NOTE Tightening torque 70 110 kg cm 5 8 ft lb 2 Press pin 709 for securing separate plate 741 using hammer and round bar...

Page 386: ...plate moves smoothly 8 Install swash piston 502 and stopper 503 9 Turn disassembling and reassembling jig 90 so shaft is changed from a horizontal position to a vertical position NOTE Be careful not t...

Page 387: ...and size 546 2ea 1 5 546 1ea 0 8 NOTE Tightening torque 70 kg cm 5 ft lb 16 After inserting valve plate 131 to valve casing tighten it to shaft casing by means of hex socket bolts 401 and 402 NOTE 1 A...

Page 388: ...ture to 100 5 C 2 Fully submerge housing 1 into oil bath by using two eye bolts of M10 and crane Be careful not to contact bottom of housing 1 to bottom of oil bath NOTE Prevent uneven heat 3 Take out...

Page 389: ...4 and measure F by using jig 2 or jig 11 6 Calculate T3 T3 F D 7 Calculate T T T1 T3 0 1 T2 8 Select shim 15 thickness Ts with value T from below table Method is to decide most approximate value Part...

Page 390: ...Do not damage seal surface when using jig 14 NOTE Pay attention to intruding of foreign materials Pay attention to damaging of O ring Reassembling of Housing 1 and Shaft Casing 25 1 After attaching tw...

Page 391: ...of end surface of pin 13 hole of coupling gear 5 with 180 space by using punch and prevent pin 13 from dropping NOTE Refer to Figure 77 3 After lightly applying Loctite 262 to threads of hex socket bo...

Page 392: ...rrier 9 by using hammer and jig 9 Using a punch close end surface of pin 12 hole of carrier 9 with two points 180 apart Figure 77 to prevent pin 12 from coming out 6 Install the remaining two cluster...

Page 393: ...of ring gear No 1 3 and set down into position aligning tooth of cluster No 1 spur gear and ring gear No 1 Insert jig 15 to M10x1 5 four bolts 23 and temporarily fasten 6 Turn the whole reduction gear...

Page 394: ...s fit thrust plate 14 to be stuck to cover 2 by using hammer 7 Fill gear oil with specific quantity NOTE Specific quantity 4 3 liters 8 Loosen M10x1 5 bolts 23 temporarily fastened at Reassembly of Ho...

Page 395: ...wo pipes Fill fully hydraulic oil in motor casing before piping Pipe to lower drain pressure under 2 kg cm2 28 psi 4 If sand or metal powder are mixed in hydraulic oil sliding surfaces will wear exces...

Page 396: ...position oil drain port to low side then drain oil If level plug is loosened the oil will drain faster Oil Filling Set LEVEL mark on cover horizontally then fill 4 3 liters of oil GENERAL CAUTION MATT...

Page 397: ...es outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handlin...

Page 398: ...ting 11 Cautions During Starting Operation 11 Troubleshooting 11 General Cautions 11 Check Pump Proper for Abnormalities 11 Overload of Prime Mover 12 Extreme Decrease of Pump Delivery Flow and Non in...

Page 399: ...r Function Diagram 32 Negative Flow Control 33 Total Horsepower Control 34 Variable Horsepower Control 36 Adjustment of Maximum and Minimum Flows 37 Adjustment of Maximum Flow 37 Adjustment of Minimum...

Page 400: ...IGNATION K 5 V 1 4 0 D T 1 C 9 R 9 N 0 1 Regulator type For more details see the instruction manual for the regulator Shaft rotation viewed from shaft end Design series number R Clockwise L Counterclo...

Page 401: ...ese are the speeds when the suction pressure is 0 kg cm2 0 psi Item Specification Size 140 Displacement 140 cm3 rev Pressure Rated 34 3 MPa 350 kg cm2 Max 37 7 MPa 385 kg cm2 Speed Max 1 2 500 min 1 M...

Page 402: ...ed by bearings 123 and 124 at both ends The shoe is caulked to the piston to form a spherical coupling It has a pocket to relieve thrust force generated by loading pressure and to take hydraulic balan...

Page 403: ...mover engine it rotates the cylinder block via a splined coupling If the swash plate is tilted as in Figure 2 the pistons arranged in the cylinder block make a reciprocating motion with respect to the...

Page 404: ...ir respective sizes shown in Tightening Torques on page 26 All types Item Caution Applied Type Rotating direction and delivery direction For the variable pump these indications depend on the command m...

Page 405: ...de pumps Tilting to both side circuit It is ideal to provide a filter of 10 in the booster line as shown in a of the following figure but there are also a number of experiences to provide filters of 1...

Page 406: ...ngs etc It is desirable to use oil at a temperature lower than 65 C as low as possible considering deterioration of working oil seals and so on All types Working oil other than mineral oil When any wo...

Page 407: ...disassembling and follow the right disassembling procedures 4 Even when any section is to be disassembled not to make dust or let it enter into the pump 5 Since the parts are finely finished handle t...

Page 408: ...of Pump Delivery Flow and Non increase of Delivery Pressure Cause Countermeasure Remark Is not the speed pressure higher than their specified values Set them as specified Is not the torque setting of...

Page 409: ...e suction pipe Increased suction resistance Damage in the caulking suction of the shoe Replace the piston shoe plate etc Cranking of the cylinder Replace the cylinder Wrong installation of the pump Co...

Page 410: ...ke 214 532 732 789 535 806 953 886 717 406 261 111 774 824 127 710 123 251 490 212 211 153 156 728 467 157 983 981 313 312 124 114 466 725 885 314 141 401 Valve plate for c clockwise rotation Valve pl...

Page 411: ...upport 261 Seal Cover F 262 Seal Cover R 271 Pump Casing 312 Valve Block 313 Valve Plate R 314 Valve Plate L 325 Valve Casing 401 Hexagon Socket Head Bolt 406 Hexagon Socket Head Bolt 466 VP Plug 468...

Page 412: ...e Necessary Tool Marked with O Part Name Pump Type Name B K5V80 K5V140 Hexagon socket head bolt PT plug PT thread PO plug PF thread Hexagon socket head setscrew Allen wrench 2 M4 2 5 M5 3 M6 4 O O M5...

Page 413: ...anner 19 O O M12 M12 VP 1 4 22 VP 3 8 24 O M16 M16 27 O M18 M18 VP 1 2 30 O M20 M20 36 O VP 3 4 41 VP 1 50 VP 11 4 55 VP 11 2 Adjustable angle wrench O O Medium size 1 set Screwdriver O O Minus type s...

Page 414: ...her pump 1 Select place suitable to disassembling 2 Remove dust rust etc from pump surfaces with cleaning oil 3 Remove drain port plug 468 and let oil out of pump casing 4 Remove hexagon socket head b...

Page 415: ...head bolts 406 and seal cover F 261 9 Remove hexagon socket head bolts 408 and seal cover R 262 NOTE In case there is a gear pump remove it first IMPORTANT Before laying this surface down spread rubb...

Page 416: ...plate support from pump casing 11 Remove shoe plate 211 and swash plate 212 from pump casing 271 12 Lightly tap ends of drive shafts 111 and 113 with plastic hammer to remove shafts from swash plate s...

Page 417: ...valve block 312 IMPORTANT When removing tilting pin use a protector to prevent pin head from being damaged Since Loctite is applied to mounting areas of tilting pin and servo piston do not damage ser...

Page 418: ...ont pump with those of the rear pump 1 Install swash plate support 251 on pump casing 271 by lightly tapping it with a hammer 2 Place pump casing with its regulator mounting surface down Install tilti...

Page 419: ...pherical bushing 156 and cylinder spring 157 6 Fit spline phases of retainer and cylinder 7 Then insert piston cylinder subassembly into pump casing IMPORTANT Do not tap drive shaft with hammer Assemb...

Page 420: ...468 IMPORTANT Do not mistake suction delivery directions of valve plate IMPORTANT Assemble the rear pump side first to make the procedure easier Do not mistake direction of valve block Clockwise rota...

Page 421: ...piston and cylinder bore D d 0 028 0 056 0 043 0 070 Replace piston or cylinder Play between piston and shoe caulking section 0 0 1 0 3 0 0 1 0 3 Replace assembly of piston and shoe Thickness of shoe...

Page 422: ...B 10 M 14 1 600 kg cm B 12 M 16 2 400 kg cm B 14 M 18 3 400 kg cm B 14 M 20 4 400 kg cm B 17 PT plug Material S45C Wind a seal tape 11 2 to 2 turns round the plug PT 1 16 70 kg cm B 4 Do PT 1 8 105 k...

Page 423: ...ol C Negative flow control With 2 stage max flow control D Positive flow control With flow cut function ARS0200L Kind of horsepower control 1 Constant horsepower control 2 Total cumulative horsepower...

Page 424: ...S0708315K Page 28 Main Pump Kawasaki CONSTRUCTION OF REGULATOR Figure 22...

Page 425: ...625 Outer Spring 626 Inner Spring 627 Adjusting Ring C 628 Adjusting Screw C 629 Cover C 630 Lock Nut 631 PF Sleeve 641 Pilot Cover 643 Pilot Piston 644 Spring Seat 645 Adjusting Ring Q 646 Pilot Spri...

Page 426: ...2 Total horsepower control P2 Companion pump pressure According to the rise of delivery pressure of a pump the tilting angle of the pump is automatically controlled and torque control is achieved comp...

Page 427: ...During normal operation 10 200 cSt Miscellaneous With proportional pressure reducing valve In case of type KR3 9 Code Control Type Control Curve Function and Features M Manual flow control With the m...

Page 428: ...XPLANATIONS The regulator for Kawasaki in line axial piston pump K3V Series consists of the following control functions 1 Negative flow control 2 Total cumulative horsepower control 3 Variable horsepo...

Page 429: ...rge diameter section of the servo position The delivery pressure P1 that is constantly admitted to the small diameter section of the servo piston moves the servo piston to the right due to the area di...

Page 430: ...1 Functional explanation Since this regulator is of the simultaneous total horsepower type it controls the tilting angles displacement volumes of the two pumps to the same values as represented by th...

Page 431: ...erential function As mentioned above flow control and horsepower control tilting angle commands are transmitted to the feedback lever and spool via the large hole sections C and F of levers 1 and 2 Ho...

Page 432: ...trol section of each pump regulator through the pump s internal path to shift it to the same set horsepower level This function permits arbitrary setting of the Pump output power thereby providing the...

Page 433: ...the hexagon nut 809 and by tightening or loosening the set screw 954 The maximum flow only is adjusted without changing other control characteristics Adjustment of Minimum Flow Adjust it by loosening...

Page 434: ...compensating rod 623 are stuck with each other Disassemble and clean the regulator 4 The Pin 898 is stuck Disassemble and clean the regulator Item Specification Speed 2200 min 1 Adjustment of Maximum...

Page 435: ...ck Disassemble and clean the regulator 4 The piston QMC stopper 647 and piston 648 are stuck with each other Disassemble and clean the regulator 5 The spool COV 637 is stuck Disassemble and clean the...

Page 436: ...embly is necessary for an unavoidable reason read through this manual to the end before starting disassembly 2 The numbers in parentheses after part names represent those in the Construction of Regula...

Page 437: ...C 624 from compensating section Then draw out adjusting ring Q 645 pilot spring 646 and spring seat 644 from pilot section CAUTION 1 Choose a clean place 2 Spread rubber mat or cloth on top of work be...

Page 438: ...ing 814 spring seat 653 return spring 654 and sleeve 651 8 Remove locking ring 858 fulcrum plug 614 and adjusting plug 615 IMPORTANT Sleeve 651 is attached with snap ring 836 When removing snap ring 8...

Page 439: ...75 12 Draw out pilot piston 643 and spool 652 13 Draw out piston case 622 compensating piston 621 and compensating rod 623 NOTE Since component parts are small do not lose them IMPORTANT Work will be...

Page 440: ...as O rings with new ones as a rule 1 Put compensating rod 623 into compensating hole of casing 601 2 Press fit pin in lever 1 612 into groove of compensating rod and fit lever 1 to pin press fitted in...

Page 441: ...nserted into pin hole of lever 2 Then attach locking ring 858 8 Insert adjusting plug 615 and install locking ring 9 Install return spring 654 and spring seat 653 into spool hole Install snap ring 814...

Page 442: ...ert spring seat 644 pilot spring 646 and adjusting ring Q 645 into pilot hole 13 Install spring seat 624 inner spring 626 and outer spring 625 into compensating hole 14 Install cover C 629 with adjust...

Page 443: ...14 1 600 kg cm 10 M 16 2 400 kg cm 12 M 18 3 400 kg cm 14 M 20 4 400 kg cm 17 PT filling plug Material S45C Wind a seal tape 1 1 2 to 2 turns round the plug PT 1 16 70 kg cm 4 Do PT 1 8 105 kg cm 5 P...

Page 444: ...S0708315K Page 48 Main Pump Kawasaki...

Page 445: ...outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling...

Page 446: ...rallel Orifice for Arm 20 Relief Valve 21 Combined Operation 22 Bucket Combined Operation 24 Antidrift Valve 25 Main Relief Valve 26 Overload Relief Valve 69 Total Six Places 27 Low Pressure Relief Va...

Page 447: ...2 Disassembly 43 General Instructions for Disassembly 43 Disassembly of Main Spool Part 43 Disassembly of Arm 1 Para Spool Turn 44 Disassembly of Arm Regeneration Release Valve Part 45 Disassembly of...

Page 448: ...rift Valve Assembly 52 Reassembly Procedure of Control Valve Body 53 Reassembly of Relief Valve 53 Reassembly of Load Check Valve 53 Reassembly of Antidrift Valve 54 Reassembly of Spare Section Part 5...

Page 449: ...ports T1 T2 and T3 Oil supplied to port P1 flows through neutral passage R1 to low pressure relief valve orifice Rc1 then to tank passage Ta and returns to ports T1 T2 and T3 The pressures of low pre...

Page 450: ...S0709401K Page 6 Main Control Valve Kayaba Figure 1...

Page 451: ...S0709401K Page 7 Main Control Valve Kayaba Figure 2...

Page 452: ...d land Rc3 into tank passage Ta 2 The same oil supplied to port PP then flows through orifice Lc5 into port PA and it also flows through passages L4 7 and R4 to bucket spool land Rc4 and then flows in...

Page 453: ...S0709401K Page 9 Main Control Valve Kayaba...

Page 454: ...allel passage R3 and passage S6 1 are equal so poppet S6 2 does not open Return oil flows through port A6 B6 to spool and returns to tank passage Ta 3 When shifting either spool section 1 or 6 land Lc...

Page 455: ...S0709401K Page 11 Main Control Valve Kayaba Figure 4...

Page 456: ...A3 B3 to spool and is returned to tank passage Ta Bucket Spool Shifting 1 Oil flow control in bucket section portion of valve is different from other sections because it has a regeneration function th...

Page 457: ...passage R1 is closed Oil supplied to port P2 flows through parallel passage R3 load check valve S7 2 passage S7 1 spool and into port A7 Oil flows through port B7 and one portion of the oil returns th...

Page 458: ...ting 1 Neutral This valve also works with anti drift valves that are installed on the bottom side of each boom cylinder When in neutral poppet AD1 Figure 7 is closed by port A8 pressure that is sent t...

Page 459: ...t P2 flows through parallel passage R3 and load check valve S8 2 to spool and flows into port A8 When boom 2 spool is shifted by increasing pressure of boom 2 section 4 pilot port Pb4 neutral passage...

Page 460: ...h parallel passage R3 and load check valve S8 2 to spool and flows into port B8 When spool AD3 of antidrift valve is shifted by increasing pressure of port P2 poppet AD1 is opened by decreasing of pre...

Page 461: ...ting 1 Neutral This valve also works with an anti drift valve that is installed on rod side of the arm cylinder When in neutral poppet AD1 Figure 10 is closed by port A5 pressure that is sent through...

Page 462: ...spool into port B5 When arm 2 spool is shifted by increasing pressure of arm 2 section 9 pilot port pb9 oil supplied to port P2 flows through neutral passage R1 load check valve S9 1 passage S9 2 and...

Page 463: ...passage Ta The other portion of the oil flows through fixed orifice b regeneration check c and fixed orifice i in arm 1 spool and joins in bridge passage S5 1 From there if load pressure of port B is...

Page 464: ...9 1 spool and passage 8 and joins at port A5 Return oil from port B5 returns through spool to tank passage Ta Parallel Orifice for Arm The orifice that is installed in parallel passage for arm 1 contr...

Page 465: ...valve The highest pressure of pump P1 and P2 is controlled by reaction of main relief valve 2 Over Load Relief Valve The over load relief valve that is installed in each cylinder port of boom 1 arm 1...

Page 466: ...el Pump 2 50 Section 6 Travel 50 If there is no travel straight circuit machine will travel in zig zag manner PT closed The oil passage is closed at the signal land Lc4 Lc7 Rc3 and Rc5 PA closed The o...

Page 467: ...S0709401K Page 23 Main Control Valve Kayaba Figure 16...

Page 468: ...piston S7 6 piston S7 5 and plug S7 4 are pressed and poppet assembly S7 2 is seated on valve housing This causes oil flowing from parallel passage R3 to open poppet S7 3 in poppet assembly and flow i...

Page 469: ...m port A5 is cut off by seat S1 and seat S2 2 Cut off condition of passage of port A5 Figure 19 and spring chamber A If port pc1 is pressurized piston 2 is moved and spool 3 reacts B Spool 3 activates...

Page 470: ...oil passage HP rises and exceeds relief valve setting pilot poppet F opens Pressurized oil flows through pilot poppet F into low pressure oil passage LP passing through hole G 3 As pilot poppet F ope...

Page 471: ...ure in cylinder port HP rises and exceeds the relief valve setting pilot poppet E opens Pressurized oil then flows through pilot poppet E into low pressure oil passage LP passing through hole H 3 As p...

Page 472: ...der port HP to eliminate cavitation LOW PRESSURE RELIEF VALVE 70 TOTAL TWO PLACES Generation of Signal Pressure Oil supplied from pump port P1 P2 flows through neutral passage L1 R1 low pressure relie...

Page 473: ...orifice Lc1 Rc1 goes to back chamber of poppet and poppet operates by the difference of pressurized area between passage and back chamber By operation of this poppet oil flows from passage through plu...

Page 474: ...Main Control Valve Kayaba PARTS LIST 75 69 37 69 92 77 81 75 52 74 76 L L B B A A C D E F G H I C D E F G H I K K 71 74 78 72 37 69 90 72 75 37 90 69 43 72 75 89 88 73 37 72 92 68 52 76 J J X VIEW X A...

Page 475: ...Page 31 Main Control Valve Kayaba Figure 33 8 15 16 17 5 70 13 7 8 12 8 8 8 8 8 70 2 3 4 5 6 7 1 63 SECTION A1 A1 61 62 33 32 72 57 SECTION A A SECTION B B SECTION L L SECTION K K X 41 Y 42 X 41 Y 42...

Page 476: ...0 7 6 5 103 104 36 SECTION C C SECTION D D SECTION E E SECTION G G SECTION H H SECTION J J SECTION I I DETAIL F1 F1 SECTION F F 34 35 53 55 54 51 35 36 36 72 72 47 49 50 45 36 44 91 105 67 38 39 35 3...

Page 477: ...5 Spring 36 O ring 37 Flange 38 Poppet 39 Spring 40 Spacer Assembly 41 O ring 42 O ring 43 Flange 44 Poppet 45 Spring 46 Plug 47 O ring 48 Spring 49 Poppet 50 Steel Ball 51 Poppet 52 Flange 53 Spacer...

Page 478: ...er Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End 5 Plug 6 Poppet 7 Spring 8 O ring 9 Backup Ring Reference Number Descr...

Page 479: ...sembly 14 Arm1 Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Sp...

Page 480: ...Regeneration Release Valve Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description 1 Spool 2 Spring Seat 3 Spring 4 Spool End Reference Number Description...

Page 481: ...7 Main Control Valve Kayaba Spacer Assembly 40 Plug Assembly 60 Reference Number Description 1 Spacer 2 O ring 3 Backup Ring 4 O ring Reference Number Description 1 Plug 2 O ring 3 O ring 4 O ring Fig...

Page 482: ...mbly 67 Figure 47 Reference Number Description 1 Body 2 Poppet 3 Plug 4 Piston 5 Spool 6 Sleeve 7 Spring 8 Spring 9 O ring 10 O ring 11 Backup Ring 12 Backup Ring 13 O ring 14 Plug Assembly 15 Plug As...

Page 483: ...ing 6 O ring Reference Number Description 1 Plug 2 O ring 3 O ring 4 Backup Ring Control Valve Specification Rated Flow 270 liter min 50 liter min at Neutral Max Pressure 34 3 MPa Allowable Back Press...

Page 484: ...cap crisscrossed Remove center and retighten cap Valve temperature uneven Warm up entire system Dirt in valve Clean valve flushing Lack of pilot pressure Check pilot valve and pilot relief pressure F...

Page 485: ...Remedy Pressure does not rise Stuck main poppet sleeve or pilot poppet opened or dirt in seat part Replace relief valve Relief pressure unstable Seat parts of pilot poppet damaged Piston or main poppe...

Page 486: ...ighten lock nut 7 after pressure has been adjusted 6 Recheck pressure setting by raising pressure once more Over Load Relief Valve 1 Shift control valve spool and read pressure gauge from stroke end o...

Page 487: ...own as assembly part number further part number Disassembly of Main Spool Part 1 Remove socket head bolt 74 two places per each section width across flats 8 mm and cap 8 ten places 2 Remove plug assem...

Page 488: ...pool end 22 width across flats 5 mm spring seat 20 and spring 21 from spool 19 IMPORTANT Work with spool gripped in vise with wood see Figure 50 not to scratch outside diameter of spool Because Loctit...

Page 489: ...on C C 7 Remove spring 33 and poppet 32 from valve housing 8 Remove plug 72 width across flats 8 mm section L L 9 Remove spacer 57 spring 33 and poppet 32 from valve housing 10 Remove plug 92 width ac...

Page 490: ...emove plug assembly 67 14 width across flats 38 mm and O ring B Remove piston 67 4 spool 67 5 and spring 67 7 C Remove plug 67 3 width across flats 38 mm and O ring D Remove sleeve 67 6 and poppet 67...

Page 491: ...ts 36 mm and O ring 5 Remove plug assembly 71 width across flats 6 mm and O ring 6 Remove plug assembly 72 width across flats 8 mm and O ring Disassembly of Valve Housing Combined Bolt 1 Remove socket...

Page 492: ...t 4 and plug 1 and replace O ring 3 If oil is leaking from nut 7 remove nut 7 and plug 8 and replace O ring 3 Disassembly of Overload Relief Valve This relief valve should be replaced as an assembly W...

Page 493: ...75 mm and O ring 2 If oil is leaking from adjusting kit 3 remove adjusting kit 3 and replace O ring 4 Disassembly of Low Pressure Relief Valve This unit has press fit portion D so that it should be re...

Page 494: ...ion inspect it using relief valve maintenance procedure 6 Replace all O rings and backup rings with new ones 7 After disassembling cap or plug check whether there are paint chips around body hole or p...

Page 495: ...e inlet At this time be careful not to touch applying part to spring seat PROCEDURE OF SUBASSEMBLY Reassembly of Spool Assembly Main Spool 1 Apply Loctite to threaded portion of spool 2 6 14 17 and in...

Page 496: ...4 Install spring 67 7 and piston 67 4 in plug 67 3 5 Tighten plug assembly 67 14 with O ring installed on plug 67 3 Tightening torque 14 99 16 01 kg m 108 116 ft lb 6 Install O ring 67 13 on plug 67...

Page 497: ...47 ft lb 4 Install poppet 51 and spring 35 in common section I I Insert spacer 53 with O ring 54 and backup ring 55 Tightening torque 3 98 4 49 kg m 29 32 ft lb 5 Install O ring 36 on spare section se...

Page 498: ...O ring 89 on cap 88 two places and fasten it in place with socket head bolt 76 Tightening torque 5 91 6 53 kg m 43 47 ft lb 2 Install O ring and backup ring on plug assembly 87 two places Install plu...

Page 499: ...t lb 3 Tighten orifice plug 63 Tightening torque 1 43 1 84 kg m 10 33 13 28 ft lb 4 Install O ring on plug assembly 92 and install Tightening torque 20 90 23 15 kg m 151 167 ft lb 5 Install O ring on...

Page 500: ...S0709401K Page 56 Main Control Valve Kayaba Figure 54...

Page 501: ...t pressure by referring to Over Load Relief Valve on page 42 NOTE The torque values are based on use of lubricated threads Reassembly of Low Pressure Relief Valve Check if there is dirt and paint chip...

Page 502: ...RT UP PROCEDURES 1 Before operating machine make sure that oil passages and hydraulic oil are clean 2 Hydraulic oil of which annealing point is 82 113 C should be used in the hydraulic system 3 Relief...

Page 503: ...d safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capabl...

Page 504: ...OF CONTENTS General Description 3 Theory of Operation 3 Structure 3 Function 3 Parts List 4 Specifications 5 Torques 5 Performance 6 Removal 6 Disassembly 9 Cleaning and Inspection Wear Limits and Tol...

Page 505: ...eutral mode the spool is thrust upward by return spring and the force of balancing spring which determines the secondary discharge pressure is not transmitted to the spool The input port is closed and...

Page 506: ...S0709451K Page 4 Pilot Control Valve Work Lever Joystick PARTS LIST 30 29 26 23 24 13 22 21 17 31 15 16 36 32 33 34 35 1 2 3 5 4 6 7 9 10 8 28 27 25 14 19 18 12 11 20 ARS2260L Figure 1...

Page 507: ...ing Pin 30 Handle Assembly 31 Bushing 32 Terminal 33 Seal Wire 34 Housing 35 Holder Rear 36 Clip Band Reference Number Description Pilot Control Valve Specification Type Pilot Control 2 Stage Joystick...

Page 508: ...joysticks in all directions to relieve pressure from accumulators 7 Set safety lever on LOCK position 8 Turn key to OFF position and remove from starter switch 9 Hang maintenance warning tag on contr...

Page 509: ...2 and pull remote control valve LH 1 out 15 Tag and disconnect hoses from remote control valve LH 1 Figure 5 Plug and cap hoses and ports to prevent contamination from entering hydraulic system or co...

Page 510: ...e four bolts 3 Figure 7 and cover 2 and pull remote control valve RH 1 out 20 Tag and disconnect hoses from remote control valve RH 1 Figure 7 Plug and cap hoses and ports to prevent contamination fro...

Page 511: ...ilot Control Valve Work Lever Joystick DISASSEMBLY 1 Lift up the boot 28 and pull the switch cord through the hole in the case 1 2 Loosen nut 27 from hex nut 25 and remove handle assembly 30 Figure 8...

Page 512: ...age 10 Pilot Control Valve Work Lever Joystick 3 Remove hex nut 25 and swash plate 24 4 Remove joint 23 from case 1 5 Remove plate 21 6 Press spring 10 and remove plug 18 Figure 11 Figure 12 Figure 13...

Page 513: ...reduction valve 6 7 8 9 11 and spring 10 8 Remove plug 3 and four plugs 2 9 Remove stopper 11 from pressure reduction valve 6 7 8 9 11 10 Remove spool 6 spring seat 9 spring 8 and shim 7 IMPORTANT Mar...

Page 514: ...S0709451K Page 12 Pilot Control Valve Work Lever Joystick 11 Remove push rod 14 and plug 18 12 Remove O ring 19 from plug 18 13 Remove seal 20 from plug 18 Figure 19 Figure 20 Figure 21...

Page 515: ...ck CLEANING AND INSPECTION WEAR LIMITS AND TOLERANCES For general cleaning and inspection procedures refer to General Maintenance Procedures section Clean all parts and dry them with compressed air Ke...

Page 516: ...3 slowly NOTE Tightening torque 350 kg cm 25 3 ft lb Tighten four plugs 2 NOTE Use Loctite 592 pipe sealant on plugs NOTE Tightening torque 150 kg cm 10 9 ft lb 2 Install shim 7 spring 8 spring seat...

Page 517: ...lve Work Lever Joystick 4 Install spring 10 in case 1 and pressure reducing valve assembly 6 7 8 9 11 5 Install seal 20 on plug 18 6 Install O ring 19 on plug 18 7 Install push rod 14 on plug 18 Figur...

Page 518: ...Valve Work Lever Joystick 8 Install spring 13 on stopper 12 9 Position stopper 12 and spring 13 on pressure reducing valve 10 Install plug 18 in case 1 11 Install plate 21 and tighten joint 23 Figure...

Page 519: ...nstall hex nut 25 and tighten swash plate 24 NOTE Tightening torque 1 240 kg cm 89 7 ft lb 14 Pull cord and tube out through hole of hex nut 25 15 Align the direction of handle 30 and tighten hex nut...

Page 520: ...S0709451K Page 18 Pilot Control Valve Work Lever Joystick 16 Grease joint 23 swash plate 24 and push rod 14 17 Install boot 28 Figure 37 Figure 38...

Page 521: ...ews two bolts and washers 7 and 8 Figure 40 and cover 4 4 Install a screw three bolts and washers 6 Figure 40 and cover 3 Push cap 5 into cover 3 5 Install four bolts and washers 2 Figure 40 and cover...

Page 522: ...Push cap 5 into cover 3 10 Install four bolts and washers 2 Figure 42 and cover 1 START UP PROCEDURES 1 Start engine and set throttle at LOW IDLE 2 Set safety lever on UNLOCK position 3 Slowly cycle b...

Page 523: ...is manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimatel...

Page 524: ...ry of Operation 3 Pressure Reducing Valve 3 Operating Theory of Damper Mechanism 5 Parts List 6 Specification 7 Torque 7 Troubleshooting Testing and Adjustment 8 Removal 9 Disassembly 11 Cleaning and...

Page 525: ...port T through inner hole of spool 2 Half Operation Condition If pedal is moved push rod moves down and they transmit this force through spring seat and control spring to spool If spool is moved prima...

Page 526: ...tted through inner hole of spool to operating port secondary pressure transmitted through spool overcomes control spring force and pushes spool up but spool is restricted by push rod and does not move...

Page 527: ...amber of upper part of low pressure at this time ball check valve becomes closing condition because high pressure operates to vibration prevention chamber of lower part 2 Operation When Operating Leve...

Page 528: ...20K Page 6 Travel Control Valve With Damper PARTS LIST 32 24 23 22 16 21 13 12 11 9 5 4 3 10 8 6 7 19 20 17 18 14 15 3 36 25 26 19 20 30 29 28 33 37 1 35 34 2 ARS1850L Figure 5 P T 1 2 3 4 ARS1860L Fi...

Page 529: ...Deal 25 Cover 26 Wrench Bolt 27 Cam 28 Bushing 29 Camshaft 30 Set Screw 31 Set Screw 32 Hex Nut 33 Bellows 34 Space 35 O ring 36 O ring 37 Wrench Bolt Reference Number Description Travel Control Valve...

Page 530: ...mary pressure Defective secondary pressure select spring Replace with new spring Gap between spool and casing is abnormally large Replace spool casing assembly Defective operating parts and components...

Page 531: ...y to OFF position and remove from starter switch 9 Hang maintenance warning tag on controls 10 Disconnect negative battery cable leading to frame from battery 11 Remove cabin under cover by loosening...

Page 532: ...ve With Damper 13 Remove rubber boots 1 Figure 9 14 Remove four bolts and washers 2 Figure 9 pedal brackets 3 with levers 15 Remove four bolts and washers 2 Figure 10 and pedal valve 1 1 2 1 ARS2951L...

Page 533: ...ainer in which disassembled parts can be stored 3 All precision parts must be handled with great care and all parts must be reassembled to their original position 4 All parts must be carefully reassem...

Page 534: ...9820K Page 12 Travel Control Valve With Damper 3 Remove cam shaft 29 and bushing 28 from cam 27 4 Remove cam 27 from cover 25 5 Remove wrench bolt 26 by using tool Figure 13 Figure 14 Figure 15 Figure...

Page 535: ...With Damper 6 Remove cover 25 from body 1 and 2 7 Remove plug assembly 21 24 with push rod assembly 14 20 8 Remove snap ring 13 9 Remove rod guide 11 IMPORTANT Be careful not to spring rod guide 11 F...

Page 536: ...820K Page 14 Travel Control Valve With Damper 10 Remove spool assembly 5 9 11 Remove spring 10 12 Remove stopper 9 spring 6 and spring seat 7 from spool assembly 5 9 Figure 21 Figure 22 Figure 23 Figu...

Page 537: ...trol Valve With Damper 13 Remove plug assembly 21 24 from push rod assembly 14 20 14 Remove seal 23 and 24 from plug 21 15 Remove O ring 22 from plug 21 16 Remove seal 16 from push rod 14 Figure 25 Fi...

Page 538: ...el Control Valve With Damper 17 Remove snap ring 20 from push rod 14 18 Remove plate 19 from push rod 14 19 Remove spring 18 from push rod 14 20 Remove steel ball 17 from push rod 14 Figure 29 Figure...

Page 539: ...d may cause poor equipment performance Be sure to use clean uncontaminated solvent when cleaning precision parts 2 Clean parts thoroughly by gently turning the solvent Dry and clean each part with a c...

Page 540: ...approved lubricant to aid in smooth assembly 6 Tighten all bolts to the specified torque rating as outlined in the torque table 7 Seal all opens ports to prevent foreign material from entering the va...

Page 541: ...nstall rod seal 23 and dust seal 24 on both sides of plug by using tool 4 Install O ring 22 on outside diameter of plug 21 and check plug whether it is abnormal 5 Install spring seat 7 spring 6 and sp...

Page 542: ...spring 18 plate 19 and spring pin 15 on push rod 14 8 Install snap ring 20 on push rod assembly 14 19 9 Install seal 16 on push rod 14 10 After installing spool assembly 5 9 on body 1 and 2 insert rod...

Page 543: ...rod assembly 14 20 on body 1 and 2 12 Install cover 25 on the upside of body 1 and 2 13 Tighten wrench bolt 26 NOTE Tightening torque 88 kg cm 6 37 ft lb 14 Put cam 27 on cover 25 and install cam shaf...

Page 544: ...by using wrench NOTE Tightening torque 88 kg cm 6 37 ft lb 16 One side holds L wrench and the other side holds spanner and tighten set screw 31 and hex nut 32 attached to cam 27 not to loose NOTE Tig...

Page 545: ...and washers 2 2 Install pedal brackets 3 and levers 4 Figure 50 on pedal valve and install four bolts and washers 2 3 Install rubber boots 1 Figure 50 4 Connect hoses as tagged during removal to peda...

Page 546: ...mper START UP PROCEDURES 1 Start engine and set throttle at LOW IDLE 2 Set safety lever on UNLOCK position 3 Slowly push and pull both travel lever about five times without a load to vent air from pil...

Page 547: ...fe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of...

Page 548: ...S0792160K Page 2 Hydraulic Schematic S300LC V TABLE OF CONTENTS General Description 3 Solar 300LC V 4...

Page 549: ...300LC V GENERAL DESCRIPTION Schematic s presented in this section are laid out on facing pages An overlapping edge has been taken into consideration so that a photocopy can be made and pasted together...

Page 550: ...B1 Dr1 A1 a4 Psv A2 500k A3 REAR 40k SENSOR Dr3 a3 Pi2 ps2 VALVE LEFT Pi2 of Pump VALVE RIGHT pa1 pb1 P1 SWING MOTOR SH PH of Sol v v PT PP PA PH pr P3 P2 pa3 TR R OPT P4 pa2 B1 A1 pb2 B2 A2 SWING BOO...

Page 551: ...4 3 P T 4 BOOM 2 1 T P 3 4 1 2 3 1 2 3 4 3 2 1 4 pb8 pb3 SOL V V P2 B2 pa3 B1 S1 pa8 pb5 pa5 B3 B4 B5 pb7 pa7 pc2 B7 B8 B6 A2 A1 A3 A4 A5 A7 A8 A6 9 pc1 Pi VALVE RIGHT pa1 pb1 pa3 TR R OPT P4 pa2 B1...

Page 552: ...S0792160K Page 6 Hydraulic Schematic S300LC V...

Page 553: ...1ELECTRICAL SYSTEM...

Page 554: ......

Page 555: ...ained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own pe...

Page 556: ...el 15 Monitoring System Schematic 16 Operation 18 Instruments 18 Warning and Indicator Lights 20 Initial Operation 22 Mode Select Switch 23 Graphic Information Area Display 24 Overview 24 Main Menus f...

Page 557: ...verheat Protection System 60 Power Boost Mode 61 Operation 61 Power Boost Control Circuit Diagram 62 Automatic Travel Speed Control 63 Automatic Travel Speed Control Circuit Diagram 64 Engine Control...

Page 558: ...t Engine throttle controller defective or not connected Repair connection or replace component Blown fuse Replace fuse Check connections and circuit components for shorts or other damage Wiring harnes...

Page 559: ...and a three phase AC generator with a rectifier The electric wiring used in the system is easily identifiable by the insulator color The color symbols used in the electrical system are listed in the f...

Page 560: ...ne stop motor When the starter switch 5 is in the preheat on and start positions the current flows from the battery 1 fusible link 3 fuse 6 starter switch 5 B terminal starter switch 5 BR terminal bat...

Page 561: ...er relay 8 are connected the pinion gear of the starter 9 is pushed forward and makes contact with the ring gear of the flywheel and the internal contacts of the starter are connected The current flow...

Page 562: ...and PP terminals are opened As a result the rotation of the starter 9 is stopped Once the engine is running the starter 9 will not operate even if the starter switch 5 is moved to the start position p...

Page 563: ...e preheat time is approximately 19 seconds A built in timer in the instrument panel will activate an indicator light approximately 19 seconds after the preheat process has been selected Even after the...

Page 564: ...is in the ON position the engine stop motor rotates 180 and comes to a stop due to the cam switch When the start switch is in the OFF position the engine stop motor moves 180 from the running mode pos...

Page 565: ...elay 5 A terminal of engine stop motor 6 E terminal of engine stop motor 6 ground The engine stop motor opens pushes the fuel shut off lever of the fuel injection pump and the system is in the running...

Page 566: ...e shut off lever of the fuel injection pump linked to the engine stop motor by a cable is moved to the close pull position and the engine is stopped The engine stop motor moves 180 from the running mo...

Page 567: ...ctrical components When the alternator 7 starts to operate a current flows from the R I terminal of alternator diode 8 battery relay 2 coil securing a path for the charging current to the battery 1 Th...

Page 568: ...plays information selected by the operator ARS0090L Figure 9 Reference Number Description 1 Instrument Panel 2 Battery 3 Engine Speed Sensor 4 Return Filter Switch 5 Pilot Filter Switch 6 e EPOS Contr...

Page 569: ...ion area 3 and 4 Figure 10 Gauges Warning Lights Mode Select Switches 1 Engine Coolant Temp Gauge 2 Fuel Gauge 3 Multi function Gauge and Graphic Information Area 4 Digital Clock 5 Service Hour Meter...

Page 570: ...ER LOAD L3 WATER TEMP L4 PREHEAT L5 WORK LAMP L1 BATTERY CHARGE L2 ENG OIL PRESS 8 7 ILLUMINATION EL 5 20 6 SIG 19 SIG L4 L1 L2 L3 6 17 L6 L5 11 1 9 10 2 22 CN2 13 CN2 14 CN2 11 CN2 12 CN2 1 RS 422 CN...

Page 571: ...ssure Sensor 7 Engine Coolant Temperature Sensor 8 Fuel Gauge 9 Engine Speed Sensor 10 Hydraulic Oil Temp Sensor 11 Engine Oil Pressure Switch 12 Air Cleaner Indicator 13 Return Filter Switch 14 Pilot...

Page 572: ...F 128 ohms Fuel Level CN4 7 CN4 8 1 10 LCD Blinking over 5K ohms FULL under 525 ohms Tachometer CN4 16 CN4 17 N 146 f 60 S300LC V N 146 f 60 S300LL N 152 f 60 S340LC V N 152 f 60 S420LC V N 152 f 60...

Page 573: ...4 2 V 0 00816 x P 1 0 V Sensor output voltage V P Displayed pressure Bar Main pump discharge pressure rear pump CN4 3 CN4 4 Function Display Sensor Specification Input Terminal Input Specification FRO...

Page 574: ...ssure CN2 11 Lights up when engine oil pressure switch is turned ON Oil pressure drops below 0 7 kg cm2 10 psi After starting engine if engine oil pressure is insufficient after 8 seconds a warning bu...

Page 575: ...Area Air Cleaner CN2 12 Lights up when air cleaner is clogged Symbol is blinking Return Filter CN2 13 Lights up when return filter pressure increases over 1 5 kg cm2 21 psi Symbol is blinking Pilot F...

Page 576: ...Initial Operation When battery voltage is input to CN7 9 starter switch is turned from OFF to ON position All LCD LED and warning lights are turned on and turned off after about 2 seconds Warning buzz...

Page 577: ...put Pump Discharge Volume Control Valve Current mA Swing Priority Solenoid Valve 7 Segment Display Power Mode Power Mode ON Variable Output 9 x Standard Mode OFF 0 7 x Work Mode Trenching Mode ON ON x...

Page 578: ...ided into two menus One is main menu for user and the other is special menu for specialist These menus can be moved from normal display mode by the combination of select buttons Selection Buttons Grap...

Page 579: ...f machine operation MENU SELECTION BUTTONS 1 Up Arrow Button 1 on Figure 12 Move the cursor to up left and previous screen 2 Down Arrow Button 2 on Figure 12 Move the cursor to down right and next scr...

Page 580: ...ter oil information to the operator Refer to the Operation and Maintenance Manual for details LANGUAGE SETTING This mode is used for setting desired language TIME SETTING This mode is used for setting...

Page 581: ...reset the operating hour and then the operating hours until the next service interval can be easily checked Menu Display Order and Icon Explanation ARO0400L Hrs 0232 Reset 1 Fuel Filter Figure 16 1 2...

Page 582: ...ESSING AND EXITING ESCAPING MENUS Entering Accessing Menus When normal mode screen is displayed if the enter button 3 and escape button ESC 4 are pressed simultaneously for more than 3 seconds normal...

Page 583: ...once again SPECIAL MENU SELECTIONS Sub menu Selection Method Various sub menus can be selected by pressing Up 1 on Figure 18 and Down 2 on Figure 18 button Move the cursor to desired menu and a select...

Page 584: ...Max 9 E G Oil Press 3 Work Travel Solenoid 10 Air Cleaner 4 Hi Speed Solenoid 11 Return Filter 5 Auto Travel 12 Pilot Filter 6 Work Lamp 13 OWD Select 7 Pressure Py 5 Output State 1 Relief Press Up 4...

Page 585: ...hine Status Information 1 EPPR Valve Current 2 Dial Voltage 3 TPS Voltage Output voltage of potentiometer built into engine control motor EPPR CURRENT ARS0870L mA 598 Figure 24 DIAL VOLTAGE ARS0880L m...

Page 586: ...on OFF and the other statuses of on off type sensors MACHINE INFO ARS1780L Input State Output State Hyd Oil Temp 4 Figure 27 1 Alternator OFF 2 Power Max ON 3 Work Travel Sel OFF 4 Hi Speed Sel OFF 5...

Page 587: ...on Remarks 1 6 BAR Lit CN 3 4 CN 3 5 Over 1 510 Below 30 C Below 86 F 1 6 2 6 BAR Lit 745 1 510 31 50 C 87 122 F 1 6 3 6 BAR Lit 332 745 51 75 C 123 167 F 1 6 4 6 BAR Lit 244 332 76 85 C 168 185 F 1 6...

Page 588: ...cursor is located in Failure Info of special menu screen press enter button 3 on Figure 18 and Failure Info screen is displayed 2 Exiting Sub menus If escape button ESC 4 on Figure 18 is pressed for...

Page 589: ...ure information Memorized record of past failure is displayed Failure code failure contents When a number of failures are produced failure information can be checked by using PRV 1 on Figure 18 or NXT...

Page 590: ...t this time deletion signal will be displayed and the screen will move to previous menu after deletion This screen will be displayed during 3 seconds When NO ESC 4 on Figure 18 button is pressed the s...

Page 591: ...82 Communication Err Communication error between e EPOS controller and instrument panel Note Automatic reset when problem is corrected 01 EPPR v v short Short Circuit Cut off output current 0 mA Afte...

Page 592: ...put voltage Over 4 6 0 2 V Cut off EPPR v v current 0 mA 24 TPS Voltage Err L Output voltage Over 0 4 0 2 V Cut off EPPR v v current 0 mA 25 Fpump Sensor Err H Output voltage Over 4 6 0 2 V 26 Fpump S...

Page 593: ...ion A Entering Sub menus When a cursor is located in Operating Info of special menu screen Figure 37 press enter button 3 on Figure 18 and Operating Info screen will be displayed Figure 38 B Informati...

Page 594: ...itch Py control valve ON status High speed High speed s v and travel pressure switch Py control valve ON status Hydraulic Oil Temperature Distribution C F Temperature of hydraulic oil is classified 6...

Page 595: ...urned to previous screen NOTE When YES 3 on Figure 18 button is pressed operation hours will reset At this time resetting signal will be displayed and the screen will move to previous menu after reset...

Page 596: ...19 Mode select signal Machine information Auto idle signal Sensors 18 Engine speed sensor signal Engine throttle control signal Drive signal Potentiometer signal Coolant water temp signal Throttle co...

Page 597: ...8 Pump Pressure Sensor 9 Engine Speed Sensor 10 Electro magnetic Proportional Pressure Reducing Valve E P P R Valve 11 Solenoid Valve Pressure Up 12 Solenoid Valve Swing Priority 13 Solenoid Valve Hi...

Page 598: ...e indicator lamp will turn ON to display the selected mode Wheel type Power mode switch signal 1 Potentiometer signal Pump control signal g 15 Low Throttle signal Hi 16 Engine throttle control signal...

Page 599: ...low the rated speed When this occurs the controller senses this decrease and immediately reduces the pump discharge volume to maintain the engine speed at the rated level On the other hand if the load...

Page 600: ...ption in comparison with Power Mode The current to the E P P R valve is shut off and pump discharge volume is controlled by pump regulator A B C D HDA6020L Figure 46 Reference Number Description A Eng...

Page 601: ...S0802220K Page 47 Electrical System Reference Number Description A Engine Horsepower hp B Engine Speed rpm C Pump Discharge Volume lpm D Pump Discharge Pressure kg cm2 Reference Number Description...

Page 602: ...1 9 9 10 8 11 CN3 9 10 11 12 14 15 13 17 16 CN1 6 5 7 8 6 4 3 2 1 20 18 19 11 CN7 14 16 15 13 12 CN3 11 CN3 10 CN3 9 CN3 12 CN3 8 CN1 7 CN1 5 CN4 11 CN4 10 CN4 13 CN4 12 LOW 1 1 5 2 3 1 4 CN2 3 12 2 2...

Page 603: ...stem Reference Number Description 1 Battery 2 Battery Relay 3 Fuse 4 e EPOS Controller 5 Instrument Panel 6 Engine Speed Sensor 7 Engine Throttle Controller 8 Engine Control Motor 9 Engine Control Dia...

Page 604: ...oid adjusts the assignment of hydraulic oil flow to each device on the equipment Wheel Engine throttle control signal Trenching mode switch signal 15 Throttle signal Hi Lo Potentiometer signal Drive s...

Page 605: ...ck stops The current to the solenoid valve for swing priority is shut off 2 Trenching Mode This mode is used for heavy duty ditch digging work or for loading work requiring big swing angles The voltag...

Page 606: ...15 16 7 6 2 1 4 5 2 1 11 3 13 2 12 1 9 8 10 14 6 5 4 7 CN7 1 13 3 2 CN3 CN4 CN2 3 20 19 1 5 2 10A CN7 TxD RxD 10 9 5 2 20A 3 TxD RxD RxD TxD CN3 8 CN3 11 CN3 12 CN3 10 CN3 9 CN1 9 CN1 14 RS 422 CN1 1...

Page 607: ...ter feed back signals are the same the engine controller shuts off the current to the control motor The engine control motor cable is a solid type and is connected to the engine fuel injection control...

Page 608: ...S0802220K Page 54 Electrical System...

Page 609: ...r switch should be turned off and the cause of abnormal load should be repaired and the starter switch can be turned on again The engine control dial can once again be used to control the engine speed...

Page 610: ...umber Description 1 Knob 2 Potentiometer Variable Resistor 2 1 1 1 VIEW POTENTIOMETER BOTTOM 1st STEP 10 10 7th STEP 13th STEP CCW MECHANICAL STOP CW MECHANICAL STOP 2 3 2 3 1 2 3 4 2 5V 1 0V 4 0V 1ST...

Page 611: ...ical System The engine control dial has a built in potentiometer When the control knob is moved the output voltage through terminals 2 and 3 will vary from the 5 V supplied from the throttle controlle...

Page 612: ...55 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse 4 e EPOS Controller 5 Instrument Panel 6 Engine Speed Sensor 7 Engine Throttle Controller 8 Engine Control Motor 9 Engine Control Dial...

Page 613: ...ers are in the neutral position the e EPOS controller sends an automatic reduction signal to the throttle controller When the engine throttle controller receives this signal it is compared with the si...

Page 614: ...throttle controller will signal the engine control motor to decrease the engine speed When the coolant is overheated the warning buzzer will sound standard mode is selected and low engine speed will...

Page 615: ...activate the power boost solenoid valve and increase the relief valve pressure from 330 350 kg cm2 4 700 5 000 psi The excavation ability is increased by approximately 6 NOTE Do not use this switch fo...

Page 616: ...CN3 11 12 13 14 17 CN1 6 7 8 6 3 4 1 2 20 11 16 CN7 CN1 1 CN4 1 3 10 7 8 9 CN1 CN3 11 CN3 12 CN3 8 CN3 10 CN3 9 RxD RxD RS 422 TxD TxD 5 6 1 CN2 3 7 6 CN1 13 CN1 9 CN1 2 CN1 8 4 1 3 20A 2 ARS1150L Fig...

Page 617: ...monitored by the two pressure sensors in the discharge lines of the front upper and rear lower pumps When the travel load is high pressure over 300 kg cm2 4 300 psi the solenoid valve is turned OFF an...

Page 618: ...2 17 14 4 9 10 15 16 1 LOW CN4 10 CN4 11 8 CN3 CN4 CN2 6 CN2 5 0 II 3 10 I 6 AUTO MANUAL 9 2 CN1 12 SIG 6 SIG 5 CN4 2 CN4 4 CN4 3 CN4 1 10A CN1 8 CN1 9 CN1 1 CN1 2 4 3 20A 2 1 ARS1170L Figure 61 Refe...

Page 619: ...stopper position and the cable slack is acceptable 3 A If the lever is not in the minimum position and touching the stopper move the 3 cable to one hole lower on the lever If the cable slack is exces...

Page 620: ...le VR1 Refer to throttle controller name plate 3 Figure 64 Standard Mode VR2 Refer to throttle controller name plate 3 Figure 64 Reference Number Description 1 VR1 Automatic Deceleration Adjusting Var...

Page 621: ...age 67 Electrical System Figure 65 Reference Number Description 1 Engine Fuel Control Lever Area 2 Control Motor Cable Bracket 3 Engine Speed Control Cable 4 To Engine Control Motor Reference Number D...

Page 622: ...in normal range 2 Engine Speed Monitor This LED light flashes according to the engine speed The flashing interval is proportional to the engine speed 3 Communication Monitor These LED lamps flash whe...

Page 623: ...re information codes a part of failure information Refer to the failure information part of letter information display for details Mode Selection Display Readout Operation Status Upper Digit Lower Dig...

Page 624: ...ssibility of motor damage or burn out exists 4 After the malfunction is corrected turn the starter switch from OFF to the ON position and normal operation will resume Throttle Controller Input Signal...

Page 625: ...ly 5 seconds Continuous Operation II Position When the wiper switch 4 is turned I position the current flows from the fuse 3 B terminal of wiper motor 7 L terminal of wiper motor 7 No 5 terminal of wi...

Page 626: ...er 6 No 4 terminal of wiper timer 6 S terminal of wiper motor 7 B terminal of wiper motor 7 and the wiper motor is stopped at the auto stop position WINDOW WASHER OPERATION When the window washer swit...

Page 627: ...S0802220K Page 73 Electrical System...

Page 628: ...2 CN3 10 CN3 9 CN3 12 CN3 11 CN3 8 CN7 1 L5 CN7 9 11 10A 15 RH 14 LH LH RH RH 16 LH 17 FL FR FMR 18 FL FR FML 30 86 87 85 7 87a 3 10 II 6 I 4 0 86 30 85 87a 87 8 13 1 7 10 9 2 10A 5 I 5 0 9 10A 20A 1...

Page 629: ...a 15 Work Light 2 ea 16 Additional Work Light 2 ea 17 Front Cabin Light 2 ea 18 Front Cabin Light 4 ea 19 Rear Cabin Light 2 ea Reference Number Description Switch Position Connected Terminal of switc...

Page 630: ...AD WARNING DEVICE OVERLOAD WARNING DEVICE CIRCUIT DIAGRAM 5 6 4 2 1 3 ARS1260L Figure 69 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse Box 4 e EPOS Controller 5 OWD Select Switch 6 Pre...

Page 631: ...safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable...

Page 632: ...S0892160K Page 2 Electrical Schematic S300LC V TABLE OF CONTENTS General Description 3 Solar 300LC V 4...

Page 633: ...300LC V GENERAL DESCRIPTION Schematic s presented in this section are laid out on facing pages An overlapping edge has been taken into consideration so that a photocopy can be made and pasted together...

Page 634: ...S0892160K Page 4 Electrical Schematic S300LC V SOLAR 300LC V Figure 2...

Page 635: ...S0892160K Page 5 Electrical Schematic S300LC V ELECTRICAL DIAGRAM DAEWOO HEAVY INDUSTRIES LTD NO 599 00035 Model Solar 300LC V Name HAAD4190...

Page 636: ...S0892160K Page 6 Electrical Schematic S300LC V...

Page 637: ...1ATTACHMENTS...

Page 638: ......

Page 639: ...nt of this manual or those contained within this section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that u...

Page 640: ...CONTENTS Front Attachment Pin Specifications 3 Front Attachment Removal and Installation 4 Arm Removal Procedure 4 Boom Removal Procedure 6 Installation 7 Arm Installation Procedure 7 Boom Installati...

Page 641: ...ns Consult Daewoo After Sales Service for information on wear tolerances and replacement limits for mounting pins Mounting Pin Diameter mm Inches Length mm Inches A 105 mm 4 134 1001 mm 39 409 B 90 mm...

Page 642: ...with the lower structure Never rotate the upper structure once the counterweight or front attachment has been removed IMPORTANT Always break down the front attachment by removing outermost sections f...

Page 643: ...ly if necessary Place a sling under the arm cylinder the cylinder used to extend and retract the attachment arm pinned to the top of the boom Lift the sling so that the weight load on the rod end of t...

Page 644: ...aulic pressure and disconnect line couplings as previously outlined in the Arm Removal Procedure observing the same precautions Disconnect wiring for work light assemblies and any other accessory line...

Page 645: ...sling from around the rod end arm cylinder pin withdraw the pin and lift the body of the arm cylinder to re pin the mounting connection BOOM INSTALLATION PROCEDURE Before reassembling the attachment m...

Page 646: ...and Arm START UP PROCEDURES Once the boom has been serviced it should be lubricated as outlined in the initial start up procedures of the operation manual Refer to the appropriate operation and mainte...

Page 647: ...s section Always use tools and equipment that is in good working order Use lifting and hoisting equipment capable of safely handling load Remember that ultimately safety is your own personal responsib...

Page 648: ...Tooth Inspection and Replacement 3 Type 1 3 Type 2 4 Bucket O ring Replacement 6 Bucket Shimming Procedures 8 New Bucket Installation 8 Bucket Attachment Removal and Reversal 9 Detaching the Bucket 9...

Page 649: ...points on the working surfaces of tooth points pits cracks chips or craters are larger than 8 mm to 10 mm 1 3 to 1 2 across 1 On a routine basis inspect the bucket teeth to make sure that tooth wear o...

Page 650: ...ng steel ball causes the boss to go inside WARNING Due to the possibility of flying metal objects always wear safety helmet protective gloves and eye protection when changing bucket teeth Curl the buc...

Page 651: ...wear down to a point that bucket adapter is exposed See Figure 4 2 To replace a tooth use a hammer 1 Figure 5 and punch 2 to drive locking pin assembly out of tooth and tooth adapter 3 Once the worn...

Page 652: ...he way 3 Remove the old O ring and temporarily install the new O ring 1 Figure 8 onto the bucket boss 2 Make sure that the O ring groove on both the bucket link 4 and boss have been cleaned 4 Realign...

Page 653: ...S0904005K Page 7 Bucket 5 Roll the new O ring 1 Figure 9 into the O ring groove ARO1392L 1 Figure 9...

Page 654: ...rance should be 1 mm 0 04 in between side face of boss and inside edge of ear bushing Y Figure 10 Too tight a fit less than 1 mm 0 04 in can cause excessive wear while too much clearance may produce e...

Page 655: ...semble the link pin end retainers and pull out the pin Lift the arm away from the bucket so that the bucket can be carried away or another end attachment can be put on the excavator ATTACHING THE BUCK...

Page 656: ...simplified if some type of rotating or swiveling support can be used on the ground underneath the bucket Follow instructions for Bucket Attachment to replace pins WARNING When making linkage alignment...

Page 657: ...EET ADDRESS TELEPHONE CITY FAX STATE PROVINCE COUNTRY NAME MACHINE MODEL SERIAL NUMBER MANUAL NUMBER SHOP MANUAL SECTION NUMBER PROPOSED DESCRIPTION OF CORRECTION AND OR SUGGESTION Use additional pape...

Page 658: ......

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