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Doosan DX300LC-5 EXCAVATOR SHOP MANUAL 950106 00980E-2 – PDF DOWNLOAD
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Doosan DX300LC-5 EXCAVATOR SHOP MANUAL 950106 00980E-2 – PDF DOWNLOAD
DX300LC-5
Serial Number 1001
Serial Number 1001
950106-00980E-2
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Description
Doosan DX300LC-5 EXCAVATOR SHOP MANUAL 950106 00980E-2 – PDF DOWNLOAD
DESCRIPTION:
Doosan DX300LC-5 EXCAVATOR SHOP MANUAL 950106 00980E-2 – PDF DOWNLOAD
DX300LC-5
Serial Number 1001
Serial Number 1001
950106-00980E-2
Safe Operation is Operator’s Responsibility:
Only trained and authorized personnel should operate and maintain the machine.
Follow all safety rules, regulations and instructions when operating or performing maintenance on machine.
• Do not operate machine if you are under the influence of drugs or alcohol. An operator who is taking prescription drugs must get medical advice to determine if he or she can safely operate a machine.
• When working with other personnel on a work site, be sure that all personnel know nature of work and understand all hand signals that are to be used.
• Be sure that all guards and shields are installed in their proper location. Have guards and shields repaired or replaced immediately if damaged.
• Be sure that you understand the use and maintenance of all safety features such as safety lever and seat belt. Use them properly.
• Never remove, modify or disable any safety features. Always keep them in good operating condition. • Always check for and know the location of underground and overhead utility lines before excavating.
• Failure to use and maintain safety features according to instructions in this manual, Safety Manual and Shop Manual can result in death or serious injury.
Know Your Machine:
- Know how to operate your machine.
- Know the purpose of all controls, gauges, signals, indicators and monitor displays. Know the rated load capacity, speed range, braking and steering characteristics, turning radius and operating clearances.
- Keep in mind that rain, snow, ice, loose gravel, soft ground, slopes etc., can change operating capabilities of your machine.
Proper Work Tools and Attachments:
- Only use work tools and attachments that are recommended by DOOSAN for use on DOOSAN machines.
- When installing and using optional attachments, read instruction manual for attachment, and general information related to attachments in this manual.
- Because DOOSAN cannot anticipate, identify or test all attachments that owners may want to install on their machines, contact DOOSAN for written authorization and approval of attachments, and their compatibility with optional kits. Attachments and attachment control systems that are compatible with the machine are required for safe and reliable machine operation. Do not exceed maximum operating weight (machine weight plus attachment) that is listed on ROPS certification plate.
- Make sure that all guards and shields are in place on machine and on work tool.
- Depending on type or combination of work equipment, there is a potential that work equipment could interfere with the cabin or other parts of machine.
- Before using unfamiliar work equipment, check if there is any potential of interference, and operate with caution. While you are performing any maintenance, testing, or adjustments to attachments, stay clear of the following areas: cutting edges, pinch points, and crushing surfaces. Never use attachment as a work platform or manlift. Contact your DOOSAN distributor about auxiliary hydraulic kits for attachments installation.
- If you are in doubt about compatibility of a particular attachment with a machine, consult your DOOSAN distributor.
TABLE OF CONTENTS:
Doosan DX300LC-5 EXCAVATOR SHOP MANUAL 950106 00980E-2 – PDF DOWNLOAD
DX300LC-5......................................................................................................... 0 NOTICE........................................................................................................ 7 Table of Contents............................................................................................. 9 Safety........................................................................................................ 11 Track Excavator Maintenance Safety........................................................................ 13 Safety Instructions................................................................................... 17 Safety Messages....................................................................................... 17 General............................................................................................... 18 Safe Operation is Operator's Responsibility....................................................... 18 Know Your Machine................................................................................. 18 Proper Work Tools and Attachments................................................................. 19 Pressurized Fluids................................................................................ 19 Flying or Falling Objects......................................................................... 20 Personal Protective Equipment (PPE)............................................................... 21 Correction of Machine Problems.................................................................... 21 Crushing and Cutting.............................................................................. 21 Hot Coolant and Oils - Burn Prevention............................................................ 22 Fire and Explosion Prevention..................................................................... 23 Fire Extinguisher and First-aid Kit (Emergency Medical Kit)....................................... 26 Electrical System and Electrical Shock............................................................ 27 Roll-over Protective Structure (ROPS)............................................................. 27 Transportation........................................................................................ 31 Obey State and Local Over-the-Road Regulations.................................................... 31 Loading and Unloading............................................................................. 31 Transporting Machine.............................................................................. 32 Operation............................................................................................. 33 Before Engine Starting............................................................................ 33 Work Site......................................................................................... 34 Mounting/Dismounting.............................................................................. 35 Cleaning.......................................................................................... 36 Operator Station.................................................................................. 36 Seat Belt......................................................................................... 37 Visibility Information............................................................................ 38 Boost Starting or Charging Engine Batteries....................................................... 39 Swinging or Traveling............................................................................. 41 Lifting and Digging............................................................................... 43 Operation on Slopes............................................................................... 44 Towing............................................................................................ 45 Attachment........................................................................................ 46 Equipment Lowering with Engine Stopped............................................................ 46 Engine Stop....................................................................................... 47 Parking Machine................................................................................... 47 Preservation/Storing Machine...................................................................... 48 Maintenance........................................................................................... 50 Cleaning.......................................................................................... 54 Proper Tools and Clothing......................................................................... 54 Disassembling Precautions......................................................................... 54 Use of Lighting................................................................................... 54 Fire and Explosion Prevention..................................................................... 55 Burn Prevention................................................................................... 56 Rubber That Contains Fluorides.................................................................... 57 Rubber and Plastics............................................................................... 58 Welding Repairs................................................................................... 59 Warning for Counterweight and Front Attachment Removal............................................ 60 Lock Inspection Covers............................................................................ 61 Working on Machine................................................................................ 61 Accumulator....................................................................................... 62 Compressed Air.................................................................................... 62 Track Tension Adjustments......................................................................... 63 Supports and Blocking for Work Equipment.......................................................... 63 High-pressure Lines, Tubes and Hoses.............................................................. 64 Battery........................................................................................... 65 Environment and Circumstances......................................................................... 67 Work Site Areas Requiring Extra Caution........................................................... 67 High-voltage Cables............................................................................... 69 Underground Operation............................................................................. 70 Working in Water.................................................................................. 70 Working in Contaminated Environment............................................................... 70 Operation in Extreme Conditions................................................................... 71 Exhaust Ventilation............................................................................... 75 Asbestos Information.............................................................................. 76 Silica Dust Information........................................................................... 76 Disposal of Hazardous Materials................................................................... 77 Sound............................................................................................. 77 Vibration Information............................................................................. 78 Specifications................................................................................................ 81 Specifications............................................................................................ 83 Safety Instructions................................................................................... 87 General Description................................................................................... 87 Component Locations................................................................................... 88 General Dimensions.................................................................................... 92 One - Piece Boom.................................................................................. 92 Two - Piece Boom.................................................................................. 93 Working Range......................................................................................... 94 One - Piece Boom.................................................................................. 94 Two - Piece Boom.................................................................................. 96 General Specifications................................................................................ 98 Approximate Weight of Workload Materials.............................................................. 100 Performance Tests..................................................................................... 102 Purpose of Performance Tests...................................................................... 102 Kinds of Tests.................................................................................... 102 Performance Standards............................................................................. 102 Precautions for Evaluation of Test Data........................................................... 102 Definition of "Performance Standard".............................................................. 102 Preparation for Performance Tests..................................................................... 103 The Machine....................................................................................... 103 Test Area......................................................................................... 103 Precautions....................................................................................... 103 Make Precise Measurement.......................................................................... 103 Operational Performance Standard Table................................................................ 104 Operational Performance Test.......................................................................... 106 Hydraulic Cylinder Cycle Time..................................................................... 106 Travel Speed...................................................................................... 108 Track Revolution Speed............................................................................ 109 Mistrack Check.................................................................................... 111 Swing Speed....................................................................................... 113 Swing Function Drift Check........................................................................ 114 General Maintenance........................................................................................... 115 General Maintenance Instructions.......................................................................... 117 Safety Instructions................................................................................... 121 Welding Precautions and Instructions.................................................................. 122 Hydraulic System - General Precautions................................................................ 123 Maintenance Service and Repair Procedure.............................................................. 125 General Precautions............................................................................... 125 Hydraulic System Cleanliness and Oil Leaks............................................................ 126 Maintenance Precautions for Hydraulic System Service.............................................. 126 Oil Leakage Precautions........................................................................... 127 Cleaning and Inspection............................................................................... 128 General Instructions.............................................................................. 128 Bearing Inspection................................................................................ 129 Standard Torques.......................................................................................... 137 Safety Instructions................................................................................... 141 Torque Values for Standard Metric Fasteners........................................................... 142 Torque Values for Standard U.S. Fasteners............................................................. 143 Type 8 Phosphate Coated Hardware...................................................................... 145 Torque Values for Hose Clamps......................................................................... 146 ORFS Swivel Nut Recommended Torque.................................................................... 146 Torque Values for Split Flanges....................................................................... 147 Torque Wrench Extension Tools......................................................................... 148 Torque Multiplication............................................................................. 148 Other Uses for Torque Wrench Extension Tools...................................................... 149 Tightening Torque Specifications (Metric)......................................................... 150 Engine........................................................................................................ 153 Engine.................................................................................................... 155 Safety Instructions................................................................................... 161 Overview.............................................................................................. 162 Inspection............................................................................................ 163 Cleaning the Engine............................................................................... 163 Special Tools......................................................................................... 163 Mounting the Engine in a Universal Stand.......................................................... 173 Engine Identification................................................................................. 174 Engine Data Plate................................................................................. 174 Engine Specification.................................................................................. 175 Engine Performance Curves............................................................................. 176 Tightening Torques.................................................................................... 178 Normal Tightening Torque.......................................................................... 178 Special Tightening Torque......................................................................... 182 Cylinder.............................................................................................. 210 Cylinder Head..................................................................................... 210 Valve Mechanism................................................................................... 228 Cylinder Block.................................................................................... 231 Cylinder Liner.................................................................................... 246 Flywheel Housing.................................................................................. 253 Front Cover....................................................................................... 255 Oil Mist Separator................................................................................ 257 Actuating System...................................................................................... 264 Camshaft.......................................................................................... 264 Connecting Rod.................................................................................... 271 Crankshaft........................................................................................ 274 Flywheel.......................................................................................... 283 Piston............................................................................................ 288 Roller Tappet..................................................................................... 294 Intake Manifold................................................................................... 296 Power Take Off.................................................................................... 296 Torsion Damper.................................................................................... 297 Belt Circuit...................................................................................... 298 Balance Shaft Unit................................................................................ 305 Timing Gear....................................................................................... 310 Lubrication System.................................................................................... 316 General Information............................................................................... 316 Centrifugal Oil Cleaner........................................................................... 318 Oil Cooler........................................................................................ 323 Oil Filter........................................................................................ 326 Oil Pump.......................................................................................... 327 Oil Sump.......................................................................................... 329 Oil Pressure Sensor............................................................................... 330 Troubleshooting Chips Found in the Engine......................................................... 331 Troubleshooting the Lubrication System............................................................ 335 Lubrication Oil Consumption....................................................................... 336 Exhaust System........................................................................................ 339 General Information............................................................................... 339 T113, Exhaust Temperature Sensor Before Catalytic Converter....................................... 354 T131 NOx Sensor................................................................................... 356 T116, Reductant Pick-up Unit...................................................................... 358 Evaporator........................................................................................ 363 V117 Reductant Doser.............................................................................. 364 V118, Coolant Valve for Heating the Reductant System.............................................. 370 V183 Reductant Pump............................................................................... 372 H25, H26 Electrically Heated Reductant Hose....................................................... 383 M4000 Electric Exhaust Brake...................................................................... 384 Reductant Tank.................................................................................... 390 Oxidation Catalytic Converter..................................................................... 397 Exhaust Manifold.................................................................................. 399 Variable Geometry Turbocharger.................................................................... 407 EGR System........................................................................................ 415 EGR Valve......................................................................................... 422 EGR Cooler........................................................................................ 427 Cooling System........................................................................................ 429 Internal Cleaning of Cooling System............................................................... 432 Charge Air Cooler................................................................................. 433 Charge Air Temperature Sensor..................................................................... 435 Charge Air Pressure Sensor........................................................................ 437 Coupling Coil for AC Compressor................................................................... 438 Thermostat........................................................................................ 439 Coolant Pump...................................................................................... 442 Coolant Temperature Sensor........................................................................ 443 Fuel System........................................................................................... 445 General Information............................................................................... 445 Accumulator....................................................................................... 450 Fuel Manifold..................................................................................... 451 Overflow Valve.................................................................................... 459 Feed Pump......................................................................................... 462 Injector.......................................................................................... 469 Fuel Filter....................................................................................... 475 Fuel Heater....................................................................................... 480 Fuel System Troubleshooting....................................................................... 481 Electrical System..................................................................................... 494 E44, Control Unit EMS............................................................................. 494 Control Unit EEC.................................................................................. 510 Engine Speed Sensor............................................................................... 515 T110 Oil Level Sensor............................................................................. 517 T111, Fuel Pressure Sensor........................................................................ 518 T125, Exhaust Back Pressure Sensor................................................................ 520 T135, Camshaft Position Sensor.................................................................... 521 V109, Solenoid Valve for Charge Pressure.......................................................... 523 V120, Fuel Inlet Metering Valve................................................................... 524 V142, V143, V144, V145, V146 Solenoid Valve for Injector.......................................... 526 T8, Coolant Level Monitor......................................................................... 527 P3, Alternator.................................................................................... 528 M1, Starter Motor................................................................................. 538 AC Compressor..................................................................................... 541 Electrical Parts.................................................................................. 544 Engine Coolant Heater (Option)............................................................................ 561 Safety Instructions................................................................................... 565 Disassembly and Assembly.............................................................................. 565 Changing the Circulating Pump..................................................................... 565 Changing the Temperature Limiter.................................................................. 567 Changing the Temperature Sensor................................................................... 568 Changing the Combustion Air Fan................................................................... 570 Changing the Burner, Flame Monitor and Glow Plug.................................................. 572 Changing the Burner Head.......................................................................... 574 Changing the Heat Exchanger....................................................................... 576 Upper Structure............................................................................................... 577 Cabin..................................................................................................... 579 Safety Instructions................................................................................... 583 Cabin Identification.................................................................................. 583 Roll-over Protective Structure (ROPS)............................................................. 583 Dimensions of Cabin Glass............................................................................. 592 Removal and Installation of Cabin Glass............................................................... 596 Removal of Cabin Glass............................................................................ 596 Installation of Cabin Glass....................................................................... 598 Installation of Upper Door Glass.................................................................. 603 Installation of Upper Front Glass................................................................. 603 Counterweight............................................................................................. 605 Safety Instructions................................................................................... 609 General............................................................................................... 610 Warning for Counterweight and Front Attachment Removal............................................ 610 Installation.......................................................................................... 613 Oil Tank.................................................................................................. 615 Safety Instructions................................................................................... 619 General............................................................................................... 619 Specification..................................................................................... 619 Air Breather...................................................................................... 622 Installation.......................................................................................... 628 Completing Work....................................................................................... 629 Fuel Tank................................................................................................. 631 Safety Instructions................................................................................... 635 General............................................................................................... 635 Specification..................................................................................... 635 Installation.......................................................................................... 643 Completing Work....................................................................................... 646 Main Pump................................................................................................. 647 Safety Instructions................................................................................... 651 Axial Piston Pump..................................................................................... 651 Specifications.................................................................................... 651 Overview.......................................................................................... 653 Hydraulic Circuit................................................................................. 655 Parts List........................................................................................ 656 Section View...................................................................................... 658 Theory of Operation............................................................................... 660 Tools............................................................................................. 662 Tightening Torque................................................................................. 663 Removal........................................................................................... 664 Installation...................................................................................... 674 Completing Work................................................................................... 674 Disassembly....................................................................................... 675 Reassembly........................................................................................ 678 Troubleshooting................................................................................... 681 Maintenance Instructions.......................................................................... 683 Regulator............................................................................................. 684 Parts List........................................................................................ 684 Port and Hydraulic Circuit........................................................................ 686 Functional Explanation............................................................................ 687 Adjustment........................................................................................ 694 Tightening Torque................................................................................. 697 Tools............................................................................................. 697 Section View...................................................................................... 698 Disassembly....................................................................................... 700 Reassembly........................................................................................ 703 Troubleshooting................................................................................... 706 Pilot Gear Pump....................................................................................... 707 Specification..................................................................................... 707 Parts List........................................................................................ 708 Theory of Operation............................................................................... 709 Port and Hydraulic Circuit........................................................................ 709 Precaution........................................................................................ 710 Drive Coupling (Main Pump)................................................................................ 711 Safety Instructions................................................................................... 715 General............................................................................................... 715 Specification..................................................................................... 715 Parts List........................................................................................ 716 Section View.......................................................................................... 718 Tools............................................................................................. 719 Disassembly........................................................................................... 720 Reassembly............................................................................................ 720 Main Control Valve........................................................................................ 723 Safety Instructions................................................................................... 727 General............................................................................................... 727 Specification..................................................................................... 727 Overview.......................................................................................... 728 Parts List........................................................................................ 734 Theory of Operation............................................................................... 740 Cautions for Operation............................................................................ 768 Precaution............................................................................................ 769 Tools and Torques................................................................................. 769 Removal............................................................................................... 770 Installation.......................................................................................... 779 Completing Work....................................................................................... 780 Disassembly........................................................................................... 781 Caution on Disassembly............................................................................ 781 Sequence of Disassembly........................................................................... 782 Cleaning and Inspection............................................................................... 793 Cleaning.......................................................................................... 793 Inspection........................................................................................ 793 Reassembly............................................................................................ 794 Caution on Assembly............................................................................... 794 Sequence of Subassembly........................................................................... 795 Maintenance of Relief Valves...................................................................... 806 Troubleshooting, Testing and Adjustment............................................................... 809 Troubleshooting................................................................................... 809 Adjustment of Valves.............................................................................. 811 Swing Device.............................................................................................. 815 Safety Instructions................................................................................... 819 General............................................................................................... 819 Specification..................................................................................... 819 Overview.......................................................................................... 820 Parts List........................................................................................ 822 Theory of Operation............................................................................... 827 Cautions for Operation............................................................................ 835 Precaution............................................................................................ 839 Tools for Disassembly and Assembly................................................................ 839 Tightening Torque................................................................................. 839 Removal............................................................................................... 841 Installation.......................................................................................... 845 Completing work....................................................................................... 845 Section View.......................................................................................... 846 Swing Motor....................................................................................... 846 Swing Reduction Gear.............................................................................. 848 Disassembly........................................................................................... 850 Swing Motor....................................................................................... 850 Swing Reduction Gear.............................................................................. 855 Reassembly............................................................................................ 859 Swing Motor....................................................................................... 859 Swing Reduction Gear.............................................................................. 866 Troubleshooting....................................................................................... 870 General Instructions.............................................................................. 870 Examination of Hydraulic Motor.................................................................... 870 Troubleshooting................................................................................... 871 Maintenance Instructions.............................................................................. 874 Replacement Standard of Worn Parts................................................................ 874 Standard of Sliding Surface Correction............................................................ 874 Fan Pump for Oil Cooler................................................................................... 875 Safety Instructions................................................................................... 879 General............................................................................................... 880 Specification..................................................................................... 880 Overview.......................................................................................... 881 Parts List........................................................................................ 882 Theory of Operation............................................................................... 884 Maintenance Guidelines................................................................................ 889 Sealing Control Valve............................................................................. 892 Tools............................................................................................. 892 Removal............................................................................................... 893 Section View.......................................................................................... 897 EPPR Valve........................................................................................ 897 Disassembly........................................................................................... 898 Disassembly of Rotary Group....................................................................... 899 Disassembly of Shaft/Bearings..................................................................... 901 Reassembly............................................................................................ 905 Fan Motor for Oil Cooler.................................................................................. 911 Safety Instructions................................................................................... 915 General............................................................................................... 915 Specification..................................................................................... 915 Overview.......................................................................................... 916 Parts List and Section View....................................................................... 917 Precaution............................................................................................ 918 Tools............................................................................................. 918 Installation.......................................................................................... 922 Completing Work....................................................................................... 922 Disassembly........................................................................................... 923 Reassembly............................................................................................ 926 Reassembly........................................................................................ 926 Assembly.......................................................................................... 927 Gear Pump (Rotation)...................................................................................... 929 Safety Instructions................................................................................... 933 General............................................................................................... 933 Specification..................................................................................... 933 Overview.......................................................................................... 934 Parts List........................................................................................ 935 Single Gear Pump...................................................................................... 936 Disassembly....................................................................................... 936 Reassembly........................................................................................ 938 Joystick Valve (Work Lever)............................................................................... 943 Safety Instructions................................................................................... 947 General............................................................................................... 947 Specifications.................................................................................... 947 Overview.......................................................................................... 948 Parts List........................................................................................ 950 Theory of Operation............................................................................... 952 Tools and Torques................................................................................. 953 Section View.......................................................................................... 954 Removal............................................................................................... 956 Installation.......................................................................................... 960 Completing work....................................................................................... 961 Disassembly........................................................................................... 962 Reassembly............................................................................................ 966 Travel Control Valve (with Damper)........................................................................ 973 Safety Instructions................................................................................... 977 General............................................................................................... 978 Specification..................................................................................... 978 Overview.......................................................................................... 979 Parts List........................................................................................ 980 Theory of Operation............................................................................... 982 Section View.......................................................................................... 984 Removal............................................................................................... 985 Installation.......................................................................................... 990 Completing Work....................................................................................... 991 Disassembly........................................................................................... 992 Reassembly............................................................................................ 995 Troubleshooting.......................................................................................1000 Solenoid Valve............................................................................................1001 Safety Instructions...................................................................................1005 General...............................................................................................1005 Specification.....................................................................................1005 Overview..........................................................................................1006 Parts List........................................................................................1008 Theory of Operation...............................................................................1009 Disassembly and Reassembly............................................................................1010 Troubleshooting.......................................................................................1011 EPPR Valve................................................................................................1013 Safety Instructions...................................................................................1017 General...............................................................................................1018 Specification.....................................................................................1018 Overview..........................................................................................1019 Hydraulic Circuit.................................................................................1020 Troubleshooting.......................................................................................1020 Accumulator...............................................................................................1021 Safety Instructions...................................................................................1025 General...............................................................................................1025 Specifications....................................................................................1027 Lower Structure and Chassis...................................................................................1029 Swing Bearing.............................................................................................1031 Safety Instructions...................................................................................1035 General...............................................................................................1036 General Description...............................................................................1036 Parts List........................................................................................1036 Maintenance Guidelines................................................................................1037 Disassembly...........................................................................................1038 Reassembly............................................................................................1040 Center Joint..............................................................................................1041 Safety Instructions...................................................................................1045 General...............................................................................................1045 General Description...............................................................................1045 Overview..........................................................................................1046 Parts List........................................................................................1047 Section View..........................................................................................1048 Removal...............................................................................................1049 Installation..........................................................................................1054 Completing Work.......................................................................................1054 Reassembly............................................................................................1058 Troubleshooting, Testing and Adjustment...............................................................1060 Inspection........................................................................................1060 Testing...........................................................................................1060 Travel Device.............................................................................................1061 Safety Instructions...................................................................................1065 General...............................................................................................1065 Specification.....................................................................................1065 Overview..........................................................................................1066 Theory of Operation...............................................................................1072 Cautions for Operation............................................................................1082 Precaution............................................................................................1086 Tools for Disassembly and Assembly................................................................1086 Tightening Torque.................................................................................1088 Removal...............................................................................................1089 Installation..........................................................................................1094 Completing Work.......................................................................................1094 Section View..........................................................................................1096 Disassembly...........................................................................................1098 Cautions on Disassembly...........................................................................1098 Disassembly Sequence..............................................................................1098 Reassembly............................................................................................1108 Cautions on Assembly..............................................................................1108 Assembly Sequence.................................................................................1108 Performance Test......................................................................................1125 Troubleshooting.......................................................................................1127 Track Assembly............................................................................................1129 Safety Instructions...................................................................................1133 General...............................................................................................1133 Track Tension.........................................................................................1134 Track Shoes and Links.................................................................................1136 Parts List........................................................................................1136 Track Removal.....................................................................................1137 Track Installation................................................................................1139 Wear Limits and Tolerances........................................................................1140 Sprocket..............................................................................................1142 Wear Limits and Tolerances........................................................................1142 Front Idler...........................................................................................1143 Parts List........................................................................................1143 Front Idler Disassembly...........................................................................1144 Front Idler Reassembly............................................................................1146 Wear Limits and Tolerances........................................................................1147 Upper Roller..........................................................................................1148 Parts List........................................................................................1148 Upper Roller Removal..............................................................................1149 Upper Roller Installation.........................................................................1149 Upper Roller Disassembly..........................................................................1150 Upper Roller Reassembly...........................................................................1151 Wear Limits and Tolerances........................................................................1152 Lower Roller..........................................................................................1153 Parts List........................................................................................1153 Lower Roller Removal..............................................................................1154 Lower Roller Installation.........................................................................1154 Lower Roller Disassembly..........................................................................1154 Lower Roller Reassembly...........................................................................1155 Wear Limits and Tolerances........................................................................1157 Track Adjuster........................................................................................1158 Parts List........................................................................................1158 Disassembly.......................................................................................1159 Assembly..........................................................................................1160 Front.........................................................................................................1163 Boom and Arm..............................................................................................1165 Safety Instructions...................................................................................1169 Specifications........................................................................................1170 One - Piece Boom..................................................................................1170 Two - Piece Boom..................................................................................1172 Removal...............................................................................................1174 Arm Removal.......................................................................................1174 Boom Removal......................................................................................1176 Installation..........................................................................................1177 Arm Installation..................................................................................1177 Boom Installation.................................................................................1177 Completing Work.......................................................................................1178 Bucket....................................................................................................1179 Safety Instructions...................................................................................1183 Bucket Tooth Inspection and Replacement...............................................................1184 Bucket O-ring Replacement.............................................................................1185 Bucket Shimming Procedures............................................................................ 0 New Bucket Installation........................................................................... 0 Shimming Procedures for Installed Bucket......................................................1187 Bucket Replacement and Reversal.......................................................................1188 Replacement.......................................................................................1189 Reversal..........................................................................................1190 Cylinders.................................................................................................1191 Safety Instructions...................................................................................1195 General...............................................................................................1195 General Description...............................................................................1195 Specification.....................................................................................1195 Parts List........................................................................................1196 Theory of Operation...............................................................................1204 Seal of Cylinder..................................................................................1205 Special Tools and Materials........................................................................... 0 Rod Bushing (DD-bushing) Pushing-in Jig...........................................................1213 Disassembly...........................................................................................1214 Reassembly............................................................................................1219 Troubleshooting.......................................................................................1223 Hydraulic System..............................................................................................1225 Hydraulic System..........................................................................................1227 Safety Instructions...................................................................................1231 Hydraulic System......................................................................................1231 General Description...............................................................................1231 Hydraulic Schematic...................................................................................1232 General Description...............................................................................1232 Hydraulic Component and Oil Flow......................................................................1234 Hydraulic Components..............................................................................1234 Main Oil Line.....................................................................................1236 Pilot Oil Line....................................................................................1238 Return Oil Line...................................................................................1240 Safety Cutoff Valve Operation.........................................................................1242 Power Up Valve Operation..............................................................................1244 Travel High-speed Valve Operation.....................................................................1246 Swing Brake Release Operation.........................................................................1248 Two Pump Valve Operation..............................................................................1250 Travel Forward and Backward Operation.................................................................1252 Boom Up Operation.....................................................................................1254 Boom Down Operation...................................................................................1256 Easy Boom Operation...................................................................................1260 Arm Dump Operation....................................................................................1262 Arm Crowd Operation...................................................................................1264 Bucket Dump Operation.................................................................................1266 Bucket Crowd Operation................................................................................1268 Combined Bucket Crowd and Boom Up Operation...........................................................1270 Combined Travel and Boom, Arm, Bucket or Swing Operation..............................................1273 Hydraulic System Testing and Adjustment...................................................................1277 Safety Instructions...................................................................................1281 Procedural Troubleshooting Baseline Recommendations...................................................1282 Initial Checks and Tests to Establish Operating Condition of the Excavator........................1282 Pilot Pressure........................................................................................1284 Adjustment and Testing............................................................................1284 Power Mode Valve......................................................................................1285 Current Signal and Hydraulic Pressure Adjustments.................................................1285 Pressure Up Valve.....................................................................................1286 Checks and Adjustments............................................................................1286 Pump Input Power Control..............................................................................1288 Pump Regulator Adjustment.........................................................................1288 Flow Meter and Flow Meter Kit Installation and Testing................................................1291 Swing System Troubleshooting..........................................................................1293 Precautions/Initial Checks........................................................................1293 Swing Relief Valve Checking and Adjustment........................................................1294 Hydraulic System Troubleshooting..........................................................................1297 Safety Instructions...................................................................................1301 Hydraulic System......................................................................................1301 Unusual Noise Comes Out from Pump Connection......................................................1301 Engine Starts but Machine Does Not Operate........................................................1302 Hydraulic Oil is Cloudy...........................................................................1303 Hydraulic Oil Overheated..........................................................................1303 Hydraulic Pump Cavitation.........................................................................1304 Hydraulic Oil is Contaminated.....................................................................1304 Boom, Arm, Bucket Speed is Slow...................................................................1305 Boom, Arm or Bucket Power is Weak.................................................................1306 Cylinder Moves When Remote Control Valve is in the Neutral Position...............................1306 TR (L), TR (R) Swing Does Not Operate When Remote Control Valve Operated..........................1307 Swing Speed is Slow...............................................................................1308 Does Not Operate Boom Floating....................................................................1309 Machine Swings but Does Not Stop..................................................................1309 One Side Speed is Falls and the Machine Curves....................................................1310 Machine Does Not Stop on a Slope..................................................................1311 Travel Motor is Powerless (Travel Only)...........................................................1311 Machine Makes a Curved Travel, When Travel and Actuator Operation are Executed a the Same Time....1312 Does Not Travel is 2nd Speed or Auto Speed........................................................1312 Troubleshooting - Swing Gearbox.......................................................................1313 Troubleshooting - Hydraulic Problems..................................................................1314 Troubleshooting - Control Valve.......................................................................1316 Troubleshooting - Travel Control Valve................................................................1317 Troubleshooting - Joystick Control Valve..............................................................1318 Electrical System.............................................................................................1319 Electrical System.........................................................................................1321 Safety Instructions...................................................................................1327 Introduction..........................................................................................1327 Electrical Supply System..............................................................................1328 Engine Starting Circuit...............................................................................1330 Start Operation...................................................................................1330 Engine Stop...........................................................................................1333 Monitoring System.....................................................................................1336 Instrument Panel..................................................................................1337 Functional Check..................................................................................1337 Monitoring System Schematic.......................................................................1338 Operation.............................................................................................1340 Instruments.......................................................................................1340 Warning and Indicator Lights.......................................................................... 0 Indication of Multifunction Gauge.................................................................1345 Initial Operation.....................................................................................1347 Graphic Information Area Display......................................................................1348 Overview..........................................................................................1348 Main Menus for the Graphic Display Area...........................................................1348 Menu Selector Buttons.............................................................................1348 User Menu.............................................................................................1349 User Menu - Access and Escape Methods.............................................................1349 Special Menu..........................................................................................1385 Entering/Accessing and Exiting/Escaping Menus.....................................................1385 Special Menu Selections...........................................................................1386 Failure Code..........................................................................................1402 Failure Code at Machine...........................................................................1402 Failure Code at Engine Side.......................................................................1405 Electronic Hydraulic Control System (EPOS)............................................................1422 Control System Schematic..........................................................................1422 Power Plus Mode Control...............................................................................1424 Operation.........................................................................................1426 Power Mode Control....................................................................................1428 Smart Power Control (SPC).............................................................................1430 Operation.........................................................................................1430 Engine Control System.................................................................................1433 Engine Control Dial...................................................................................1434 Engine Control........................................................................................1436 Automatic Deceleration Control (Auto Idle Control)....................................................1438 Engine Overheat Protection System.....................................................................1440 Power Boost Mode......................................................................................1443 Operation.........................................................................................1443 Power Boost Control...............................................................................1444 Automatic Travel Speed Control........................................................................1446 Water in Fuel Warning System..........................................................................1449 Operation.........................................................................................1449 Self-diagnostic Function..............................................................................1450 EPOS Controller...................................................................................1450 Air Conditioner System................................................................................1452 Outline...........................................................................................1452 Internal and External Filters.....................................................................1453 Air-Conditioning System Layout....................................................................1454 Air Conditioner/Heater Circuit Diagram............................................................1455 Air Conditioner/Heater Unit.......................................................................1456 Ambient Air Temperature Sensor....................................................................1461 Receiver Dryer....................................................................................1470 Troubleshooting.......................................................................................1471 Refrigerant System Repairs............................................................................1473 Refrigerant Safe Handling Procedures..............................................................1473 Repair and Replacement Procedure..................................................................1474 Refrigerant Recovery..............................................................................1476 Vacuuming Refrigerant System......................................................................1476 Leakage Check.....................................................................................1478 Refrigerant Charging..............................................................................1478 Inspecting System For Leakage.....................................................................1480 Wiper System.......................................................................................... 0 Wiper Operation...................................................................................1482 Lighting System....................................................................................... 0 Kind of Light.....................................................................................1485 Operation.........................................................................................1485 Electrical System Troubleshooting.........................................................................1489 Safety Instructions...................................................................................1493 Electrical System.....................................................................................1493 When Starter Switch is Turn ON, Monitor Panel Display Does Not Appear.............................1493 Communication Error Flashes on the Panel..........................................................1494 Battery Charging Warning Light Lights, When Engine is Started.....................................1495 When Coolant Overheat Warning Light Lights, When Engine is Started................................1496 When Engine Oil Pressure Warning Light Lights, When Engine is Started.............................1496 When Water Separator Warning Light Lights, When Engine Is Started.................................1497 Does Not Control the Engine Control Dial..........................................................1497 Does Not Control the Engine Auto Idle (PA, PT)....................................................1498 When Pilot Cutoff Solenoid Does Not Operate.......................................................1498 When Does Not Operate Auto Travel Speed...........................................................1499 Does Not Operation Wiper Motor, When Starting Switch Is Turned ON.................................1500 All Actuators Speed are Slow (EPPR Valve).........................................................1501 Engine Stall (EPPR Valve).........................................................................1502 Options.......................................................................................................1503 One Way...................................................................................................1505 Safety Instructions...................................................................................1509 General...............................................................................................1509 General Description...............................................................................1509 Theory of Operation...............................................................................1509 Hydraulic Circuit.................................................................................1510 Caution for Installation..........................................................................1511 Installation Procedure................................................................................1512 Main Piping - One and Two-way.....................................................................1512 Main Piping - One Way.............................................................................1514 Boom Piping - One and Two-way.....................................................................1518 Arm Piping - One and Two-way......................................................................1520 After Installation Precautions....................................................................1521 Air Bleeding......................................................................................1521 Completing Work.......................................................................................1522 Two-way...................................................................................................1523 Safety Instructions...................................................................................1527 General...............................................................................................1527 General Description...............................................................................1527 Theory of Operation...............................................................................1527 Structure.........................................................................................1528 Hydraulic Circuit.................................................................................1529 Caution for Installation..........................................................................1531 Installation Procedure................................................................................1532 Main Piping - One and Two-way.....................................................................1532 Main Piping - Two-way.............................................................................1534 Pilot Piping - Two-way............................................................................1538 Boom Piping - One and Two-way.....................................................................1542 Arm Piping - One and Two-way......................................................................1544 After Installation Precautions....................................................................1545 Air Bleeding......................................................................................1545 Completing Work.......................................................................................1546 Rotating..................................................................................................1547 Safety Instructions...................................................................................1551 General...............................................................................................1551 General Description...............................................................................1551 Theory of Operation...............................................................................1551 Structure.........................................................................................1552 Hydraulic Circuit.................................................................................1553 Caution for Installation..........................................................................1554 Installation Procedure................................................................................ 0 Pilot Piping - Rotating...........................................................................1558 Boom Piping - Rotating............................................................................1560 Arm Piping - Rotating.............................................................................1562 After Installation Precautions....................................................................1563 Air Bleeding......................................................................................1563 Completing Work.......................................................................................1563 Quick Coupler.............................................................................................1565 Safety Instructions...................................................................................1569 General...............................................................................................1569 General Description...............................................................................1569 Theory of Operation...............................................................................1569 Hydraulic Circuit.................................................................................1570 Caution for Installation..........................................................................1571 Quick Coupler Operation...............................................................................1572 Securing Work Tool................................................................................1572 Attaching Quick Coupler to Excavator..............................................................1572 Releasing the Work Tool...........................................................................1574 Installation Procedure................................................................................1576 Main Piping - Quick Coupler.......................................................................1576 Electric Parts - Quick Coupler....................................................................1577 Boom Piping - Quick Coupler.......................................................................1578 Arm Piping - Quick Coupler........................................................................1580 After Installation Precautions....................................................................1581 Air Bleeding......................................................................................1581 Completing Work.......................................................................................1581 Two Pump..................................................................................................1583 Safety Instructions...................................................................................1587 General...............................................................................................1587 General Description...............................................................................1587 Theory of Operation...............................................................................1587 Hydraulic Circuit.................................................................................1588 Caution for Installation..........................................................................1589 Installation Procedure................................................................................1590 Main Piping - Two Pump............................................................................1590 Pilot Piping - Two Pump...........................................................................1592 After Installation Precautions....................................................................1593 Air Bleeding......................................................................................1593 Schematic.....................................................................................................1595 Hydraulic Schematic / Electrical Schematic................................................................1597 Blank Page........................................................................................................1600 Blank Page........................................................................................................1602
DOOSAN DX300LC-5 EXCAVATOR SHOP MANUAL 950106 00980E-2 – PDF DOWNLOAD:
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