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Doosan DX300LL Excavator Shop Manual K1011789AE-1 – PDF DOWNLOAD
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Doosan DX300LL Excavator Shop Manual K1011789AE-1 – PDF DOWNLOAD
Serial Number 5062 and UP
K1011789AE-1
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Description
Doosan DX300LL Excavator Shop Manual K1011789AE-1 – PDF DOWNLOAD
DESCRIPTION:
Doosan DX300LL Excavator Shop Manual K1011789AE-1 – PDF DOWNLOAD
Serial Number 5062 and UP
K1011789AE-1
GENERAL SAFETY ESSENTIALS
Accessory Applications
Accessory Applications
- The excavator has been primarily designed for moving earth with a bucket. For use as a grapple or for other object handling, contact DOOSAN for proper installation and application. Lifting-work applications (unless restricted or prohibited by local regulations) are permitted in approved lift configuration, to rated capacity only, with no side-loading.
- DO NOT use the machine for activities for which it was not intended. DO NOT use the bucket for lifting work, unless lift slings are used in the approved configuration.
- Use of an accessory hydraulic hammer (breaker), work in rough terrain, demolition applications or other hazardous operation may require installation of additional protective structures to safeguard the operator.
Lifting Capacity Rating Configuration
- Lifting capacity ratings that are printed at the end of this safety section are based on the machine being level, on a firm supporting surface, with hooks and slings attached in approved configuration. Loads must be balanced and supported evenly.
- Use tag lines to keep the load steady if wind conditions and large surface area are a problem. Work crew hand signals, individual tasks and safe procedures should all be universally understood before the lift is made.
TABLE OF CONTENTS:
Doosan DX300LL Excavator Shop Manual K1011789AE-1 – PDF DOWNLOAD
DX300LL..................................................................................................................... 0 Table of Contents....................................................................................................... 7 Safety.................................................................................................................. 9 Track Forest Machine Safety SP002218................................................................................ 11 Safety Precautions.............................................................................................. 15 Applicable Models............................................................................................... 15 To the Operator of a DOOSAN Forest Machine...................................................................... 16 Learn Signal Words Used with Safety Alert Symbol............................................................ 18 General Safety Essentials....................................................................................... 19 Accessory Applications...................................................................................... 19 Lifting Capacity Rating Configuration....................................................................... 19 Location of Safety Labels....................................................................................... 20 Summary of Safety Precautions for Lifting in Digging Mode....................................................... 21 Unauthorized Modifications...................................................................................... 22 General Hazard Information...................................................................................... 22 Safety Rules................................................................................................ 22 Safety Features............................................................................................. 22 Inside Operator's Cabin..................................................................................... 23 Clothing and Personal Protective Items...................................................................... 23 Breathing Masks, Ear Protection May Be Required............................................................. 24 Vibration Level Information................................................................................. 24 Recommendations for Limiting Vibrations..................................................................... 24 Mounting and Dismounting.................................................................................... 25 Fuel, Oil and Hydraulic Fluid Fire Hazards.................................................................. 26 Precautions When Handling Fluids at High Temperature........................................................ 26 Asbestos Dust Hazard Prevention............................................................................. 27 Injury from Work Equipment.................................................................................. 27 Fire Extinguisher and First Aid Kit......................................................................... 27 Protection from Falling or Flying Objects................................................................... 28 Attachment Precautions...................................................................................... 29 Accumulator................................................................................................. 29 Indoor Ventilation.......................................................................................... 29 Emergency Exit.............................................................................................. 30 Emergency Exit (ROPS)....................................................................................... 30 Before Starting Engine.......................................................................................... 31 Work Site Precautions....................................................................................... 31 Checks Before Starting Engine............................................................................... 32 Engine Starting............................................................................................. 32 Before Operating Machine.................................................................................... 33 Machine Operation............................................................................................... 34 When Swinging or Changing Direction of Travel............................................................... 34 Travel Precautions.......................................................................................... 34 Traveling on Slopes......................................................................................... 35 Prohibited Operations....................................................................................... 36 Precautions for Operation................................................................................... 37 Avoid High-voltage Cables................................................................................... 37 Roll Over Protective Structure (ROPS) When Required by Local Regulations.................................... 38 Operate Carefully on Snow, Ice and in Very Cold Temperatures................................................ 39 Operations on Slopes........................................................................................ 40 Parking Machine............................................................................................. 40 Never Let Anyone Ride on Attachment......................................................................... 40 Maintenance..................................................................................................... 41 Warning Tag................................................................................................. 41 Clean Before Inspection or Maintenance...................................................................... 41 Proper Tools................................................................................................ 42 Use of Lighting............................................................................................. 42 Fire Prevention and Explosion Prevention.................................................................... 42 Burn Prevention............................................................................................. 43 Welding Repairs............................................................................................. 44 Warning for Counterweight and Front Attachment Removal...................................................... 45 Precautions for Removal, Installation, and Storage of Attachments........................................... 46 Precautions When Working on Machine......................................................................... 46 Lock Inspection Covers...................................................................................... 46 Prevention of Crushing and Cutting.......................................................................... 47 Track Tension Adjustments Require Caution................................................................... 47 Supports and Blocking for Work Equipment.................................................................... 47 Action When Abnormality Is Found During Inspection.......................................................... 48 Precautions with High-pressure Lines, Tubes and Hoses....................................................... 48 Waste Materials............................................................................................. 49 Hydraulic Cylinders, Pins and Bushings...................................................................... 49 Battery......................................................................................................... 50 Battery Hazard Prevention................................................................................... 50 Boost Starting or Charging Engine Batteries................................................................. 51 Towing.......................................................................................................... 52 Precautions When Towing..................................................................................... 52 Shipping and Transportation..................................................................................... 53 Obey State and Local Over-the-Road Regulations.............................................................. 53 Lifting With Sling.............................................................................................. 53 Specifications.......................................................................................................... 55 Specification for DX300LL........................................................................................... 57 Safety Precautions.............................................................................................. 61 Applicable Models............................................................................................... 61 General Description............................................................................................. 63 Component Locations............................................................................................. 64 General Dimensions.............................................................................................. 66 Working Range................................................................................................... 68 General Specifications.......................................................................................... 69 Engine Performance Curves (Per DIN 6270 Standard)............................................................... 70 Approximate Weight of Workload Materials........................................................................ 72 Performance Tests............................................................................................... 74 Log Loader Performance Standards................................................................................ 75 Test Conditions............................................................................................. 75 Travel Speed and Travel Motor Balance (Steering Deviation) Tests............................................ 75 Speed Test.............................................................................................. 75 Travel Deviation........................................................................................ 77 Swing Speed and Deceleration Force Test..................................................................... 77 Swing Speed Test........................................................................................ 77 Swing Deceleration Force Test........................................................................... 78 Cylinder Performance Tests.................................................................................. 79 Hoist Cylinders Test.................................................................................... 79 Stick Cylinder Test..................................................................................... 79 Heel Cylinder Test...................................................................................... 79 Hydraulic Cylinder Natural Drop Test.................................................................... 79 Travel Motor Jack-up Test............................................................................... 80 General Maintenance..................................................................................................... 81 General Maintenance Procedures...................................................................................... 83 Safety Precautions.............................................................................................. 87 Applicable Models............................................................................................... 87 Welding Precautions and Guidelines.............................................................................. 88 Hydraulic System - General Precautions.......................................................................... 89 Maintenance Service and Repair Procedure........................................................................ 91 General Precautions......................................................................................... 91 Hydraulic System Cleanliness and Oil Leaks...................................................................... 92 Maintenance Precautions for Hydraulic System Service........................................................ 92 Oil Leakage Precautions..................................................................................... 93 Cleaning and Inspection......................................................................................... 94 General Guidelines.......................................................................................... 94 Bearing Inspection.......................................................................................... 95 Normal Bearing.......................................................................................... 96 Bent Cage............................................................................................... 96 Galling................................................................................................. 97 Abrasive Step Wear...................................................................................... 97 Etching................................................................................................. 98 Misalignment............................................................................................ 98 Indentations............................................................................................ 98 Fatigue Spalling........................................................................................ 99 Brinelling.............................................................................................. 99 Cage Wear............................................................................................... 99 Abrasive Roller Wear....................................................................................100 Cracked Inner Race......................................................................................100 Smears..................................................................................................100 Frettage................................................................................................101 Heat Discoloration......................................................................................101 Stain Discoloration.....................................................................................101 Standard Torques....................................................................................................103 Safety Precautions..............................................................................................107 Applicable Models...............................................................................................107 Torque Values for Standard Metric Fasteners.....................................................................108 Torque Values for Standard U.S. Fasteners.......................................................................109 Type 8 Phosphate Coated Hardware................................................................................111 Torque Values for Hose Clamps...................................................................................112 Torque Values for Split Flanges.................................................................................113 Torque Wrench Extension Tools...................................................................................114 Torque Multiplication.......................................................................................114 Other Uses for Torque Wrench Extension Tools................................................................115 Tightening Torque Specifications (Metric)...................................................................116 I. "Loctite" Fastener Adhesives.........................................................................117 II. "Loctite" Pipe Thread Sealant.......................................................................117 III. "Loctite" gasket/flange sealer.....................................................................117 IV. "Loctite" retaining compounds.......................................................................118 V. "Loctite" Adhesives..................................................................................118 Upper Structure.........................................................................................................119 Cabin (NON-ROPS)....................................................................................................121 Safety Precautions..............................................................................................125 Applicable Models...............................................................................................125 Cab Identification..............................................................................................126 Removal.........................................................................................................127 Installation....................................................................................................131 Cabin (ROPS)........................................................................................................135 Safety Precautions..............................................................................................139 Applicable Models...............................................................................................139 Cab Identification..............................................................................................140 Roll Over Protective Structure (ROPS) When Required by Local Regulations....................................140 General ROPS Guidelines for ROPS Certified Cabins.......................................................140 ROPS Certification......................................................................................141 Removal.........................................................................................................142 Installation....................................................................................................146 Counterweight.......................................................................................................149 Safety Precautions..............................................................................................153 Applicable Models...............................................................................................153 General.........................................................................................................154 Warning for Counterweight and Front Attachment Removal......................................................154 Removal.........................................................................................................156 Installation....................................................................................................158 Fuel Tank...........................................................................................................159 Safety Precautions..............................................................................................163 Applicable Models...............................................................................................163 General Description.............................................................................................164 Parts List..................................................................................................164 Specifications..............................................................................................165 Removal.........................................................................................................166 Installation....................................................................................................171 Start-up Procedures.............................................................................................174 Fuel Transfer Pump (Opt)............................................................................................175 Safety Precautions..............................................................................................179 Applicable Models...............................................................................................179 General Description.............................................................................................180 Theory of Operation.........................................................................................180 Troubleshooting.................................................................................................181 Replacement of Rotor and Vane...................................................................................181 Replacement of Rear Cover.......................................................................................182 Replacement of Armature.........................................................................................182 Swing Bearing.......................................................................................................183 Safety Precautions..............................................................................................187 Applicable Models...............................................................................................187 Swing Bearing Maintenance.......................................................................................188 Operating Recommendation....................................................................................188 Measuring Swing Bearing Axial Play..........................................................................188 Measuring Bearing Lateral Play..............................................................................188 Swing Bearing Basic Operation...............................................................................189 Disassembly.................................................................................................189 Assembly....................................................................................................191 Swing Reduction Gear................................................................................................193 Safety Precautions..............................................................................................197 Applicable Models...............................................................................................197 General Description.............................................................................................199 Theory of Operation.........................................................................................199 Parts List..................................................................................................200 Specifications..............................................................................................201 Troubleshooting, Testing and Adjustment.........................................................................202 Removal.........................................................................................................203 Disassembly.....................................................................................................204 Cleaning and Inspection (Wear Limits and Tolerances)............................................................213 Reassembly......................................................................................................214 Shaft and S/R Bearing Heat-fit..............................................................................214 Assembly of Carrier Subassemblies...........................................................................214 Cleaning Carrier........................................................................................214 Cleaning Planet Gear....................................................................................214 Assembly of No. 1 Carrier...............................................................................214 Assembly of No. 2 Carrier...............................................................................217 Assembly of Main Case.......................................................................................220 Cleaning Casing and Other Parts.........................................................................220 Assembly of Shaft and Pinion............................................................................220 Assembly of Seal and Bearing............................................................................225 Assembly of Ring Gear...................................................................................229 Assembly of Carrier.....................................................................................231 Assembly of Motor...........................................................................................236 Add Gear Oil............................................................................................236 Assembly of Motor.......................................................................................236 Supply of Grease........................................................................................238 Installation....................................................................................................240 Start-up Procedures.............................................................................................241 Lower Structure and Chassis.............................................................................................243 Track Assembly......................................................................................................245 Safety Precautions..............................................................................................249 Applicable Models...............................................................................................249 General Description.............................................................................................250 Track Tension...................................................................................................250 Cleaning and Inspection (Wear Limits and Tolerances)............................................................252 Track Shoe..................................................................................................254 Lower Roller................................................................................................256 Upper Roller................................................................................................257 Front Idler.................................................................................................258 Track Shoes and Links...........................................................................................259 Track Removal...............................................................................................259 Track Installation..........................................................................................260 Front Idler Roller..............................................................................................262 Parts List..................................................................................................262 Front Idler Roller Disassembly..............................................................................263 Front Idler Roller Reassembly...............................................................................264 Lower & Upper Roller............................................................................................266 Parts List..................................................................................................266 Lower & Upper Roller Removal................................................................................267 Lower & Upper Roller Disassembly............................................................................267 Lower & Upper Roller Reassembly.............................................................................268 Lower & Upper Roller Installation...........................................................................269 Track Spring and Track Adjusting Cylinder.......................................................................270 Parts List..................................................................................................270 Engine and Drive Train..................................................................................................273 Drive Coupling (Main Pump)..........................................................................................275 Safety Precautions..............................................................................................279 Applicable Models...............................................................................................279 Drive Coupling..................................................................................................280 Installation of Drive Coupling..................................................................................281 Installation Procedure......................................................................................281 Hydraulics..............................................................................................................283 Hydraulic System Troubleshooting, Testing and Adjustment............................................................285 Safety Precautions..............................................................................................289 Applicable Models...............................................................................................289 Hydraulic System - General Notes................................................................................291 Hydraulic Schematic.............................................................................................292 General Notes...............................................................................................292 Operation of Working Components.................................................................................294 Boom Operating Circuit......................................................................................294 Boom Up Circuit.............................................................................................294 Boom Down Circuit...........................................................................................295 Arm Operating Circuit.......................................................................................295 Arm Crowd Circuit...........................................................................................296 Arm Dump Circuit............................................................................................296 Bucket Operating Circuit....................................................................................297 Bucket Crowd Circuit........................................................................................297 Bucket Dump Circuit.........................................................................................297 Swing Operating Circuit.....................................................................................298 Right Swing Operating Circuit...............................................................................298 Left Swing Operating Circuit................................................................................298 Swing Relief Valve and Makeup Valve.........................................................................298 Travel Operating Circuit....................................................................................299 Forward Travel Circuit......................................................................................299 Reverse Travel Circuit......................................................................................299 Procedural Troubleshooting Baseline Recommendations.............................................................300 Initial Checks and Tests to Establish Operating Condition of the Excavator..................................300 Triage Summary..........................................................................................300 Pilot Pressure..................................................................................................302 Adjustment and Testing......................................................................................302 Power Mode Valve................................................................................................303 Current Signal and Hydraulic Pressure Adjustments...........................................................303 Pressure Up Valve...............................................................................................304 Checks and Adjustments......................................................................................304 Pump Input Power Control........................................................................................306 Pump Regulator Adjustment...................................................................................306 Flow Meter and Flow Meter Kit Installation and Testing..........................................................309 Installation and Testing Procedure..........................................................................309 Swing System Troubleshooting....................................................................................311 Precautions/Initial Checks..................................................................................311 Swing Relief Valve Checking and Adjustment..................................................................312 Troubleshooting - Swing Gearbox.................................................................................314 Troubleshooting - Hydraulic Problems............................................................................315 Troubleshooting - Control Valve.................................................................................317 Troubleshooting - Travel Control Valve..........................................................................318 Troubleshooting - Joystick Control Valve........................................................................319 Accumulator.........................................................................................................321 Safety Precautions..............................................................................................325 Applicable Models...............................................................................................325 General Description.............................................................................................326 Specifications..............................................................................................328 Center Joint (Swivel)...............................................................................................329 Safety Precautions..............................................................................................333 Applicable Models...............................................................................................333 General Description.............................................................................................334 Parts List..................................................................................................335 Troubleshooting, Testing and Adjustment.........................................................................336 Inspection..................................................................................................336 Testing.....................................................................................................336 Disassembly.....................................................................................................337 Reassembly......................................................................................................338 Cylinders...........................................................................................................339 Safety Precautions..............................................................................................343 Applicable Models...............................................................................................343 General Description.............................................................................................344 Theory of Operation.........................................................................................344 Parts List..................................................................................................346 Special Tools and Materials.....................................................................................348 Piston Nut..................................................................................................348 Piston Jig..................................................................................................350 Steel Bushing Jig...........................................................................................352 Dust Wiper Jig..............................................................................................354 Slipper Seal Jig............................................................................................356 Slipper Seal Straightening Jig..............................................................................358 Disassembly.....................................................................................................360 Reassembly......................................................................................................365 Swing Motor.........................................................................................................369 Safety Precautions..............................................................................................373 Applicable Models...............................................................................................373 General Description.............................................................................................374 Theory of Operation.........................................................................................374 Structure...............................................................................................374 Circuit Diagram.........................................................................................374 Generation of Rotary Power..............................................................................375 Operation of Relief Valve...............................................................................376 Operation of Parking Brake..............................................................................376 Makeup Check Valve..........................................................................................377 Operation of Time Delay Valve...............................................................................377 External Pilot Pressure: When Pi = 0 (Large Tilt Angle).................................................377 Operation of Swing Reactionless Valve.......................................................................377 Parts List..................................................................................................378 Specifications..............................................................................................380 Torques.....................................................................................................380 Tools and Materials.............................................................................................381 Tools.......................................................................................................381 Troubleshooting, Testing and Adjustment.........................................................................382 General Precautions.........................................................................................382 How to Check Faults of Hydraulic Motor......................................................................382 Troubleshooting.............................................................................................382 Disassembly.....................................................................................................384 General Cautions............................................................................................384 Disassembly.................................................................................................384 Cleaning and Inspection (Wear Limits and Tolerances)............................................................391 Reassembly......................................................................................................392 General Cautions............................................................................................392 Assembly....................................................................................................392 Assembly of Cylinder Block Assembly Subassembly.............................................................395 Assembly of Rear Cover Assembly Subassembly.................................................................399 Air Pressure Test...........................................................................................405 Oil Leakage Check...........................................................................................405 Travel Motor........................................................................................................407 Safety Precautions..............................................................................................411 Applicable Models...............................................................................................411 General Description.............................................................................................413 Theory of Operation.........................................................................................414 Hydraulic Motor.........................................................................................414 Operation of Reduction Gear.............................................................................421 Parts List..................................................................................................422 Hydraulic Motor.........................................................................................422 Reduction Gear..........................................................................................424 Specifications..............................................................................................425 Special Tools and Materials.....................................................................................426 Hydraulic Motor Part........................................................................................426 Reduction Gear Part.........................................................................................427 Tightening Torque Chart.....................................................................................428 Troubleshooting, Testing and Adjustment.........................................................................429 General Precautions.........................................................................................429 Troubleshooting.............................................................................................429 Disassembly.....................................................................................................433 General Caution Matters.....................................................................................433 Reduction Gear Part.........................................................................................433 Hydraulic Motor Part........................................................................................439 Disassembly of Main Body of Motor Section...............................................................439 Disassembly of Valve Casing Subassembly.................................................................442 Disassembly of Cylinder Block Assembly..................................................................443 Cleaning and Inspection (Wear Limits and Tolerances)............................................................444 Maintenance Standard........................................................................................444 Changing Standard of Hydraulic Motor Part...............................................................444 Parts Inspection and Inspection Standard of Reduction Gear..............................................446 Reassembly......................................................................................................447 General Caution Matters.....................................................................................447 Hydraulic Motor Part........................................................................................447 Reassembling of Drive Shaft Subassembly.................................................................447 Assembly of Valve Casing Subassembly....................................................................447 Assembly of Valve Casing Subassembly....................................................................448 Assembly of Cylinder Subassembly........................................................................450 Reduction Gear Part.....................................................................................455 Checkup after Assembly......................................................................................463 Air Test for Reduction Gear.............................................................................463 Air Test for Motor......................................................................................463 Performance Test............................................................................................463 If Test Equipment Is Available..........................................................................463 If on-site performance test is unavoidable as test equipment is not available...........................464 Installation....................................................................................................465 Check.......................................................................................................465 Piping......................................................................................................465 Gear Oil....................................................................................................465 Kind of Oil.............................................................................................465 Oil Drain...............................................................................................466 Oil Filling.................................................................................................466 General Caution Matters.....................................................................................466 Gear Pump...........................................................................................................467 Safety Precautions..............................................................................................471 Applicable Models...............................................................................................471 Single Gear Pump................................................................................................472 Disassembly.................................................................................................472 Reassembly..................................................................................................474 Double Gear Pump................................................................................................478 Disassembly.................................................................................................478 Reassembly..................................................................................................480 Axial Piston Pump SP000068..........................................................................................485 Safety Precautions..............................................................................................489 Applicable Models...............................................................................................489 Axial Piston Pump...............................................................................................490 General Description.........................................................................................490 Special Tools and Materials.................................................................................495 Troubleshooting, Testing and Adjustment.....................................................................497 Disassembly.................................................................................................499 Cleaning and Inspection (Wear Limits and Tolerances)........................................................502 Reassembly..................................................................................................504 Start-up Procedures.........................................................................................508 Regulator for Axial Piston Pump.................................................................................509 General Description.........................................................................................509 Special Tools and Materials.................................................................................520 Troubleshooting, Testing and Adjustment.....................................................................520 Preparation for Disassembly.................................................................................523 Regulator Disassembly.......................................................................................523 Regulator Reassembly........................................................................................526 Main Control Valve..................................................................................................529 Safety Precautions..............................................................................................533 Applicable Models...............................................................................................533 General Description.............................................................................................534 Theory of Operation.........................................................................................534 When All Spools are in Neutral..........................................................................534 Single Operation........................................................................................540 Compound Operation......................................................................................554 Antidrift Valve.........................................................................................560 Main Relief Valve.......................................................................................561 Overload Relief Valve...................................................................................562 Low-pressure Relief Valve...............................................................................564 Parts List..................................................................................................566 Specifications..............................................................................................571 Troubleshooting, Testing and Adjustment.........................................................................572 Troubleshooting.............................................................................................572 Overall Control Valve...................................................................................572 Relief Valve............................................................................................573 Overall Oil Pressure....................................................................................573 Adjustment of Valves........................................................................................573 Main Relief Valve.......................................................................................573 Overload Relief Valve...................................................................................574 Disassembly.....................................................................................................575 Caution in Disassembly......................................................................................575 Disassembly of Main Spool Part..............................................................................576 Disassembly of Arm 1 Para-turn Spool Part...................................................................577 Disassembly of Arm Regeneration Release Valve Part..........................................................577 Disassembly of Load Check Valve Part........................................................................578 Disassembly of Antidrift Valve Part.........................................................................579 Disassembly of Relief Valve.................................................................................580 Disassembly of Option Section Part..........................................................................580 Disassembly of Other Plugs..................................................................................580 Disassembly of Valve Housing Bolt...........................................................................581 Disassembly of Main Relief Valve............................................................................582 Disassembly of Overload Relief Valve........................................................................583 Instruction of Disassembly and Assembly of Low- pressure Relief Valve.......................................584 Cleaning and Inspection (Wear Limits and Tolerances)............................................................585 Cleaning....................................................................................................585 Inspection..................................................................................................585 Reassembly......................................................................................................586 Caution on Assembly.........................................................................................586 Caution on Handling O-ring..............................................................................586 Caution on Handling Spool...............................................................................586 Method of Painting the Adhesives (screw part and arm screw part of parts requiring the adhesiveness)....586 Sequence of Subassembly.....................................................................................587 Spool Assembly (Main Spool).............................................................................587 Arm 1 Para-turn Spool Assembly..........................................................................587 Antidrift Valve Assembly................................................................................588 Assembly Sequence of Main Body of the Control Valve.....................................................588 Assembly of Relief Valve................................................................................589 Assembly of Load Check Valve............................................................................589 Assembly of Antidrift Valve.............................................................................590 Assembly of Option Section Part.........................................................................590 Assembly of Arm Regeneration Release Valve..............................................................590 Assembly of Arm 1 Para-turn Spool.......................................................................591 Assembly of Main Spool..................................................................................591 Assembly of Other Plugs.................................................................................592 Maintenance of Relief Valves................................................................................593 Reassembly of Main Relief Valve.........................................................................593 Reassembly of Overload Relief Valve (69, Total of 6 Places).............................................594 Reassembly of Low-pressure Relief Valve (70, Total of 2 Places).........................................595 Installation....................................................................................................596 Start-up Procedures.............................................................................................596 Remote Control Valve (Work Lever / Joystick)........................................................................597 Safety Precautions..............................................................................................601 Applicable Models...............................................................................................601 General Description.............................................................................................603 Theory of Operation.........................................................................................603 Structure...............................................................................................603 Function................................................................................................603 Parts List..................................................................................................604 Specifications..............................................................................................606 Performance.............................................................................................606 Torques.....................................................................................................606 Tools and Materials.............................................................................................606 Disassembly.....................................................................................................607 Cleaning and Inspection (Wear Limits and Tolerances)............................................................610 Reassembly......................................................................................................611 Start-up Procedures.............................................................................................617 Travel Control Valve (with Damper)..................................................................................619 Safety Precautions..............................................................................................623 Applicable Models...............................................................................................623 General Description.............................................................................................625 Theory of Operation.........................................................................................625 Pressure Reducing Valve.....................................................................................626 Operating Theory of Damper Mechanism........................................................................627 Causes of Faults and Measures...................................................................................629 Parts List..................................................................................................630 Specification...............................................................................................632 Torques.....................................................................................................632 Removal.........................................................................................................633 Disassembly.....................................................................................................634 Cleaning and Inspection (Wear Limits and Tolerances)............................................................636 Reassembly......................................................................................................637 Installation....................................................................................................642 Start-up Procedures.............................................................................................643 Solenoid Valve Assembly.............................................................................................645 Safety Precautions..............................................................................................649 Applicable Models...............................................................................................649 Parts List......................................................................................................650 Functions of 5-Solenoid Valve Assembly Package..................................................................651 Functions of Solenoid Valve Assembly Package................................................................651 This solenoid valve assembly package have the following functions.......................................651 Functions and Operations of Solenoid Valves.............................................................651 Detailed Functions and Operations of Solenoid Valves....................................................651 Assembly Diagram and Tools Required.........................................................................653 Cautions During Disassembly and Reassembly..............................................................654 Solenoid Valve Diagram......................................................................................655 Check Points and Solutions for Problems.....................................................................656 Checking of Pilot Pressure for Defects..................................................................656 Hydraulic Schematic (DX300LL).......................................................................................657 Safety Precautions..............................................................................................661 Applicable Models...............................................................................................661 DX300ll.........................................................................................................663 Electrical System.......................................................................................................665 Electrical System (NON-ROPS)........................................................................................667 Safety Precautions..............................................................................................672 Applicable Models...............................................................................................672 Introduction....................................................................................................673 Electrical Supply System........................................................................................674 Engine Starting Circuit.........................................................................................676 Start Operation.............................................................................................676 After Start.................................................................................................678 Engine Preheating System........................................................................................680 Engine Stop.....................................................................................................682 Charging System.................................................................................................684 Monitoring System...............................................................................................685 Instrument Panel............................................................................................686 Monitoring System Schematic.................................................................................688 Operation.......................................................................................................690 Instruments.................................................................................................690 Warning and Indicator Lights....................................................................................692 Indication of Warning Lights................................................................................692 Indication of Multifunction Gauge and Letter Information Area...............................................693 Initial Operation...............................................................................................695 Mode Selector Switch............................................................................................695 Graphic Information Area Display................................................................................696 Overview....................................................................................................696 Main Menus for the Graphic Display Area.....................................................................697 Menu Selector Buttons.......................................................................................697 Main Menu.......................................................................................................698 Language....................................................................................................698 Set Clock...................................................................................................699 Filter/Oil Info.............................................................................................699 Adjust Display..............................................................................................700 Set Password................................................................................................701 Special Menu....................................................................................................702 Entering/Accessing and Exiting/Escaping Menus...............................................................702 Special Menu Selections.....................................................................................703 Electronic Hydraulic Control System (e-EPOS)....................................................................720 Control System Schematic....................................................................................720 Power Mode Control..............................................................................................722 Operation...................................................................................................724 Power / Economy Mode Control - Circuit Diagram..................................................................727 Engine Control System...........................................................................................728 Engine Control Dial.............................................................................................729 Engine Control Circuit Diagram..................................................................................730 Automatic Deceleration Control (Auto Idle Control)..............................................................732 Engine Overheat Protection System...............................................................................734 Power Boost Mode................................................................................................736 Operation...................................................................................................736 Power Boost Control - Circuit Diagram.......................................................................738 Automatic Travel Speed Control..................................................................................740 Automatic Travel Speed Control - Circuit Diagram............................................................742 Self-diagnostic Function........................................................................................743 e-EPOS Controller...........................................................................................743 Air Conditioner System..........................................................................................745 Outline.....................................................................................................745 Internal and External Filters...............................................................................746 Air-Conditioning System Layout..............................................................................748 Air Conditioner/Heater Circuit Diagram......................................................................749 Air Conditioner/Heater Unit.................................................................................750 Relay - Blower..............................................................................................754 Relay - A/C.................................................................................................754 Duct Sensor.................................................................................................754 Water Temp Sensor...........................................................................................755 Internal Air Temp Sensor....................................................................................755 Ambient Air Temperature Sensor..............................................................................755 Sun Sensor..................................................................................................756 Control Panel...............................................................................................756 Compressor..................................................................................................763 Receiver Dryer..............................................................................................763 Troubleshooting.................................................................................................764 Weight of R134a Gas Used In Machines............................................................................766 Refrigerant System Repairs......................................................................................767 Refrigerant Safe Handling Procedures........................................................................767 Repair and Replacement Procedure............................................................................768 Refrigerant Recovery........................................................................................770 Vacuuming Refrigerant System................................................................................770 Leakage Check...............................................................................................772 Refrigerant Charging........................................................................................772 Inspecting System For Leakage...............................................................................774 Wiper System....................................................................................................775 Wiper Circuit...............................................................................................775 Wiper operation.............................................................................................776 Lighting System.................................................................................................778 Lighting System Circuit Diagram.............................................................................778 Kind of Light...............................................................................................779 Operation...................................................................................................779 Audio Controller................................................................................................780 Audio Controller Circuit Diagram............................................................................780 Electrical System (ROPS)............................................................................................781 Safety Precautions..............................................................................................786 Applicable Models...............................................................................................786 Introduction....................................................................................................787 Electrical Supply System........................................................................................788 Engine Starting Circuit.........................................................................................790 Start Operation.............................................................................................790 After Start.................................................................................................792 Engine Preheating System........................................................................................794 Engine Stop.....................................................................................................796 Charging System.................................................................................................798 Monitoring System...............................................................................................799 Instrument Panel............................................................................................800 Monitoring System Schematic.................................................................................802 Operation.......................................................................................................804 Instruments.................................................................................................804 Warning and Indicator Lights....................................................................................806 Indication of Warning Lights................................................................................806 Indication of Multifunction Gauge and Letter Information Area...............................................807 Initial Operation...............................................................................................809 Mode Selector Switch............................................................................................809 Graphic Information Area Display................................................................................810 Overview....................................................................................................810 Main Menus for the Graphic Display Area.....................................................................811 Menu Selector Buttons.......................................................................................811 Main Menu.......................................................................................................812 Language....................................................................................................812 Set Clock...................................................................................................813 Filter/Oil Info.............................................................................................813 Adjust Display..............................................................................................814 Set Password................................................................................................815 Special Menu....................................................................................................816 Entering/Accessing and Exiting/Escaping Menus...............................................................816 Special Menu Selections.....................................................................................817 Electronic Hydraulic Control System (e-EPOS)....................................................................834 Control System Schematic....................................................................................834 Power Mode Control..............................................................................................836 Operation...................................................................................................838 Power / Economy Mode Control - Circuit Diagram..................................................................841 Engine Control System...........................................................................................842 Engine Control Dial.............................................................................................843 Engine Control Circuit Diagram..................................................................................844 Automatic Deceleration Control (Auto Idle Control)..............................................................846 Engine Overheat Protection System...............................................................................848 Power Boost Mode................................................................................................850 Operation...................................................................................................850 Power Boost Control - Circuit Diagram.......................................................................852 Automatic Travel Speed Control..................................................................................854 Automatic Travel Speed Control - Circuit Diagram............................................................856 Self-diagnostic Function........................................................................................857 e-EPOS Controller...........................................................................................857 Air Conditioner System..........................................................................................859 Outline.....................................................................................................859 Internal and External Filters...............................................................................860 Air-Conditioning System Layout..............................................................................862 Air Conditioner/Heater Circuit Diagram......................................................................863 Air Conditioner/Heater Unit.................................................................................864 Relay - Blower..............................................................................................868 Relay - A/C.................................................................................................868 Duct Sensor.................................................................................................868 Water Temp Sensor...........................................................................................869 Internal Air Temp Sensor....................................................................................869 Ambient Air Temperature Sensor..............................................................................869 Sun Sensor..................................................................................................870 Control Panel...............................................................................................870 Compressor..................................................................................................877 Receiver Dryer..............................................................................................877 Troubleshooting.................................................................................................878 Weight of R134a Gas Used In Machines............................................................................880 Refrigerant System Repairs......................................................................................881 Refrigerant Safe Handling Procedures........................................................................881 Repair and Replacement Procedure............................................................................882 Refrigerant Recovery........................................................................................884 Vacuuming Refrigerant System................................................................................884 Leakage Check...............................................................................................886 Refrigerant Charging........................................................................................886 Inspecting System For Leakage...............................................................................888 Wiper System....................................................................................................889 Wiper Circuit...............................................................................................889 Wiper operation.............................................................................................890 Lighting System.................................................................................................892 Lighting System Circuit Diagram.............................................................................892 Kind of Light...............................................................................................893 Operation...................................................................................................893 Audio Controller................................................................................................894 Audio Controller Circuit Diagram............................................................................894 Electrical Schematic (NON-ROPS).....................................................................................895 Safety Precautions..............................................................................................899 Applicable Models...............................................................................................899 DX300LL/DX300/340/350/380/420/480/520LC.........................................................................901 Electrical Schematic (ROPS).........................................................................................902 Safety Precautions..............................................................................................906 Applicable Models...............................................................................................906 DX300LL/DX300/340/350/380/420/480/520LC.........................................................................908 Attachments.............................................................................................................909 Boom and Stick......................................................................................................911 Safety Precautions..............................................................................................915 Applicable Models...............................................................................................915 Front Attachment Pin Specifications.............................................................................916 DX300LL.....................................................................................................917 Size and Weight Specifications..............................................................................917 Front Attachment - Removal and Installation.....................................................................918 Stick Removal Procedure.....................................................................................918 Boom Removal Procedure......................................................................................920 Installation....................................................................................................921 Stick Installation Procedure................................................................................921 Boom Installation Procedure.................................................................................921 Start-up Procedures.............................................................................................921 Boom and Arm (Exca. Front Option)...................................................................................923 Safety Precautions..............................................................................................927 Applicable Models...............................................................................................927 Front Attachment Pin Specifications.............................................................................928 DX300LC.....................................................................................................929 Front Attachment - Removal and Installation.....................................................................930 Arm Removal Procedure.......................................................................................930 Boom Removal Procedure......................................................................................933 Installation....................................................................................................934 Arm Installation Procedure..................................................................................934 Boom Installation Procedure.................................................................................934 Start-up Procedures.............................................................................................934 Bucket..............................................................................................................935 Safety Precautions..............................................................................................939 Applicable Models...............................................................................................939 Bucket Tooth Inspection and Replacement.........................................................................940 Bucket O-ring Replacement.......................................................................................941 Bucket Shimming Procedures......................................................................................943 New Bucket Installation.....................................................................................943 Shimming Procedures for Installed Bucket................................................................944 Bucket Attachment, Removal and Reversal.........................................................................945 Detaching the Bucket........................................................................................945 Attaching the Bucket........................................................................................945 Reversing the Bucket........................................................................................946
DOOSAN DX300LL EXCAVATOR SHOP MANUAL K1011789AE-1 – PDF DOWNLOAD:
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