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DOOSAN DX300MH 3 EXCAVATOR MATRIAL HANDLER SHOP MANUAL 950106 01404EMH – PDF DOWNLOAD
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DOOSAN DX300MH 3 EXCAVATOR MATRIAL HANDLER SHOP MANUAL 950106 01404EMH – PDF DOWNLOAD
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Description
DOOSAN DX300MH 3 EXCAVATOR MATRIAL HANDLER SHOP MANUAL 950106 01404EMH – PDF DOWNLOAD
DESCRIPTION:
DOOSAN DX300MH 3 EXCAVATOR MATRIAL HANDLER SHOP MANUAL 950106 01404EMH – PDF DOWNLOAD
GENERAL:
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 lock lever and seat belt.
Use them properly.
• Never remove, modify or disable any safety features.
Always keep them in good operating condition.
• Always check for and know the location of underground
and overhead utility lines before excavating.
• Failure to use and maintain safety features according to
instructions in this manual, Safety Manual and Shop
Manual can result in death or serious injury.
TABLE OF CONTENTS:
DOOSAN DX300MH 3 EXCAVATOR MATRIAL HANDLER SHOP MANUAL 950106 01404EMH – PDF DOWNLOAD
Table of Contents....................................................................................................... 7 Safety.................................................................................................................. 9 Material Handler Maintenance Safety................................................................................. 11 Safety Instructions............................................................................................. 15 Applicable Models............................................................................................... 15 Safety Messages................................................................................................. 16 Signal Words................................................................................................ 16 Safety Decals................................................................................................... 17 General......................................................................................................... 17 Safe Operation is Operator's Responsibility................................................................. 17 Know Your Machine........................................................................................... 17 Proper Work Tools and Attachments........................................................................... 18 Pressurized Fluids.......................................................................................... 18 Flying or Falling Objects................................................................................... 19 Personal Protective Equipment (PPE)......................................................................... 20 Correction of Machine Problems.............................................................................. 20 Crushing and Cutting........................................................................................ 20 Hot Coolant and Oils - Burn Prevention...................................................................... 21 Fire and Explosion Prevention............................................................................... 22 Maintenance............................................................................................. 22 Operation............................................................................................... 22 Electrical.............................................................................................. 23 Hydraulic System........................................................................................ 23 Fueling................................................................................................. 24 Never Use Ether Starting Aids........................................................................... 24 Welding and Grinding.................................................................................... 24 If a Fire Occurs........................................................................................ 25 Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)................................................. 25 Electrical System and Electrical Shock...................................................................... 26 Protecting Cabin from Flying or Falling Objects (Optional).............................................. 27 Emergency Exit from Operator's Station.................................................................. 28 Tilting Riser Egress Ladder............................................................................. 28 Lowering Elevating Cabin................................................................................ 29 Transportation.................................................................................................. 30 Obey State and Local Over-the-Road Regulations.............................................................. 30 Loading and Unloading....................................................................................... 30 Transporting Machine........................................................................................ 31 Operation....................................................................................................... 32 Before Engine Starting...................................................................................... 32 Machine Condition....................................................................................... 32 Work Site................................................................................................... 33 Mounting/Dismounting........................................................................................ 34 Elevating Cabin (If Equipped)........................................................................... 34 Tilting Riser (If Equipped)............................................................................. 35 Cleaning.................................................................................................... 36 Operator Station............................................................................................ 36 Seat Belt................................................................................................... 37 Visibility Information...................................................................................... 38 Work Site Rules......................................................................................... 38 Boost Starting or Charging Engine Batteries................................................................. 39 Starting Engine............................................................................................. 40 Swinging or Traveling....................................................................................... 41 Lifting..................................................................................................... 43 Towing...................................................................................................... 44 Attachment.................................................................................................. 45 Equipment Lowering with Engine Stopped...................................................................... 45 Lowering Elevating Cabin with Engine Stopped................................................................ 46 Engine Stop................................................................................................. 46 Parking Machine............................................................................................. 47 Preservation/Storing Machine................................................................................ 48 Check After Long-term Parking........................................................................... 49 Maintenance..................................................................................................... 50 Warning Tag................................................................................................. 53 Cleaning.................................................................................................... 54 Proper Tools and Clothing................................................................................... 54 Disassembling Precautions................................................................................... 54 Use of Lighting............................................................................................. 55 Fire and Explosion Prevention............................................................................... 55 Burn Prevention............................................................................................. 56 Rubber That Contains Fluorides.............................................................................. 57 Rubber and Plastics......................................................................................... 58 Waste Hazardous to the Environment...................................................................... 58 Check List After Fire................................................................................... 58 Welding Repairs............................................................................................. 59 Preparation for Electrical Welding On Body Structure.................................................... 60 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 Battery Hazard Prevention............................................................................... 65 Environment and Circumstances................................................................................... 67 Work Site Areas Requiring Extra Caution..................................................................... 67 Drop-off or Edge........................................................................................ 67 Poor Visibility......................................................................................... 67 Loose or Soft Ground.................................................................................... 68 High-voltage Cables......................................................................................... 68 Working in Water............................................................................................ 69 Working in Contaminated Environment......................................................................... 69 Operation in Extreme Conditions............................................................................. 70 Operation In Extreme Cold............................................................................... 70 Operation in Extreme Heat............................................................................... 71 Operation In Dusty and Sandy Areas...................................................................... 72 Operation in Rainy or Humid Conditions.................................................................. 72 Operation in Saltwater Areas............................................................................ 73 Operation at High Altitudes............................................................................. 73 Operation During Electrical Storms...................................................................... 73 Exhaust Ventilation......................................................................................... 74 Ventilation for Enclosed Area........................................................................... 74 Asbestos Information........................................................................................ 74 Silica Dust Information..................................................................................... 75 Disposal of Hazardous Materials............................................................................. 75 Specifications.......................................................................................................... 77 Specifications...................................................................................................... 79 Safety Instructions............................................................................................. 83 Applicable Models............................................................................................... 83 General Description............................................................................................. 85 Component Locations............................................................................................. 86 Tilting Riser............................................................................................... 88 Elevating Cabin............................................................................................. 89 General Dimensions.............................................................................................. 90 Tilting Riser With One - Piece Boom......................................................................... 90 Elevating Cabin With One - Piece Boom....................................................................... 91 Working Range................................................................................................... 92 One - Piece Boom............................................................................................ 92 General Specifications.......................................................................................... 93 Engine Performance Curves (Per KS-R1004 Standard)............................................................... 94 Performance Tests............................................................................................... 96 Material Handler Performance Measurements....................................................................... 97 Test Conditions............................................................................................. 97 Travel Speed and Travel Motor Balance (Steering Deviation) Tests............................................ 97 Speed Test.............................................................................................. 97 Travel Deviation........................................................................................ 99 Swing Speed and Deceleration Force Test..................................................................... 99 Swing Speed Test........................................................................................ 99 Swing Deceleration Force Test...........................................................................100 Cylinder Performance Tests..................................................................................101 Boom Cylinders Test.....................................................................................101 Arm Cylinder Test.......................................................................................101 Hydraulic Cylinder Natural Drop Test....................................................................101 Travel Motor Jack-up Test...............................................................................101 General Maintenance.....................................................................................................103 General Maintenance Instructions....................................................................................105 Safety Instructions.............................................................................................109 Applicable Models...............................................................................................109 Welding Precautions and Instructions............................................................................110 Hydraulic System - General Precautions..........................................................................111 Maintenance Service and Repair Procedure........................................................................113 General Precautions.........................................................................................113 Hydraulic System Cleanliness and Oil Leaks......................................................................114 Maintenance Precautions for Hydraulic System Service........................................................114 Oil Leakage Precautions.....................................................................................115 Cleaning and Inspection.........................................................................................116 General Instructions........................................................................................116 Bearing inspection..........................................................................................117 Normal Bearing..........................................................................................118 Bent Cage...............................................................................................118 Galling.................................................................................................119 Abrasive Step Wear......................................................................................119 Etching.................................................................................................120 Misalignment............................................................................................120 Indentations............................................................................................120 Fatigue Spalling........................................................................................121 Brinelling..............................................................................................121 Cage Wear...............................................................................................121 Abrasive Roller Wear....................................................................................122 Cracked Inner Race......................................................................................122 Smears..................................................................................................122 Frettage................................................................................................123 Heat Discoloration......................................................................................123 Stain Discoloration.....................................................................................123 Standard Torques....................................................................................................125 Safety Instructions.............................................................................................129 Applicable Models...............................................................................................129 Torque Values for Standard Metric Fasteners.....................................................................130 Torque Values for Standard U.S. Fasteners.......................................................................131 Type 8 Phosphate Coated Hardware................................................................................133 Torque Values for Hose Clamps...................................................................................134 ORFS Swivel Nut Recommended Torque..............................................................................134 Torque Values for Split Flanges.................................................................................135 Torque Wrench Extension Tools...................................................................................136 Torque Multiplication.......................................................................................136 Other Uses for Torque Wrench Extension Tools................................................................137 Tightening Torque Specifications (Metric)...................................................................138 I. "Loctite" Fastener Adhesives.........................................................................139 II. "Loctite" Pipe Thread Sealant.......................................................................139 III. "Loctite" gasket/flange sealer.....................................................................139 IV. "Loctite" retaining compounds.......................................................................140 V. "Loctite" Adhesives..................................................................................140 Upper Structure.........................................................................................................141 Cabin...............................................................................................................143 Safety Instructions.............................................................................................147 Applicable Models...............................................................................................147 Cabin Identification............................................................................................148 General Instructions for Cabin..............................................................................148 Removal.........................................................................................................149 Installation....................................................................................................153 Counterweight.......................................................................................................157 Safety Instructions.............................................................................................161 Applicable Models...............................................................................................161 General.........................................................................................................162 Warning for Counterweight and Front Attachment Removal......................................................162 Removal.........................................................................................................164 Installation....................................................................................................166 Fuel Tank...........................................................................................................169 Safety Instructions.............................................................................................173 Applicable Models...............................................................................................173 General Description.............................................................................................174 Parts List..................................................................................................174 Specifications..............................................................................................175 Removal.........................................................................................................176 Installation....................................................................................................181 Start-up Procedures.............................................................................................184 Fuel Transfer Pump (Option).........................................................................................185 Safety Instructions.............................................................................................189 Applicable Models...............................................................................................189 General Description.............................................................................................190 Theory of Operation.........................................................................................190 Troubleshooting.................................................................................................192 Replacement of Rotor and Vane...................................................................................192 Replacement of Rear Cover.......................................................................................193 Replacement of Armature.........................................................................................193 Swing Bearing.......................................................................................................195 Safety Instructions.............................................................................................199 Applicable Models...............................................................................................199 Swing Bearing Maintenance.......................................................................................200 Operating Recommendation....................................................................................200 Measuring Swing Bearing Axial Play..........................................................................200 Measuring Bearing Lateral Play..............................................................................200 Swing Bearing Basic Operation...............................................................................201 Disassembly.................................................................................................201 Assembly....................................................................................................203 Lower Structure and Chassis.............................................................................................205 Track Assembly......................................................................................................207 Safety Instructions.............................................................................................211 Applicable Models...............................................................................................211 General Description.............................................................................................212 Track Tension...................................................................................................213 Cleaning and Inspection (Wear Limits and Tolerances)............................................................215 Track Shoe..................................................................................................216 Lower Roller................................................................................................218 Upper Roller................................................................................................219 Front Idler.................................................................................................220 Track Shoes and Links...........................................................................................221 Track Removal...............................................................................................221 Track Installation..........................................................................................222 Front Idler Roller..............................................................................................224 Parts List..................................................................................................224 Front Idler Roller Disassembly..............................................................................225 Front Idler Roller Reassembly...............................................................................227 Parts List..................................................................................................228 Lower Roller Removal........................................................................................229 Lower Roller Disassembly....................................................................................229 Lower Roller Reassembly.....................................................................................230 Lower Roller Installation...................................................................................231 Parts List..................................................................................................232 Upper Roller Removal........................................................................................233 Upper Roller Disassembly....................................................................................233 Upper Roller Reassembly.....................................................................................235 Track Spring and Track Adjusting Cylinder.......................................................................236 Parts List..................................................................................................236 Engine and Drivetrain...................................................................................................239 Engine Coolant Heater (Option)......................................................................................241 Safety Instructions.............................................................................................245 Applicable Models...............................................................................................245 Disassembly and Assembly........................................................................................246 Changing the Circulating Pump...............................................................................246 Removal.................................................................................................246 Installation............................................................................................246 Changing the Temperature Limiter............................................................................248 Removal.................................................................................................248 Installation............................................................................................248 Changing the Temperature Sensor.............................................................................249 Removal.................................................................................................249 Installation............................................................................................249 Changing the Combustion Air Fan.............................................................................251 Removal.................................................................................................251 Fitting.................................................................................................251 Changing the Burner, Flame Monitor and Glow Plug............................................................253 Removal.................................................................................................253 Installation............................................................................................253 Changing the Burner Head....................................................................................255 Removal.................................................................................................255 Installation............................................................................................255 Changing the Heat Exchanger.................................................................................257 Removal.................................................................................................257 Installation............................................................................................257 Drive Coupling (Main Pump)..........................................................................................259 Safety Instructions.............................................................................................263 Applicable Models...............................................................................................263 Drive Coupling..................................................................................................264 Special Tools...................................................................................................265 Drive Coupling Installation.....................................................................................266 Installation Procedure......................................................................................268 Hydraulics..............................................................................................................269 Hydraulic System Troubleshooting, Testing and Adjustment............................................................271 Safety Instructions.............................................................................................275 Applicable Models...............................................................................................275 Hydraulic System - General Notes................................................................................276 Hydraulic Schematic.............................................................................................277 General Notes...............................................................................................277 Operation of Working Components.................................................................................279 Boom Operating Circuit......................................................................................279 Boom Up Circuit.............................................................................................279 Boom Down Circuit...........................................................................................279 Arm Operating Circuit.......................................................................................280 Arm Crowd Circuit...........................................................................................280 Arm Dump Circuit............................................................................................280 Grapple Operating Circuit...................................................................................281 Grapple Close Circuit.......................................................................................281 Grapple Open Circuit........................................................................................281 Swing Operating Circuit.....................................................................................281 Right Swing Operating Circuit...............................................................................282 Left Swing Operating Circuit................................................................................282 Swing Relief Valve and Makeup Valve.........................................................................282 Travel Operating Circuit....................................................................................282 Forward Travel Circuit......................................................................................283 Reverse Travel Circuit......................................................................................283 Procedural Troubleshooting Baseline Recommendations.............................................................284 Initial Checks and Tests to Establish Operating Condition of the Material Handler...........................284 Troubleshooting Recommendations.........................................................................284 Pilot Pressure..................................................................................................286 Adjustment and Testing......................................................................................286 Power Mode Valve................................................................................................287 Current Signal and Hydraulic Pressure Adjustments...........................................................287 Pressure Up Valve...............................................................................................288 Checks and Adjustments......................................................................................288 Pump Input Power Control........................................................................................290 Pump Regulator Adjustment...................................................................................290 Flow Meter and Flow Meter Kit Installation and Testing..........................................................293 Installation and Testing Procedure..........................................................................293 Swing System Troubleshooting....................................................................................295 Precautions/Initial Checks..................................................................................295 Swing Relief Valve Checking and Adjustment..................................................................296 Troubleshooting – Swing Gearbox.................................................................................298 Troubleshooting – Hydraulic Problems............................................................................299 Troubleshooting – Control Valve.................................................................................301 Troubleshooting – Travel Control Valve..........................................................................302 Troubleshooting – Joystick Control Valve........................................................................303 Accumulator.........................................................................................................305 Safety Instructions.............................................................................................309 Applicable Models...............................................................................................309 General Description.............................................................................................310 Specifications..............................................................................................312 Center Joint (Swivel)...............................................................................................313 Safety Instructions.............................................................................................317 Applicable Models...............................................................................................317 General Description.............................................................................................318 Parts List..................................................................................................319 Troubleshooting, Testing and Adjustment.........................................................................320 Inspection..................................................................................................320 Testing.....................................................................................................320 Disassembly.....................................................................................................321 Reassembly......................................................................................................324 Cylinders...........................................................................................................327 Safety Instructions.............................................................................................331 Applicable Models...............................................................................................331 General Description.............................................................................................332 Theory of Operation.........................................................................................332 Parts List..................................................................................................334 Special Tools and Materials.....................................................................................340 Piston Nut..................................................................................................340 Piston Jig..................................................................................................342 Steel Bushing Jig...........................................................................................345 Dust Wiper Jig..............................................................................................348 Slipper Seal Jig............................................................................................351 Slipper Seal Straightening Jig..............................................................................354 Disassembly.....................................................................................................357 Reassembly......................................................................................................362 Swing Device........................................................................................................367 Safety Instructions.............................................................................................371 Applicable Models...............................................................................................371 Structure and Principle of Operation........................................................................372 Structure...............................................................................................372 Principle of Operation..................................................................................377 Valve Casing............................................................................................378 Brake Part..............................................................................................382 Instructions before Operation...............................................................................383 Inspection..............................................................................................383 Direction of Rotation...................................................................................383 External Load at the End of Shaft.......................................................................384 Hydraulic Oil and Temperature Range.....................................................................384 Filter..................................................................................................385 Installation and Piping.................................................................................385 Oil Filling and Air Ventilation.........................................................................386 Instructions before Starting to Operate.................................................................386 Troubleshooting.............................................................................................387 General Instructions....................................................................................387 Examination of Hydraulic Motor..........................................................................387 Troubleshooting.........................................................................................388 Disassembly and Reassembly..................................................................................391 Tightening Torque of Bolts..............................................................................391 Tools for Disassembly and Reassembly....................................................................391 Remove and Install Swing Device.................................................................................393 Removal.....................................................................................................393 Remove Swing Motor......................................................................................395 Install Swing Motor.....................................................................................395 Installation................................................................................................396 Disassemble Swing Motor.................................................................................398 Reassemble Swing Motor..................................................................................402 Disassemble the Reduction Gear..........................................................................409 Reassemble the Reduction Gear...........................................................................413 Maintenance Instructions....................................................................................417 Replacement Standard of Worn Parts......................................................................417 Standard of Sliding Surface Correction..................................................................417 Travel Device.......................................................................................................419 Safety Instructions.............................................................................................423 Applicable Models...............................................................................................423 Basic Structure and Drawings................................................................................424 Basic Structure of TM Motor.............................................................................424 Motor (M)...............................................................................................425 Reduction Gear (R)......................................................................................427 Operation Principle.........................................................................................429 Reduction Gear..........................................................................................429 Hydraulic Motor (Brake Valve, Parking Brake, High-Low 2-Stage Switching Mechanism)......................430 Cautions for Operation......................................................................................438 Installation Method (refer to the Outline Drawing)......................................................438 Pipeline................................................................................................438 Hydraulic Oil...........................................................................................439 Lubricant...............................................................................................440 Maintenance/Service.....................................................................................441 Troubleshooting.............................................................................................441 Maintenance Guidelines......................................................................................443 Jigs and Tools for Assembly and Disassembly.............................................................443 Remove and Install Travel Device................................................................................446 Removal.....................................................................................................446 Disassembly.................................................................................................447 General Cautions for Maintenance Work...................................................................447 Disassembly Sequence....................................................................................447 Assembly....................................................................................................457 General Cautions for Maintenance Work...................................................................457 Assembly Sequence.......................................................................................457 Installation................................................................................................474 Matters to Check after Assembly.............................................................................475 Performance Test............................................................................................475 Main Pump...........................................................................................................477 Safety Instructions.............................................................................................481 Applicable Models...............................................................................................481 Axial Piston Pump...............................................................................................482 General Description.........................................................................................482 Model Number Designation................................................................................482 Theory of Operation.....................................................................................483 Parts List..............................................................................................484 Torques.................................................................................................486 Special Tools and Materials.................................................................................487 Tools...................................................................................................487 Troubleshooting, Testing and Adjustment.....................................................................489 Remove and Install Pump Device..................................................................................491 Removal.....................................................................................................491 Disassembly.................................................................................................491 Cleaning and Inspection (Wear Limits and Tolerances)........................................................494 Worn Part Replacement Criteria..........................................................................494 Correction Criteria for Cylinder, Valve Plate and Swash Plate (Shoe Plate)..............................495 Reassembly..................................................................................................496 Installation................................................................................................498 Start-up Procedures.........................................................................................500 Oil filling and Air Venting.............................................................................500 Cautions During Starting Operation......................................................................500 Regulator for Axial Piston Pump.................................................................................501 General Description.........................................................................................501 Model Number Designation................................................................................501 Parts List..............................................................................................502 Outline.................................................................................................503 Specifications..........................................................................................505 Functional Explanations.................................................................................505 Tightening Torque.......................................................................................511 Special Tools and Materials.................................................................................512 Tools...................................................................................................512 Troubleshooting, Testing and Adjustment.....................................................................512 Prime Mover is Overloaded...............................................................................512 Maximum Flow Is Not Available...........................................................................513 Adjustment of Maximum and Minimum Flows.................................................................513 Preparation for Disassembly.................................................................................515 Regulator Disassembly.......................................................................................516 Regulator Reassembly........................................................................................519 Gear Pump (Option)..................................................................................................523 Safety Instructions.............................................................................................527 Applicable Models...............................................................................................527 Single Gear Pump................................................................................................528 Disassembly.................................................................................................528 Reassembly..................................................................................................530 Double Gear Pump................................................................................................534 Disassembly.................................................................................................534 Reassembly..................................................................................................536 Main Control Valve..................................................................................................541 Safety Instructions.............................................................................................545 Applicable Models...............................................................................................545 General Description.............................................................................................546 Theory of Operation.........................................................................................546 When All Spools are in Neutral..........................................................................546 Single Operation........................................................................................552 Compound Operation......................................................................................566 Antidrift Valve.........................................................................................572 Main Relief Valve.......................................................................................573 Overload Relief Valve...................................................................................574 Low-pressure Relief Valve...............................................................................576 Parts List..................................................................................................578 Specifications..............................................................................................583 Troubleshooting, Testing and Adjustment.........................................................................584 Troubleshooting.............................................................................................584 Overall Control Valve...................................................................................584 Relief Valve............................................................................................585 Overall Oil Pressure....................................................................................585 Adjustment of Valves........................................................................................585 Main Relief Valve.......................................................................................585 Overload Relief Valve...................................................................................586 Removal.........................................................................................................587 Disassembly.....................................................................................................588 Caution in Disassembly......................................................................................588 Disassembly of Main Spool Part..............................................................................589 Disassembly of Arm 1 Para-turn Spool Part...................................................................590 Disassembly of Arm Regeneration Release Valve Part..........................................................590 Disassembly of Load Check Valve Part........................................................................591 Disassembly of Antidrift Valve Part.........................................................................592 Disassembly of Relief Valve.................................................................................593 Disassembly of Option Section Part..........................................................................593 Disassembly of Other Plugs..................................................................................593 Disassembly of Valve Housing Bolt...........................................................................594 Disassembly of Main Relief Valve............................................................................594 Disassembly of Overload Relief Valve........................................................................595 Instruction of Disassembly and Assembly of Low-pressure Relief Valve........................................596 Cleaning and Inspection (Wear Limits and Tolerances)............................................................597 Cleaning....................................................................................................597 Inspection..................................................................................................597 Reassembly......................................................................................................598 Caution on Assembly.........................................................................................598 Caution on Handling O-ring..............................................................................598 Caution on Handling Spool...............................................................................598 Method of Painting the Adhesives (screw part and arm screw part of parts requiring the adhesiveness)....598 Sequence of Subassembly.....................................................................................599 Spool Assembly (Main Spool).............................................................................599 Arm 1 Para-turn Spool Assembly..........................................................................599 Antidrift Valve Assembly................................................................................600 Assembly Sequence of Main Body of the Control Valve.....................................................600 Assembly of Relief Valve................................................................................601 Assembly of Load Check Valve............................................................................601 Assembly of Antidrift Valve.............................................................................602 Assembly of Option Section Part.........................................................................602 Assembly of Arm Regeneration Release Valve..............................................................602 Assembly of Arm 1 Para-turn Spool.......................................................................603 Assembly of Main Spool..................................................................................603 Assembly of Other Plugs.................................................................................604 Maintenance of Relief Valves................................................................................605 Reassembly of Main Relief Valve.........................................................................605 Reassembly of Overload Relief Valve (69, Total of 6 Places).............................................606 Reassembly of Low-pressure Relief Valve (70, Total of 2 Places).........................................607 Installation....................................................................................................608 Start-up Procedures.............................................................................................609 Remote Control Valve (Work Lever / Joystick)........................................................................611 Safety Instructions.............................................................................................615 Applicable Models...............................................................................................615 General Description.............................................................................................616 Theory of Operation.........................................................................................616 Structure...............................................................................................616 Function................................................................................................616 Parts List..................................................................................................618 Specifications..............................................................................................620 Performance.............................................................................................620 Torques.....................................................................................................620 Tools and Materials.............................................................................................620 Disassembly.....................................................................................................621 Reassembly......................................................................................................624 Start-up Procedures.............................................................................................632 Travel Control Valve (with Damper)..................................................................................633 Safety Instructions.............................................................................................637 Applicable Models...............................................................................................637 General Description.............................................................................................638 Theory of Operation.........................................................................................638 Pressure Reducing Valve.....................................................................................639 Operating Theory of Damper Mechanism........................................................................640 Causes of Faults and Measures...................................................................................641 Parts List..................................................................................................642 Specification...............................................................................................644 Torques.....................................................................................................644 Removal.........................................................................................................645 Disassembly.....................................................................................................648 Cleaning and Inspection (Wear Limits and Tolerances)............................................................650 Reassembly......................................................................................................651 Installation....................................................................................................656 Start-up Procedures.............................................................................................659 Solenoid Valve Assembly.............................................................................................661 Safety Instructions.............................................................................................665 Applicable Models...............................................................................................665 5-Solenoid Valve................................................................................................666 Parts List..................................................................................................666 Functions of 5-Solenoid Valve Assembly......................................................................667 Functions and Operations of Solenoid Valves.............................................................667 Assembly Diagram and Tools Required.........................................................................668 Cautions During Disassembly and Reassembly..................................................................669 Solenoid Valve Diagram......................................................................................670 Check Points and Solutions for Problems.....................................................................671 Checking of Pilot Pressure for Defects..................................................................671 Hydraulic Schematic.................................................................................................673 Safety Instructions.............................................................................................677 Applicable Models...............................................................................................677 DX300LC-3/DX300MH-3.............................................................................................679 Electrical System.......................................................................................................681 Electrical System...................................................................................................683 Safety Instructions.............................................................................................689 Applicable Models...............................................................................................689 Introduction....................................................................................................690 Electrical Wire Color.......................................................................................690 Electrical Supply System........................................................................................692 Engine Starting Circuit.........................................................................................694 Start Operation.............................................................................................694 After Start.................................................................................................696 Operation of the Start Circuit (2) - Immediately After Start............................................697 Engine Preheating System........................................................................................698 Engine Stop.....................................................................................................700 Charging System.................................................................................................702 Monitoring System...............................................................................................703 Instrument Panel............................................................................................704 Functional Check............................................................................................704 Monitoring System Schematic.................................................................................706 Operation.......................................................................................................708 Instruments.................................................................................................708 Warning and Indicator Lights....................................................................................710 Indication of Warning Lights................................................................................710 Indication of Multifunction Gauge...........................................................................712 Initial Operation...............................................................................................713 Graphic Information Area Display................................................................................714 Overview....................................................................................................714 Main Menus for the Graphic Display Area.....................................................................714 Menu Selector Buttons.......................................................................................714 User Menu.......................................................................................................715 User Menu - Access and Escape Methods.......................................................................715 Access Method...........................................................................................715 Escape Method...........................................................................................715 User Menu...............................................................................................715 Special Menu....................................................................................................747 Entering/Accessing and Exiting/Escaping Menus...............................................................747 Entering/Accessing Menus................................................................................747 Exiting/Escaping Menus..................................................................................748 Special Menu Selections.....................................................................................748 Monitoring..............................................................................................748 Graph...................................................................................................754 Failure Information.....................................................................................755 FMIs (Failure Mode Identifier)..........................................................................765 Information of Machine Operation........................................................................766 Vehicle Configuration...................................................................................769 Electronic Hydraulic Control System (e-EPOS)....................................................................774 Control System Schematic....................................................................................774 Power Plus Mode Control.........................................................................................776 Operation...................................................................................................778 1. Power Plus Mode......................................................................................778 2. Power Mode, Standard Mode, Economy Mode..............................................................779 Power Mode Control - Circuit Diagram............................................................................780 Engine Control System...........................................................................................782 Engine Control Dial.............................................................................................783 Engine Control Circuit Diagram..................................................................................784 Automatic Deceleration Control (Auto Idle Control)..............................................................786 Engine Overheat Protection System...............................................................................788 Power Boost Mode................................................................................................790 Operation...................................................................................................790 Power Boost Control - Circuit Diagram.......................................................................792 Automatic Travel Speed Control..................................................................................794 Automatic Travel Speed Control - Circuit Diagram............................................................796 Self-diagnostic Function........................................................................................797 e-EPOS Controller...........................................................................................797 Air Conditioner System..........................................................................................799 Outline.....................................................................................................799 Internal and External Filters...............................................................................800 How to Check Internal Air Filter........................................................................800 How to Check External Air Filter........................................................................800 Air-Conditioning System Layout..............................................................................802 Air Conditioner/Heater Circuit Diagram......................................................................803 Air Conditioner/Heater Unit.................................................................................804 Airflow Diagram.........................................................................................804 Door Open by Vent Modes.................................................................................805 Main Components.........................................................................................805 Actuator - Airflow Direction Control....................................................................806 Actuator - Temperature Control..........................................................................806 Actuator - Internal/external Air Exchange...............................................................807 Airflow Control Module..................................................................................807 Ambient Air Temperature Sensor..............................................................................809 Sun Sensor..................................................................................................810 Control Panel...............................................................................................810 Appearance and Terminal Arrangement.....................................................................810 Terminal Terms..........................................................................................810 Control Logic...........................................................................................812 Self-diagnossi..........................................................................................816 Ambient Temperature Display.............................................................................817 Compressor..................................................................................................818 Receiver Dryer..............................................................................................818 Troubleshooting.................................................................................................819 Refrigerant Pressure Check..................................................................................819 Weight of R134a Gas Used In Machines............................................................................821 Refrigerant System Repairs......................................................................................822 Refrigerant Safe Handling Procedures........................................................................822 Repair and Replacement Procedure............................................................................823 Refrigerant Recovery........................................................................................825 Vacuuming Refrigerant System................................................................................825 Leakage Check...............................................................................................827 Refrigerant Charging........................................................................................827 Inspecting System For Leakage...............................................................................829 Wiper System....................................................................................................830 Wiper Circuit...............................................................................................830 Wiper operation.............................................................................................831 Continuous operation....................................................................................831 Intermittent operation..................................................................................831 Lighting System.................................................................................................834 Lighting System Circuit Diagram.............................................................................834 Kind of Light...............................................................................................835 Operation...................................................................................................835 Overload Warning Device.........................................................................................836 Overload Warning Device Circuit Diagram.....................................................................836 Audio Controller................................................................................................837 Audio Controller Circuit Diagram............................................................................837 Operations Via Audio Control Panel......................................................................837 Electrical Schematic................................................................................................839 Safety Instructions.............................................................................................843 Applicable Models...............................................................................................843 DX300LC-3/DX300MH-3.............................................................................................845 Attachments.............................................................................................................847 Boom and Arm........................................................................................................849 Safety Instructions.............................................................................................853 Applicable Models...............................................................................................853 Front Attachment Pin Specifications.............................................................................854 DX300MH-3...................................................................................................855 Front Attachment - Removal and Installation.....................................................................856 Arm Removal Procedure.......................................................................................856 Boom Removal Procedure......................................................................................863 Installation....................................................................................................869 Boom Installation Procedure.................................................................................869 Arm Installation Procedure..................................................................................876 Start-up Procedures.............................................................................................881 Attachment..........................................................................................................883 Safety Instructions.............................................................................................887 Applicable Models...............................................................................................887 Attachments.....................................................................................................888 Installation and Removal....................................................................................888
DOOSAN DX300MH 3 EXCAVATOR MATRIAL HANDLER SHOP MANUAL 950106 01404EMH – PDF DOWNLOAD:
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