Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Doosan DX380LL-5 Excavator Log Loader Shop Manual 950106-01572 – PDF DOWNLOAD
Original price was: $65.95.$31.95Current price is: $31.95.
Doosan DX380LL-5 Excavator Log Loader Shop Manual 950106-01572 – PDF DOWNLOAD
Serial Number 10001 and Up
950106-01572
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Doosan DX380LL-5 Excavator Log Loader Shop Manual 950106-01572 – PDF DOWNLOAD
DESCRIPTION:
Doosan DX380LL-5 Excavator Log Loader Shop Manual 950106-01572 – PDF DOWNLOAD
Serial Number 10001 and Up
950106-01572
GENERAL
Safe Operation is Operator’s Responsibility:
Safe Operation is Operator’s Responsibility:
- Only trained and authorized personnel should operate and maintain the machine. Follow all safety rules, regulations and instructions when operating or performing maintenance on machine.
- Do not operate machine if you are under the influence of drugs or alcohol. An operator who is taking prescription drugs must get medical advice to determine if he or she can safely operate a machine.
- When working with other personnel on a work site, be sure that all personnel know nature of work and understand all hand signals that are to be used.
- Be sure that all guards and shields are installed in their proper location. Have guards and shields repaired or replaced immediately if damaged.
- Be sure that you understand the use and maintenance of all safety features such as safety lever and seat belt. Use them properly.
- Never remove, modify or disable any safety features. Always keep them in good operating condition.
- Failure to use and maintain safety features according to instructions in this manual, Safety Manual and Shop Manual can result in death or serious injury.
Know Your Machine
- Know how to operate your machine. Know the purpose of all controls, gauges, signals, indicators and monitor displays. Know the rated load capacity, speed range, braking and steering characteristics, turning radius and operating clearances.Keep in mind that rain, snow, ice, loose gravel, soft ground, slopes etc., can change operating capabilities of your machine.
TABLE OF CONTENTS:
Doosan DX380LL-5 Excavator Log Loader Shop Manual 950106-01572 – PDF DOWNLOAD
DX380LL-5..................................................................................................................................... 0 Table of Contents......................................................................................................................... 7 Safety.................................................................................................................................... 9 Forestry Machine Maintenance Safety................................................................................................... 11 Safety Instructions............................................................................................................... 11 Safety Messages................................................................................................................... 13 General........................................................................................................................... 13 Safe Operation is Operator's Responsibility................................................................................... 13 Know Your Machine............................................................................................................. 13 Proper Work Tools and Attachments............................................................................................. 14 Pressurized Fluids............................................................................................................ 14 Flying or Falling Objects..................................................................................................... 15 Personal Protective Equipment (PPE)........................................................................................... 16 Correction of Machine Problems................................................................................................ 16 Crushing and Cutting.......................................................................................................... 16 Hot Coolant and Oils - Burn Prevention........................................................................................ 17 Fire and Explosion Prevention................................................................................................. 18 Fire Extinguisher and First-aid Kit (Emergency Medical Kit)................................................................... 21 Electrical System and Electrical Shock........................................................................................ 22 Operator Protective Guards and Structures (Optional).......................................................................... 22 Emergency Exit from Operator's Station........................................................................................ 22 Transportation.................................................................................................................... 23 Obey State and Local Over-the-Road Regulations................................................................................ 23 Loading and Unloading......................................................................................................... 23 Transporting Machine.......................................................................................................... 24 Operation......................................................................................................................... 25 Before Engine Starting........................................................................................................ 25 Work Site..................................................................................................................... 26 Mounting/Dismounting.......................................................................................................... 27 Cleaning...................................................................................................................... 28 Operator Station.............................................................................................................. 28 Seat Belt..................................................................................................................... 29 Visibility Information........................................................................................................ 30 Boost Starting or Charging Engine Batteries................................................................................... 31 Starting Engine............................................................................................................... 32 Swinging or Traveling......................................................................................................... 33 Lifting and Logging........................................................................................................... 35 Operation on Slopes........................................................................................................... 36 Towing........................................................................................................................ 37 Attachment.................................................................................................................... 38 Equipment Lowering with Engine Stopped........................................................................................ 38 Engine Stop................................................................................................................... 39 Parking Machine............................................................................................................... 39 Preservation/Storing Machine.................................................................................................. 40 Maintenance....................................................................................................................... 42 Warning Tag................................................................................................................... 44 Cleaning...................................................................................................................... 45 Proper Tools and Clothing..................................................................................................... 45 Disassembling Precautions..................................................................................................... 45 Use of Lighting............................................................................................................... 45 Fire and Explosion Prevention................................................................................................. 46 Burn Prevention............................................................................................................... 47 Rubber That Contains Fluorides................................................................................................ 48 Rubber and Plastics........................................................................................................... 49 Welding Repairs............................................................................................................... 50 Warning for Counterweight and Front Attachment Removal........................................................................ 51 Lock Inspection Covers........................................................................................................ 52 Working on Machine............................................................................................................ 52 Accumulator................................................................................................................... 53 Compressed Air................................................................................................................ 53 Track Tension Adjustments..................................................................................................... 54 Supports and Blocking for Work Equipment...................................................................................... 54 High-pressure Lines, Tubes and Hoses.......................................................................................... 55 Battery....................................................................................................................... 56 Environment and Circumstances..................................................................................................... 58 Work Site Areas Requiring Extra Caution....................................................................................... 58 High-voltage Cables........................................................................................................... 59 Roll Over Protective Structure (ROPS), Falling Object protective Structure (FOPS)............................................. 60 ROPS/FOPS Certification....................................................................................................... 61 Working in Water.............................................................................................................. 61 Working in Contaminated Environment........................................................................................... 61 Operation in Extreme Conditions............................................................................................... 62 Exhaust Ventilation........................................................................................................... 66 Asbestos Information.......................................................................................................... 67 Silica Dust Information....................................................................................................... 67 Disposal of Hazardous Materials............................................................................................... 68 Specifications............................................................................................................................ 69 Specifications........................................................................................................................ 71 Safety Instructions............................................................................................................... 71 General Description............................................................................................................... 73 Component Locations............................................................................................................... 74 General Dimensions................................................................................................................ 78 Working Range..................................................................................................................... 80 General Specifications............................................................................................................ 82 Approximate Weight of Workload Materials.......................................................................................... 83 Performance Tests................................................................................................................. 85 Purpose of Performance Tests.................................................................................................. 85 Kinds of Tests................................................................................................................ 85 Performance Standards......................................................................................................... 85 Precautions for Evaluation of Test Data....................................................................................... 85 Definition of "Performance Standard".......................................................................................... 85 Preparation for Performance Tests................................................................................................. 86 The Machine................................................................................................................... 86 Test Area..................................................................................................................... 86 Precautions................................................................................................................... 86 Make Precise Measurement...................................................................................................... 86 Operational Performance Standard Table............................................................................................ 87 Operational Performance Test...................................................................................................... 89 Hydraulic Cylinder Cycle Time................................................................................................. 89 Travel Speed.................................................................................................................. 91 Track Revolution Speed........................................................................................................ 92 Mistrack Check................................................................................................................ 94 Swing Speed................................................................................................................... 96 Swing Function Drift Check.................................................................................................... 97 General Maintenance....................................................................................................................... 99 General Maintenance Instructions...................................................................................................... 101 Safety Instructions............................................................................................................... 101 Welding Precautions and Instructions.............................................................................................. 103 Hydraulic System - General Precautions............................................................................................ 104 Maintenance Service and Repair Procedure.......................................................................................... 106 General Precautions........................................................................................................... 106 Hydraulic System Cleanliness and Oil Leaks........................................................................................ 107 Maintenance Precautions for Hydraulic System Service.......................................................................... 107 Oil Leakage Precautions....................................................................................................... 108 Cleaning and Inspection........................................................................................................... 109 General Instructions.......................................................................................................... 109 Bearing Inspection............................................................................................................ 110 Standard Torques...................................................................................................................... 117 Safety Instructions............................................................................................................... 117 Torque Values for Standard Metric Fasteners....................................................................................... 119 Torque Values for Standard U.S. Fasteners......................................................................................... 120 Type 8 Phosphate Coated Hardware.................................................................................................. 122 Torque Values for Hose Clamps..................................................................................................... 123 ORFS Swivel Nut Recommended Torque................................................................................................ 123 Torque Values for Split Flanges................................................................................................... 124 Torque Wrench Extension Tools..................................................................................................... 125 Torque Multiplication......................................................................................................... 125 Other Uses for Torque Wrench Extension Tools.................................................................................. 126 Tightening Torque Specifications (Metric)..................................................................................... 127 Engine.................................................................................................................................... 131 Engine................................................................................................................................ 133 Safety Instructions............................................................................................................... 133 Overview.......................................................................................................................... 137 Inspection........................................................................................................................ 138 Cleaning the Engine........................................................................................................... 138 Special Tools..................................................................................................................... 138 Mounting the Engine in a Universal Stand...................................................................................... 148 Engine Identification............................................................................................................. 149 Engine Data Plate............................................................................................................. 149 Engine Specification.............................................................................................................. 150 Engine Performance Curves......................................................................................................... 151 Tightening Torques................................................................................................................ 153 Normal Tightening Torque...................................................................................................... 153 Special Tightening Torque..................................................................................................... 157 Cylinder.......................................................................................................................... 185 Cylinder Head................................................................................................................. 185 Valve Mechanism............................................................................................................... 203 Cylinder Block................................................................................................................ 206 Cylinder Liner................................................................................................................ 221 Flywheel Housing.............................................................................................................. 228 Front Cover................................................................................................................... 231 Oil Mist Separator............................................................................................................ 233 Actuating System.................................................................................................................. 239 Camshaft...................................................................................................................... 239 Connecting Rod................................................................................................................ 247 Crankshaft.................................................................................................................... 249 Flywheel...................................................................................................................... 258 Piston........................................................................................................................ 263 Roller Tappet................................................................................................................. 269 Intake Manifold............................................................................................................... 270 Power Take Off................................................................................................................ 270 Torsion Damper................................................................................................................ 271 Belt Circuit.................................................................................................................. 272 Balance Shaft Unit............................................................................................................ 279 Timing Gear................................................................................................................... 284 Lubrication System................................................................................................................ 290 General Information........................................................................................................... 290 Centrifugal Oil Cleaner....................................................................................................... 292 Oil Cooler.................................................................................................................... 297 Oil Filter.................................................................................................................... 300 Oil Pump...................................................................................................................... 301 Oil Sump...................................................................................................................... 303 Oil Pressure Sensor........................................................................................................... 304 Troubleshooting Chips Found in the Engine..................................................................................... 305 Troubleshooting the Lubrication System........................................................................................ 309 Lubrication Oil Consumption................................................................................................... 310 Exhaust System.................................................................................................................... 313 General Information........................................................................................................... 313 T113, Exhaust Temperature Sensor before Catalytic Converter................................................................... 329 T115, NOx Sensor.............................................................................................................. 330 T131 NOx Sensor............................................................................................................... 331 T116, Reductant Pick-up Unit.................................................................................................. 333 Evaporator.................................................................................................................... 338 V117 Reductant Doser.......................................................................................................... 338 V118, Coolant Valve for Heating the Reductant System.......................................................................... 345 V183 Reductant Pump........................................................................................................... 347 H25, H26 Electrically Heated Reductant Hose................................................................................... 358 M4000 Electric Exhaust Brake.................................................................................................. 359 Reductant Tank................................................................................................................ 365 Oxidation Catalytic Converter................................................................................................. 372 Exhaust Manifold.............................................................................................................. 374 Variable Geometry Turbocharger................................................................................................ 382 EGR System.................................................................................................................... 390 EGR Valve..................................................................................................................... 397 EGR Cooler.................................................................................................................... 402 Cooling System.................................................................................................................... 404 Internal Cleaning of Cooling System........................................................................................... 407 Charge Air Cooler............................................................................................................. 408 Charge Air Temperature Sensor................................................................................................. 410 Charge Air Pressure Sensor.................................................................................................... 412 Coupling Coil for AC Compressor............................................................................................... 413 Thermostat.................................................................................................................... 414 Coolant Pump.................................................................................................................. 417 Coolant Temperature Sensor.................................................................................................... 418 Fuel System....................................................................................................................... 420 General Information........................................................................................................... 420 Accumulator................................................................................................................... 425 Fuel Manifold................................................................................................................. 426 Overflow Valve................................................................................................................ 435 Feed Pump..................................................................................................................... 438 Injector...................................................................................................................... 444 Fuel Filter................................................................................................................... 450 Fuel Heater................................................................................................................... 454 Fuel System Troubleshooting................................................................................................... 455 Electrical System................................................................................................................. 469 E44, Control Unit EMS......................................................................................................... 469 Control Unit EEC.............................................................................................................. 485 Engine Speed Sensor........................................................................................................... 490 T110 Oil Level Sensor......................................................................................................... 492 T111, Fuel Pressure Sensor.................................................................................................... 493 T125, Exhaust Back Pressure Sensor............................................................................................ 495 T135, Camshaft Position Sensor................................................................................................ 496 V109, Solenoid Valve for Charge Pressure...................................................................................... 498 V120, Fuel Inlet Metering Valve............................................................................................... 499 V142, V143, V144, V145, V146 Solenoid Valve for Injector...................................................................... 501 T8, Coolant Level Monitor..................................................................................................... 502 P3, Alternator................................................................................................................ 503 M1, Starter Motor............................................................................................................. 513 AC Compressor................................................................................................................. 516 Electrical Parts.............................................................................................................. 519 Engine Coolant Heater (Option)........................................................................................................ 531 Safety Instructions............................................................................................................... 531 Disassembly and Assembly.......................................................................................................... 533 Changing the Circulating Pump................................................................................................. 533 Changing the Temperature Limiter.............................................................................................. 535 Changing the Temperature Sensor............................................................................................... 536 Changing the Combustion Air Fan............................................................................................... 538 Changing the Burner, Flame Monitor and Glow Plug.............................................................................. 540 Changing the Burner Head...................................................................................................... 542 Changing the Heat Exchanger................................................................................................... 544 Upper Structure........................................................................................................................... 545 Cabin................................................................................................................................. 547 Safety Instructions............................................................................................................... 547 Cabin Identification.............................................................................................................. 549 Roll-over Protective Structure (ROPS), Falling Object Protective Structure (FOPS)............................................. 549 ROPS/FOPS Certification....................................................................................................... 549 Removal........................................................................................................................... 550 Installation...................................................................................................................... 555 Completing work................................................................................................................... 555 Dimensions of Cabin Glass......................................................................................................... 556 Front & Roof Glass............................................................................................................ 556 Left Glass (1)................................................................................................................ 557 Left Glass (2)................................................................................................................ 558 Rear Side Glass............................................................................................................... 559 Right Glass................................................................................................................... 560 Dimension of Rubber & Damper...................................................................................................... 561 Left Rubber and Damper........................................................................................................ 561 Right Rubber.................................................................................................................. 562 Front Rubber.................................................................................................................. 563 Roof and Rear Rubber.......................................................................................................... 564 Removal and Installation of Cabin Glass........................................................................................... 565 Removal of Cabin Glass........................................................................................................ 565 Installation of Cabin Glass................................................................................................... 567 Counterweight......................................................................................................................... 569 Safety Instructions............................................................................................................... 569 General........................................................................................................................... 571 Warning for Counterweight and Front Attachment Removal........................................................................ 571 Removal........................................................................................................................... 573 Installation...................................................................................................................... 574 Hydraulic Oil Tank.................................................................................................................... 575 Safety Instructions............................................................................................................... 575 General........................................................................................................................... 577 Specification................................................................................................................. 577 Parts List.................................................................................................................... 578 Air Breather.................................................................................................................. 580 Removal........................................................................................................................... 581 Installation...................................................................................................................... 588 Completing Work................................................................................................................... 589 Fuel Tank............................................................................................................................. 591 Safety Instructions............................................................................................................... 591 General........................................................................................................................... 593 Specification................................................................................................................. 593 Parts List.................................................................................................................... 594 Removal........................................................................................................................... 596 Installation...................................................................................................................... 601 Completing Work................................................................................................................... 602 Main Pump............................................................................................................................. 603 Safety Instructions............................................................................................................... 603 General........................................................................................................................... 608 Specifications................................................................................................................ 608 Overview...................................................................................................................... 611 Hydraulic Circuit............................................................................................................. 612 Parts List.................................................................................................................... 614 Theory of Operation........................................................................................................... 618 Manual Override............................................................................................................... 626 Angle Sensor.................................................................................................................. 628 PPRV (Peak Pressure Reducing Valve)............................................................................................... 629 Installation.................................................................................................................. 636 Hydraulic Oil................................................................................................................. 636 Guide for External Oil Leakage................................................................................................ 636 Repair............................................................................................................................ 637 Necessary Tools and Jigs...................................................................................................... 637 Cautions During Disassembling and Assembling.................................................................................. 638 Disassembling Procedure....................................................................................................... 639 Assembling Procedure.......................................................................................................... 642 Precaution........................................................................................................................ 643 Tightening Torques............................................................................................................ 643 Slotted Screws................................................................................................................ 643 Threaded Plugs................................................................................................................ 644 Sealing Nuts.................................................................................................................. 645 Maintenance and Repair............................................................................................................ 646 Cleaning and Care............................................................................................................. 646 Inspection.................................................................................................................... 647 Maintenance................................................................................................................... 647 Repair........................................................................................................................ 648 Spare Parts................................................................................................................... 648 Decommissioning................................................................................................................... 649 Removal and Replacement........................................................................................................... 649 Required Tools................................................................................................................ 649 Preparing for Removal......................................................................................................... 649 Removing the Axial Piston Unit................................................................................................ 650 Preparing the Components for Storage or Further Use........................................................................... 650 Troubleshooting................................................................................................................... 651 How to Proceed for Troubleshooting............................................................................................ 651 Malfunction Table............................................................................................................. 652 Section View.................................................................................................................. 654 Removal........................................................................................................................... 655 Installation...................................................................................................................... 666 Completing Work................................................................................................................... 666 Replacing Seals and Assembly Groups............................................................................................... 667 Replacing the Shaft Seal...................................................................................................... 668 Sealing or Replacing the Gear Pump............................................................................................ 671 Sealing the Cover of the Power Take-off....................................................................................... 673 Sealing the Port Plate with Valve............................................................................................. 675 Sealing or Replacing the Pressure Reducing Valve.............................................................................. 677 Replacing the Angle Position Sensor........................................................................................... 678 Replacing Sealing Nuts........................................................................................................ 682 D-Eco Power System................................................................................................................ 683 Introduction of D-Eco Power System............................................................................................ 683 Initialization of D-Eco Power System.......................................................................................... 693 D-Eco Power Diagnostic Tools Operation............................................................................................ 719 Program Start................................................................................................................. 719 D-Eco Power Diagnostic Tools Main Screen...................................................................................... 720 Contents and Function......................................................................................................... 720 D-Eco Power Diagnostic Check List............................................................................................. 721 D-Eco Power Diagnostic Tools Check................................................................................................ 722 Joystick Check................................................................................................................ 722 Angle Check................................................................................................................... 733 EPPR Valve Check.............................................................................................................. 737 Main Pump Check............................................................................................................... 743 Relief Pressure Check......................................................................................................... 749 Drive Coupling (Main Pump)............................................................................................................ 753 Safety Instructions............................................................................................................... 753 General........................................................................................................................... 755 Specification................................................................................................................. 755 Parts List.................................................................................................................... 756 Section View...................................................................................................................... 758 Tools......................................................................................................................... 759 Disassembly....................................................................................................................... 760 Reassembly........................................................................................................................ 760 Main Control Valve.................................................................................................................... 763 Safety Instructions............................................................................................................... 763 General........................................................................................................................... 765 Specification................................................................................................................. 765 Overview...................................................................................................................... 766 Parts List.................................................................................................................... 770 Theory of Operation........................................................................................................... 773 Removal........................................................................................................................... 814 Installation...................................................................................................................... 823 Completing Work................................................................................................................... 824 Disassembly....................................................................................................................... 825 General Repair Instructions................................................................................................... 825 Repair Instructions........................................................................................................... 826 Reassembly........................................................................................................................ 845 Maintenance and Repair........................................................................................................ 852 Troubleshooting................................................................................................................... 858 Troubleshooting, Testing and Adjustment....................................................................................... 858 Start-up Procedures............................................................................................................... 861 Commissioning................................................................................................................. 861 Swing Device.......................................................................................................................... 865 Safety Instructions............................................................................................................... 865 General........................................................................................................................... 867 Specification................................................................................................................. 867 Overview...................................................................................................................... 868 Hydraulics Circuit............................................................................................................ 869 Parts List.................................................................................................................... 870 Theory of Operation........................................................................................................... 875 Cautions for Operation............................................................................................................ 883 Precaution........................................................................................................................ 887 Tools for Disassembly and Assembly............................................................................................ 887 Removal........................................................................................................................... 889 Installation...................................................................................................................... 895 Completing work................................................................................................................... 895 Disassembly and Reassembly........................................................................................................ 896 Disassemble Swing Motor....................................................................................................... 896 Reassemble Swing Motor........................................................................................................ 901 Disassemble the Reduction Gear................................................................................................ 907 Reassemble the Reduction Gear................................................................................................. 911 Troubleshooting................................................................................................................... 918 General Instructions.......................................................................................................... 918 Examination of Hydraulic Motor................................................................................................ 918 Troubleshooting............................................................................................................... 919 Maintenance Instructions.......................................................................................................... 922 Replacement Standard of Worn Parts............................................................................................ 922 Standard of Sliding Surface Correction........................................................................................ 922 Fan Pump for Oil Cooler............................................................................................................... 923 Safety Instructions............................................................................................................... 923 General........................................................................................................................... 925 Specification................................................................................................................. 925 Overview...................................................................................................................... 926 Parts List.................................................................................................................... 928 Theory of Operation........................................................................................................... 930 Maintenance Guidelines............................................................................................................ 935 Sealing Driveshaft............................................................................................................ 936 Sealing Control Valve......................................................................................................... 938 Tools......................................................................................................................... 938 Removal........................................................................................................................... 939 Installation...................................................................................................................... 944 Completing Work................................................................................................................... 944 Section View...................................................................................................................... 945 EPPR Valve.................................................................................................................... 945 Disassembly....................................................................................................................... 946 Disassembly of Rotary Group................................................................................................... 947 Disassembly of Control Device................................................................................................. 948 Disassembly of Shaft/Bearings................................................................................................. 949 Cleaning and Inspection........................................................................................................... 950 Reassembly........................................................................................................................ 953 Adjustment of Taper Roller Bearing............................................................................................ 954 Fan Motor for Oil Cooler.............................................................................................................. 959 Safety Instructions............................................................................................................... 959 General........................................................................................................................... 961 Specification................................................................................................................. 961 Overview...................................................................................................................... 961 Parts List and Section View................................................................................................... 962 Precaution........................................................................................................................ 963 Tools......................................................................................................................... 963 Removal........................................................................................................................... 964 Installation...................................................................................................................... 969 Completing Work................................................................................................................... 969 Disassembly....................................................................................................................... 970 Reassembly........................................................................................................................ 973 Reassembly.................................................................................................................... 973 Assembly...................................................................................................................... 974 Joystick Valve (Work Lever)........................................................................................................... 977 Safety Instructions............................................................................................................... 977 General........................................................................................................................... 979 Specifications................................................................................................................ 979 Overview...................................................................................................................... 980 Parts List.................................................................................................................... 982 Theory of Operation........................................................................................................... 984 Tools and Torques............................................................................................................. 985 Section View...................................................................................................................... 986 Removal........................................................................................................................... 988 Installation...................................................................................................................... 993 Completing work................................................................................................................... 994 Disassembly....................................................................................................................... 995 Reassembly........................................................................................................................ 999 Travel Control Valve (with Damper)....................................................................................................1005 Safety Instructions...............................................................................................................1005 General...........................................................................................................................1007 Specification.................................................................................................................1007 Overview......................................................................................................................1008 Parts List....................................................................................................................1010 Theory of Operation...........................................................................................................1012 Tools and Torques.............................................................................................................1013 Section View......................................................................................................................1014 Removal...........................................................................................................................1015 Installation......................................................................................................................1020 Completing Work...................................................................................................................1021 Disassembly.......................................................................................................................1022 Reassembly........................................................................................................................1025 Troubleshooting...................................................................................................................1030 Solenoid Valve........................................................................................................................1031 Safety Instructions...............................................................................................................1031 General...........................................................................................................................1033 Specification.................................................................................................................1033 Overview......................................................................................................................1034 Parts List....................................................................................................................1036 Theory of Operation...........................................................................................................1037 Disassembly and Reassembly........................................................................................................1038 Troubleshooting...................................................................................................................1039 Accumulator...........................................................................................................................1041 Safety Instructions...............................................................................................................1041 General...........................................................................................................................1043 Specifications................................................................................................................1044 Gear Pump (Rotating)..................................................................................................................1045 Safety Instructions...............................................................................................................1045 General...........................................................................................................................1047 Specification.................................................................................................................1047 Overview......................................................................................................................1047 Location......................................................................................................................1048 Parts List....................................................................................................................1049 One Spool Valve (Rotating)............................................................................................................1051 Safety Instructions...............................................................................................................1051 General...........................................................................................................................1053 Specification.................................................................................................................1053 Overview......................................................................................................................1053 Theory of Operation...........................................................................................................1054 Disassembly and Assembly..........................................................................................................1056 General Cautions..............................................................................................................1056 Replacement of Spool..........................................................................................................1057 Replacement of Main Relief Valve..............................................................................................1059 Replacement of Overload Relief Valve..........................................................................................1060 Replacement of Sub-Block......................................................................................................1062 Rotating Grapple......................................................................................................................1065 Safety Instructions...............................................................................................................1065 General...........................................................................................................................1067 General Description...........................................................................................................1067 Theory of Operation...........................................................................................................1067 Structure.....................................................................................................................1068 Hydraulic Circuit.............................................................................................................1069 Lower Structure and Chassis...............................................................................................................1071 Swing Bearing.........................................................................................................................1073 Safety Instructions...............................................................................................................1073 General...........................................................................................................................1075 General Description...........................................................................................................1075 Parts List....................................................................................................................1075 Maintenance Guidelines............................................................................................................1076 Disassembly.......................................................................................................................1077 Reassembly........................................................................................................................1079 Center Joint..........................................................................................................................1081 Safety Instructions...............................................................................................................1081 General...........................................................................................................................1083 General Description...........................................................................................................1083 Overview......................................................................................................................1083 Section View......................................................................................................................1085 Removal...........................................................................................................................1086 Installation......................................................................................................................1092 Completing Work...................................................................................................................1092 Disassembly.......................................................................................................................1093 Reassembly........................................................................................................................1096 Troubleshooting, Testing and Adjustment...........................................................................................1099 Inspection....................................................................................................................1099 Testing.......................................................................................................................1099 Travel Device.........................................................................................................................1101 Safety Instructions...............................................................................................................1101 General...........................................................................................................................1103 Specification.................................................................................................................1103 Overview......................................................................................................................1104 Parts List....................................................................................................................1106 Theory of Operation...........................................................................................................1110 Cautions for Operation........................................................................................................1120 Precaution........................................................................................................................1123 Tools for Disassembly and Assembly............................................................................................1123 Tightening Torque.............................................................................................................1125 Removal...........................................................................................................................1126 Installation......................................................................................................................1132 Completing Work...................................................................................................................1133 Section View......................................................................................................................1134 Disassembly.......................................................................................................................1137 Cautions on Disassembly.......................................................................................................1137 Disassembly Sequence..........................................................................................................1137 Reassembly........................................................................................................................1147 Cautions on Assembly..........................................................................................................1147 Assembly Sequence.............................................................................................................1147 Performance Test..................................................................................................................1166 Troubleshooting...................................................................................................................1168 Track Assembly........................................................................................................................1171 Safety Instructions...............................................................................................................1171 General...........................................................................................................................1173 Track Tension.....................................................................................................................1174 Track Shoes and Links.............................................................................................................1176 Parts List....................................................................................................................1176 Track Removal.................................................................................................................1177 Track Installation............................................................................................................1179 Track Shoe....................................................................................................................1180 Sprocket..........................................................................................................................1182 Wear Limits and Tolerances....................................................................................................1182 Front Idler.......................................................................................................................1183 Overview......................................................................................................................1183 Parts List....................................................................................................................1184 Front Idler Disassembly.......................................................................................................1185 Front Idler Reassembly........................................................................................................1187 Upper and Lower Roller............................................................................................................1188 Overview......................................................................................................................1188 Parts List....................................................................................................................1189 Roller Removal................................................................................................................1190 Roller Installation...........................................................................................................1190 Roller Disassembly............................................................................................................1190 Roller Reassembly.............................................................................................................1191 Track Adjuster....................................................................................................................1194 Parts List....................................................................................................................1194 Disassembly...................................................................................................................1195 Assembly......................................................................................................................1196 Front.....................................................................................................................................1199 Boom and Stick........................................................................................................................1201 Safety Instructions...............................................................................................................1201 Specifications....................................................................................................................1203 Size and Weight...............................................................................................................1204 Removal...........................................................................................................................1205 Stick Removal.................................................................................................................1205 Boom Removal..................................................................................................................1207 Installation......................................................................................................................1208 Stick Installation............................................................................................................1208 Boom Installation.............................................................................................................1208 Start-up Procedures...............................................................................................................1208 Cylinders.............................................................................................................................1209 Safety Instructions...............................................................................................................1209 General...........................................................................................................................1211 General Description...........................................................................................................1211 Parts List....................................................................................................................1212 Theory of Operation...........................................................................................................1220 Seal of Cylinder..............................................................................................................1221 Special Tools and Materials.......................................................................................................1223 Piston Nut....................................................................................................................1223 Piston Jig....................................................................................................................1224 Steel Bushing Jig.............................................................................................................1225 Dust Wiper Jig................................................................................................................1226 Slipper Seal Jig..............................................................................................................1227 Slipper Seal Straightening Jig................................................................................................1228 Rod Bushing (DD-bushing) Pushing-in Jig.......................................................................................1229 Disassembly.......................................................................................................................1230 Reassembly........................................................................................................................1235 Troubleshooting...................................................................................................................1239 Hydraulic System..........................................................................................................................1241 Hydraulic System......................................................................................................................1243 Safety Instructions...............................................................................................................1243 General...........................................................................................................................1245 General Description...........................................................................................................1245 Hydraulic Schematic...............................................................................................................1246 General Description...........................................................................................................1246 Hydraulic Component...............................................................................................................1248 Safety Cutoff Valve Operation.....................................................................................................1250 Boom Up Operation.................................................................................................................1252 Boom Down Operation...............................................................................................................1254 Arm (Stick) Crowd Operation.......................................................................................................1256 Arm (Stick) Dump Operation........................................................................................................1258 Heel Rack In Operation............................................................................................................1260 Heel Rack Out Operation...........................................................................................................1262 Swing Operation...................................................................................................................1264 ON Swing Signal...............................................................................................................1265 OFF Swing Signal..............................................................................................................1265 Travel Forward and Backward Operation.............................................................................................1266 Travel Straight Operation.........................................................................................................1267 Bypass Cut Valve and Bypass Cut Solenoid Valve Operation..........................................................................1268 Hydraulic System Testing and Adjustment...............................................................................................1269 Safety Instructions...............................................................................................................1269 Procedural Troubleshooting Baseline Recommendations...............................................................................1271 Initial Checks and Tests to Establish Operating Condition of the Machine......................................................1271 Pilot Pressure....................................................................................................................1272 Adjustment and Testing........................................................................................................1272 Pump Swash Plate..................................................................................................................1273 Adjustment and Testing........................................................................................................1273 Pump EPPRV........................................................................................................................1274 Adjustment and Testing........................................................................................................1274 Pump Pressure.....................................................................................................................1275 Adjustment and Testing........................................................................................................1275 Pump Regulator....................................................................................................................1276 Adjustment and Testing........................................................................................................1276 Installation and Testing of Flow Meter and Flow Meter Kit.........................................................................1278 Installation and Testing Procedures...........................................................................................1278 Swing System Troubleshooting......................................................................................................1279 Precautions/Initial Checks....................................................................................................1279 Swing Relief Valve Checking and Adjustment....................................................................................1280 Hydraulic System Troubleshooting......................................................................................................1283 Safety Instructions...............................................................................................................1283 Hydraulic System..................................................................................................................1286 Unusual Noise Comes Out from Pump Connection..................................................................................1286 Engine Starts but Machine Does Not Operate....................................................................................1287 Hydraulic Oil is Cloudy.......................................................................................................1288 Hydraulic Oil Overheated......................................................................................................1288 Hydraulic Pump Cavitation.....................................................................................................1289 Hydraulic Oil is Contaminated.................................................................................................1289 Attachment Cylinders, Swing and Travel Motors are All Operable. But Speed Is Lower and Power Lacks............................1290 Travel Left, Heel are Inoperable. But Boom Up and Arm are Slower Than Normal Operation........................................1291 Travel Right, Swing are Inoperable. But Boom Up and Arm are Slower Than Normal Operation......................................1292 Attachment Cylinders, Swing and Travel Motors are All Operable. But Fine Operation Is Difficult and Loud Noises are Heard.....1293 Travel Right Motor are Inoperable or Operable in One Direction Only...........................................................1294 Travel Left Motor are Inoperable or Operable in One Direction Only............................................................1294 Swing Motor are Inoperable or Operable in One Direction Only..................................................................1295 Arm Is Operable but Slower in One Direction...................................................................................1295 Two Pump (Breaker etc.) Becomes Slower........................................................................................1296 Machine Cannot Travel Straight During Combined Operation of Travel and Front..................................................1297 Machine Cannot Travel Straight During Travel Operation........................................................................1297 Considerable Flow at Pump with Neutral Lever Position.........................................................................1298 Troubleshooting – Swing Gearbox...................................................................................................1299 Troubleshooting – Hydraulic Problems..............................................................................................1300 Troubleshooting – Main Pump.......................................................................................................1303 Troubleshooting – Control Valve...................................................................................................1305 Troubleshooting – Travel Control Valve............................................................................................1307 Troubleshooting – Joystick Control Valve..........................................................................................1307 Electrical System.........................................................................................................................1309 Electrical System.....................................................................................................................1311 Safety Instructions...............................................................................................................1311 Introduction......................................................................................................................1315 Electrical Supply System..........................................................................................................1316 Engine Starting Circuit...........................................................................................................1318 Start Operation...............................................................................................................1318 After Start...................................................................................................................1320 Engine Stop.......................................................................................................................1321 Charging System...................................................................................................................1323 Monitoring System.................................................................................................................1324 Instrument Panel..............................................................................................................1325 Functional Check..............................................................................................................1325 Monitoring System Schematic...................................................................................................1326 Operation.........................................................................................................................1328 Instruments...................................................................................................................1328 Warning and Indicator Lights......................................................................................................1330 Indication of Warning Lights..................................................................................................1330 Indication of Multifunction Gauge.............................................................................................1333 Initial Operation.................................................................................................................1335 Graphic Information Area Display..................................................................................................1336 Overview......................................................................................................................1336 Main Menus for the Graphic Display Area.......................................................................................1336 Menu Selector Buttons.........................................................................................................1336 User Menu.........................................................................................................................1337 User Menu - Access and Escape Methods.........................................................................................1337 Special Menu......................................................................................................................1368 Entering/Accessing and Exiting/Escaping Menus.................................................................................1368 Special Menu Selections.......................................................................................................1369 Failure Code......................................................................................................................1386 Failure Code at Machine.......................................................................................................1386 Failure Code at Engine Side...................................................................................................1390 Electronic Hydraulic Control System (EPOS)........................................................................................1406 Control System Schematic......................................................................................................1406 Power Plus Mode Control...........................................................................................................1408 Operation.....................................................................................................................1410 Power Mode Control................................................................................................................1412 Engine Control System.............................................................................................................1414 Engine Control Dial...............................................................................................................1415 Engine Control....................................................................................................................1416 Automatic Deceleration Control (Auto Idle Control)................................................................................1418 Engine Overheat Protection System.................................................................................................1419 Automatic Travel Speed Control....................................................................................................1422 Automatic Travel Speed Control................................................................................................1424 Water in Fuel Warning System......................................................................................................1425 Operation.....................................................................................................................1425 Self-diagnostic Function..........................................................................................................1426 EPOS Controller...............................................................................................................1426 Air Conditioner System............................................................................................................1428 Outline.......................................................................................................................1428 Internal and External Filters.................................................................................................1429 Air-Conditioning System Layout................................................................................................1430 Air Conditioner/Heater Circuit Diagram........................................................................................1431 Air Conditioner/Heater Unit...................................................................................................1432 Ambient Air Temperature Sensor................................................................................................1437 Sun Sensor....................................................................................................................1438 Control Panel.................................................................................................................1438 Receiver Dryer................................................................................................................1446 Troubleshooting...................................................................................................................1447 Refrigerant System Repairs........................................................................................................1449 Refrigerant Safe Handling Procedures..........................................................................................1449 Repair and Replacement Procedure..............................................................................................1450 Refrigerant Recovery..........................................................................................................1452 Vacuuming Refrigerant System..................................................................................................1452 Leakage Check.................................................................................................................1454 Refrigerant Charging..........................................................................................................1454 Inspecting System For Leakage.................................................................................................1456 Wiper System......................................................................................................................1458 Wiper Circuit.................................................................................................................1458 Wiper Operation...............................................................................................................1459 Lighting System...................................................................................................................1460 Lighting System Circuit Diagram...............................................................................................1460 Kind of Light.................................................................................................................1461 Operation.....................................................................................................................1461 Audio Controller..................................................................................................................1462 Audio Controller Circuit Diagram..............................................................................................1462 Options...................................................................................................................................1463 Auto Grease System....................................................................................................................1465 Safety Instructions...............................................................................................................1465 General...........................................................................................................................1468 Layout........................................................................................................................1468 Location......................................................................................................................1470 Assembly Pump.....................................................................................................................1471 Overview......................................................................................................................1471 Mounting Dimensions...........................................................................................................1472 Functional Description of Progressive System..................................................................................1472 Assembly Instructions.........................................................................................................1473 Troubleshooting...................................................................................................................1481 Pump Display and Control Elements of Control Screen...........................................................................1481 Schematic.................................................................................................................................1487 Hydraulic Schematic / Electrical Schematic............................................................................................1489 Hydraulic Schematic...............................................................................................................1491 Electrical Schematic (1/2)........................................................................................................1493 Electrical Schematic (2/2)........................................................................................................1495 Blank Page....................................................................................................................................1492 Blank Page....................................................................................................................................1494 Blank Page....................................................................................................................................1496
DOOSAN DX380LL-5 EXCAVATOR LOG LOADER SHOP MANUAL 950106-01572 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
R.D
1 review for Doosan DX380LL-5 Excavator Log Loader Shop Manual 950106-01572 – PDF DOWNLOAD
Add a review
Jad Jad –