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Doosan DX490LC-5 DX530LC-5 Excavator Shop Manual 950106-01005E-1 – PDF DOWNLOAD
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Doosan DX490LC-5 DX530LC-5 Excavator Shop Manual 950106-01005E-1 – PDF DOWNLOAD
DX490LC-5/DX530LC-5
Serial Number 10001
Serial Number 10001
950106-01005E-1
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Description
Doosan DX490LC-5 DX530LC-5 Excavator Shop Manual 950106-01005E-1 – PDF DOWNLOAD
DESCRIPTION:
Doosan DX490LC-5 DX530LC-5 Excavator Shop Manual 950106-01005E-1 – PDF DOWNLOAD
DX490LC-5/DX530LC-5
Serial Number 10001
Serial Number 10001
950106-01005E-1
Safe Operation is Operator’s Responsibility:
Only trained and authorized personnel should operate and maintain the machine.
Follow all safety rules, regulations and instructions when operating or performing maintenance on machine.
• Do not operate machine if you are under the influence of drugs or alcohol. An operator who is taking prescription drugs must get medical advice to determine if he or she can safely operate a machine.
• When working with other personnel on a work site, be sure that all personnel know nature of work and understand all hand signals that are to be used.
• Be sure that all guards and shields are installed in their proper location. Have guards and shields repaired or replaced immediately if damaged.
• Be sure that you understand the use and maintenance of all safety features such as safety lever and seat belt. Use them properly.
• Never remove, modify or disable any safety features. Always keep them in good operating condition.
• Always check for and know the location of underground and overhead utility lines before excavating.
• Failure to use and maintain safety features according to instructions in this manual, Safety Manual and Shop Manual can result in death or serious injury.
Know Your Machine:
- Know how to operate your machine.
- Know the purpose of all controls, gauges, signals, indicators and monitor displays.
- Know the rated load capacity, speed range, braking and steering characteristics, turning radius and operating clearances. Keep in mind that rain, snow, ice, loose gravel, soft ground, slopes etc., can change operating capabilities of your machine.
Proper Work Tools and Attachments;
- Only use work tools and attachments that are recommended by DOOSAN for use on DOOSAN machines.
- When installing and using optional attachments, read instruction manual for attachment, and general information related to attachments in this manual.
- Because DOOSAN cannot anticipate, identify or test all attachments that owners may want to install on their machines, contact DOOSAN for written authorization and approval of attachments, and their compatibility with optional kits.
- Attachments and attachment control systems that are compatible with the machine are required for safe and reliable machine operation. Do not exceed maximum operating weight (machine weight plus attachment) that is listed on ROPS certification plate.
- Make sure that all guards and shields are in place on machine and on work tool.
- Depending on type or combination of work equipment, there is a potential that work equipment could interfere with the cabin or other parts of machine. Before using unfamiliar work equipment, check if there is any potential of interference, and operate with caution.
- While you are performing any maintenance, testing, or adjustments to attachments, stay clear of the following areas: cutting edges, pinch points, and crushing surfaces. Never use attachment as a work platform or manlift.
- Contact your DOOSAN distributor about auxiliary hydraulic kits for attachments installation.
- If you are in doubt about compatibility of a particular attachment with a machine, consult your DOOSAN distributor.
TABLE OF CONTENTS:
Doosan DX490LC-5 DX530LC-5 Excavator Shop Manual 950106-01005E-1 – PDF DOWNLOAD
DX490LC-5/DX530LC-5............................................................................................... 0 NOTICE........................................................................................................ 7 Table of Contents............................................................................................. 9 Safety........................................................................................................ 11 Track Excavator Maintenance Safety........................................................................ 13 Safety Instructions................................................................................... 17 Safety Messages....................................................................................... 17 General............................................................................................... 18 Safe Operation is Operator's Responsibility....................................................... 18 Know Your Machine................................................................................. 18 Proper Work Tools and Attachments................................................................. 19 Pressurized Fluids................................................................................ 19 Flying or Falling Objects......................................................................... 20 Personal Protective Equipment (PPE)............................................................... 21 Correction of Machine Problems.................................................................... 21 Crushing and Cutting.............................................................................. 21 Hot Coolant and Oils - Burn Prevention............................................................ 22 Fire and Explosion Prevention..................................................................... 23 Fire Extinguisher and First-aid Kit (Emergency Medical Kit)....................................... 26 Electrical System and Electrical Shock............................................................ 27 Roll-over Protective Structure (ROPS)............................................................. 27 Transportation........................................................................................ 31 Obey State and Local Over-the-Road Regulations.................................................... 31 Loading and Unloading............................................................................. 31 Transporting Machine.............................................................................. 32 Operation............................................................................................. 33 Before Engine Starting............................................................................ 33 Work Site......................................................................................... 34 Mounting/Dismounting.............................................................................. 35 Cleaning.......................................................................................... 36 Operator Station.................................................................................. 36 Seat Belt......................................................................................... 37 Visibility Information............................................................................ 38 Boost Starting or Charging Engine Batteries....................................................... 39 Swinging or Traveling............................................................................. 41 Lifting and Digging............................................................................... 43 Operation on Slopes............................................................................... 44 Towing............................................................................................ 45 Attachment........................................................................................ 46 Equipment Lowering with Engine Stopped............................................................ 46 Engine Stop....................................................................................... 47 Parking Machine................................................................................... 47 Preservation/Storing Machine...................................................................... 48 Maintenance........................................................................................... 50 Cleaning.......................................................................................... 54 Proper Tools and Clothing......................................................................... 54 Disassembling Precautions......................................................................... 54 Use of Lighting................................................................................... 54 Fire and Explosion Prevention..................................................................... 55 Burn Prevention................................................................................... 56 Rubber That Contains Fluorides.................................................................... 57 Rubber and Plastics............................................................................... 58 Welding Repairs................................................................................... 59 Warning for Counterweight and Front Attachment Removal............................................ 60 Lock Inspection Covers............................................................................ 61 Working on Machine................................................................................ 61 Accumulator....................................................................................... 62 Compressed Air.................................................................................... 62 Track Tension Adjustments......................................................................... 63 Supports and Blocking for Work Equipment.......................................................... 63 High-pressure Lines, Tubes and Hoses.............................................................. 64 Battery........................................................................................... 65 Environment and Circumstances......................................................................... 67 Work Site Areas Requiring Extra Caution........................................................... 67 High-voltage Cables............................................................................... 69 Underground Operation............................................................................. 70 Working in Water.................................................................................. 70 Working in Contaminated Environment............................................................... 70 Operation in Extreme Conditions................................................................... 71 Exhaust Ventilation............................................................................... 75 Asbestos Information.............................................................................. 76 Silica Dust Information........................................................................... 76 Disposal of Hazardous Materials................................................................... 77 Sound............................................................................................. 78 Vibration......................................................................................... 78 Specifications................................................................................................ 79 Specifications............................................................................................ 81 Safety Instructions................................................................................... 85 General Description................................................................................... 85 Component Locations................................................................................... 86 General Dimensions.................................................................................... 90 Variable Track (1/2).............................................................................. 90 Variable Track (2/2).............................................................................. 91 Fixed Track....................................................................................... 92 Working Range......................................................................................... 94 Variable Track.................................................................................... 94 Fixed Track....................................................................................... 96 General Specifications................................................................................ 98 DX490LC-5......................................................................................... 98 DX530LC-5......................................................................................... 100 Approximate Weight of Workload Materials.............................................................. 102 Performance Tests..................................................................................... 104 Purpose of Performance Tests...................................................................... 104 Kinds of Tests.................................................................................... 104 Performance Standards............................................................................. 104 Precautions for Evaluation of Test Data........................................................... 104 Definition of "Performance Standard".............................................................. 104 Preparation for Performance Tests..................................................................... 105 The Machine....................................................................................... 105 Test Area......................................................................................... 105 Precautions....................................................................................... 105 Make Precise Measurement.......................................................................... 105 Operational Performance Standard Table................................................................ 106 Operational Performance Test.......................................................................... 108 Hydraulic Cylinder Cycle Time..................................................................... 108 Travel Speed...................................................................................... 110 Track Revolution Speed............................................................................ 111 Mistrack Check.................................................................................... 113 Swing Speed....................................................................................... 115 Swing Function Drift Check........................................................................ 116 General Maintenance........................................................................................... 117 General Maintenance Instructions.......................................................................... 119 Safety Instructions................................................................................... 123 Welding Precautions and Instructions.................................................................. 124 Hydraulic System - General Precautions................................................................ 125 Maintenance Service and Repair Procedure.............................................................. 127 General Precautions............................................................................... 127 Hydraulic System Cleanliness and Oil Leaks............................................................ 128 Maintenance Precautions for Hydraulic System Service.............................................. 128 Oil Leakage Precautions........................................................................... 129 Cleaning and Inspection............................................................................... 130 General Instructions.............................................................................. 130 Bearing Inspection................................................................................ 131 Standard Torques.......................................................................................... 139 Safety Instructions................................................................................... 143 Torque Values for Standard Metric Fasteners........................................................... 144 Torque Values for Standard U.S. Fasteners............................................................. 145 Type 8 Phosphate Coated Hardware...................................................................... 147 Torque Values for Hose Clamps......................................................................... 148 ORFS Swivel Nut Recommended Torque.................................................................... 148 Torque Values for Split Flanges....................................................................... 149 Torque Wrench Extension Tools......................................................................... 150 Torque Multiplication............................................................................. 150 Other Uses for Torque Wrench Extension Tools...................................................... 151 Tightening Torque Specifications (Metric)......................................................... 152 Engine........................................................................................................ 155 Engine.................................................................................................... 157 Safety Instructions................................................................................... 163 Overview.............................................................................................. 164 Inspection............................................................................................ 165 Cleaning the Engine............................................................................... 165 Special Tools......................................................................................... 165 Mounting the Engine in a Universal Stand.......................................................... 175 Engine Identification................................................................................. 176 Engine Data Plate................................................................................. 176 Engine Specification.................................................................................. 177 Engine Performance Curves............................................................................. 178 Tightening Torques.................................................................................... 180 Normal Tightening Torque.......................................................................... 180 Special Tightening Torque......................................................................... 184 Cylinder.............................................................................................. 211 Cylinder Head..................................................................................... 211 Valve Mechanism................................................................................... 230 Cylinder Block.................................................................................... 233 Cylinder Liner.................................................................................... 248 Flywheel Housing.................................................................................. 255 Front Cover....................................................................................... 258 Oil Mist Separator................................................................................ 260 Actuating System...................................................................................... 266 Camshaft.......................................................................................... 266 Connecting Rod.................................................................................... 274 Crankshaft........................................................................................ 276 Flywheel.......................................................................................... 285 Piston............................................................................................ 290 Roller Tappet..................................................................................... 296 Intake Manifold................................................................................... 297 Power Take Off.................................................................................... 297 Torsion Damper.................................................................................... 298 Belt Circuit...................................................................................... 299 Timing Gear....................................................................................... 306 Lubrication System.................................................................................... 312 General Information............................................................................... 312 Centrifugal Oil Cleaner........................................................................... 314 Oil Cooler........................................................................................ 319 Oil Filter........................................................................................ 322 Oil Pump.......................................................................................... 323 Oil Sump.......................................................................................... 325 Oil Pressure Sensor............................................................................... 327 Troubleshooting Chips Found in the Engine......................................................... 328 Troubleshooting the Lubrication System............................................................ 332 Lubrication Oil Consumption....................................................................... 333 Exhaust System........................................................................................ 336 General Information............................................................................... 336 T113, Exhaust Temperature Sensor Before Catalytic Converter....................................... 352 T131 NOx Sensor................................................................................... 354 T116, Reductant Pick-up Unit...................................................................... 356 Evaporator........................................................................................ 361 V117 Reductant Doser.............................................................................. 362 V118, Coolant Valve for Heating the Reductant System.............................................. 368 V183 Reductant Pump............................................................................... 370 H25, H26 Electrically Heated Reductant Hose....................................................... 381 M4000 Electric Exhaust Brake...................................................................... 382 Reductant Tank.................................................................................... 388 Oxidation Catalytic Converter..................................................................... 395 Exhaust Manifold.................................................................................. 397 Variable Geometry Turbocharger.................................................................... 403 EGR System........................................................................................ 411 EGR Valve......................................................................................... 418 EGR Cooler........................................................................................ 423 Cooling System........................................................................................ 425 Internal Cleaning of Cooling System............................................................... 428 Charge Air Cooler................................................................................. 429 Charge Air Temperature Sensor..................................................................... 431 Charge Air Pressure Sensor........................................................................ 433 Coupling Coil for AC Compressor................................................................... 434 Thermostat........................................................................................ 435 Coolant Pump...................................................................................... 438 Coolant Temperature Sensor........................................................................ 439 Fuel System........................................................................................... 441 General Information............................................................................... 441 Accumulator....................................................................................... 446 Fuel Manifold..................................................................................... 447 Overflow Valve.................................................................................... 456 Feed Pump......................................................................................... 459 Injector.......................................................................................... 465 Fuel Filter....................................................................................... 471 Fuel Heater....................................................................................... 475 Fuel System Troubleshooting....................................................................... 476 Electrical System..................................................................................... 490 E44, Control Unit EMS............................................................................. 490 Control Unit EEC.................................................................................. 507 Engine Speed Sensor............................................................................... 512 T110 Oil Level Sensor............................................................................. 514 T111, Fuel Pressure Sensor........................................................................ 515 T125, Exhaust Back Pressure Sensor................................................................ 517 T135, Camshaft Position Sensor.................................................................... 518 V109, Solenoid Valve for Charge Pressure.......................................................... 520 V120, Fuel Inlet Metering Valve................................................................... 521 V141, V142, V143, V144, V145, V146 Solenoid Valve for Injector.................................... 523 T8, Coolant Level Monitor......................................................................... 524 P3, Alternator.................................................................................... 525 M1, Starter Motor................................................................................. 535 AC Compressor..................................................................................... 538 Electrical Parts.................................................................................. 541 EMS S8 (1/2)...................................................................................... 553 EMS S8 (2/2)...................................................................................... 555 EEC, EEC3 Exhaust Emission Control (9, 13 Liter Engines XPI)...................................... 557 Engine Coolant Heater (Option)............................................................................ 559 Safety Instructions................................................................................... 563 Disassembly and Assembly.............................................................................. 563 Changing the Circulating Pump..................................................................... 563 Changing the Temperature Limiter.................................................................. 565 Changing the Temperature Sensor................................................................... 566 Changing the Combustion Air Fan................................................................... 568 Changing the Burner, Flame Monitor and Glow Plug.................................................. 570 Changing the Burner Head.......................................................................... 572 Changing the Heat Exchanger....................................................................... 574 Upper Structure............................................................................................... 575 Cabin..................................................................................................... 577 Safety Instructions................................................................................... 581 Cabin Identification.................................................................................. 581 Roll-over Protective Structure (ROPS)............................................................. 581 Dimensions of Cabin Glass............................................................................. 590 Removal and Installation of Cabin Glass............................................................... 594 Removal of Cabin Glass............................................................................ 594 Installation of Cabin Glass....................................................................... 596 Installation of Upper Door Glass.................................................................. 601 Installation of Upper Front Glass................................................................. 601 Counterweight............................................................................................. 603 Safety Instructions................................................................................... 607 General............................................................................................... 608 Warning for Counterweight and Front Attachment Removal............................................ 608 Installation.......................................................................................... 611 Hydraulic Oil Tank........................................................................................ 613 Safety Instructions................................................................................... 617 General............................................................................................... 617 Specification..................................................................................... 617 Air Breather...................................................................................... 620 Removal............................................................................................... 621 Fuel Tank................................................................................................. 629 Safety Instructions................................................................................... 633 General............................................................................................... 633 Specification..................................................................................... 633 Parts List........................................................................................ 634 Completing Work....................................................................................... 642 Main Pump................................................................................................. 643 Safety Instructions................................................................................... 647 General............................................................................................... 647 Specifications.................................................................................... 647 Overview.......................................................................................... 650 Hydraulic Circuit................................................................................. 651 Parts List........................................................................................ 652 Theory of Operation............................................................................... 656 Section View.......................................................................................... 669 Removal............................................................................................... 670 Installation.......................................................................................... 679 Completing Work....................................................................................... 679 Assembly Guidelines for Tightening Torques............................................................ 680 Bolts............................................................................................. 680 Plugs with Internal Hexagon and Profile Seal Ring................................................. 681 Seal-lock - Sealing Nuts.......................................................................... 681 Disassembly and Reassembly............................................................................ 682 General Repair Guidelines......................................................................... 682 Seal Kits and Subassemblies....................................................................... 684 Sealing the Driveshaft............................................................................ 688 Gear Pump Sealing................................................................................. 690 Removing Control Housing.......................................................................... 691 Control Module.................................................................................... 694 Removing the Controller........................................................................... 696 Valve Plate with Valves........................................................................... 698 Remove Rotary Groups.............................................................................. 699 Remove Intermediate Wheel......................................................................... 702 Remove Auxiliary Drive............................................................................ 704 Inspection........................................................................................ 707 Assembling the Rotary Group....................................................................... 712 Pump Assembly..................................................................................... 714 Hydraulic Component - Measurement "D"............................................................. 717 Installation of Control Housing................................................................... 720 Assembly of Intermediate Wheel.................................................................... 723 Installation of Gear Pump......................................................................... 724 Installation of Cover/Auxiliary Drive............................................................. 725 Troubleshooting....................................................................................... 726 How to Proceed for Troubleshooting................................................................ 726 Malfunction Table................................................................................. 727 Drive Coupling (Main Pump)................................................................................ 729 Safety Instructions................................................................................... 733 General............................................................................................... 733 Specification..................................................................................... 733 Parts List........................................................................................ 734 Section View.......................................................................................... 736 Tools............................................................................................. 737 Disassembly........................................................................................... 738 Reassembly............................................................................................ 738 Main Control Valve........................................................................................ 741 Safety Instructions................................................................................... 745 General............................................................................................... 745 Specification..................................................................................... 745 Overview.......................................................................................... 746 Hydraulic Circuit................................................................................. 748 Parts List........................................................................................ 750 Theory of Operation............................................................................... 756 Section View.......................................................................................... 784 Removal............................................................................................... 785 Installation.......................................................................................... 794 Completing Work....................................................................................... 795 Disassembly........................................................................................... 796 Cautions on Disassembly........................................................................... 796 Disassembly of Main Spools........................................................................ 797 Disassembly of Load Check......................................................................... 803 Cleaning and Inspection (Wear Limits and Tolerances).................................................. 809 Cleaning.......................................................................................... 809 Inspection........................................................................................ 809 Reassembly............................................................................................ 810 Subassembly....................................................................................... 810 Main Spool........................................................................................ 810 Reassembly of Control Valve....................................................................... 813 Reassembly of Main Spool (3) ~ (11)............................................................... 819 Adjustment of Relief Valve........................................................................ 824 Troubleshooting, Testing and Adjustment............................................................... 826 General........................................................................................... 826 Relief Valve...................................................................................... 827 Hydraulic System.................................................................................. 827 Start-up Procedures................................................................................... 828 Swing Device.............................................................................................. 829 Safety Instructions................................................................................... 833 General............................................................................................... 833 Specification..................................................................................... 833 Overview.......................................................................................... 834 Hydraulics Circuit................................................................................ 835 Parts List........................................................................................ 836 Theory of Operation............................................................................... 841 Cautions for Operation................................................................................ 849 Precaution............................................................................................ 853 Tools for Disassembly and Assembly................................................................ 853 Removal............................................................................................... 855 Installation.......................................................................................... 859 Completing work....................................................................................... 859 Disassembly and Reassembly............................................................................ 860 Disassemble Swing Motor........................................................................... 860 Reassemble Swing Motor............................................................................ 865 Disassemble the Reduction Gear.................................................................... 871 Reassemble the Reduction Gear..................................................................... 875 Troubleshooting....................................................................................... 882 General Instructions.............................................................................. 882 Examination of Hydraulic Motor.................................................................... 882 Troubleshooting................................................................................... 883 Maintenance Instructions.............................................................................. 886 Replacement Standard of Worn Parts................................................................ 886 Standard of Sliding Surface Correction............................................................ 886 Fan Pump for Oil Cooler................................................................................... 887 Safety Instructions................................................................................... 891 General............................................................................................... 892 Specification..................................................................................... 892 Overview.......................................................................................... 893 Parts List........................................................................................ 894 Theory of Operation............................................................................... 896 Maintenance Guidelines................................................................................ 901 Sealing Control Valve............................................................................. 904 Tools............................................................................................. 904 Removal............................................................................................... 905 Installation.......................................................................................... 909 Completing Work....................................................................................... 909 Section View.......................................................................................... 910 EPPR Valve........................................................................................ 910 Disassembly........................................................................................... 911 Disassembly of Rotary Group....................................................................... 912 Disassembly of Shaft/Bearings..................................................................... 914 Reassembly............................................................................................ 918 Fan Motor for Oil Cooler.................................................................................. 925 Safety Instructions................................................................................... 929 General............................................................................................... 929 Specification..................................................................................... 929 Overview.......................................................................................... 930 Parts List and Section View....................................................................... 931 Precaution............................................................................................ 932 Tools............................................................................................. 932 Removal............................................................................................... 933 Installation.......................................................................................... 937 Completing Work....................................................................................... 937 Disassembly........................................................................................... 938 Reassembly............................................................................................ 941 Reassembly........................................................................................ 941 Assembly.......................................................................................... 942 Gear Pump (Rotation)...................................................................................... 945 Safety Instructions................................................................................... 949 General............................................................................................... 949 Specification..................................................................................... 949 Overview.......................................................................................... 950 Joystick Valve (Work Lever)............................................................................... 953 Safety Instructions................................................................................... 957 General............................................................................................... 957 Specifications.................................................................................... 957 Overview.......................................................................................... 958 Parts List........................................................................................ 960 Theory of Operation............................................................................... 962 Tools and Torques................................................................................. 963 Section View.......................................................................................... 964 Removal............................................................................................... 966 Installation.......................................................................................... 971 Completing work....................................................................................... 971 Disassembly........................................................................................... 972 Reassembly............................................................................................ 976 Travel Control Valve (with Damper)........................................................................ 983 Safety Instructions................................................................................... 987 General............................................................................................... 988 Specification..................................................................................... 988 Overview.......................................................................................... 989 Parts List........................................................................................ 990 Theory of Operation............................................................................... 992 Section View.......................................................................................... 994 Removal............................................................................................... 995 Installation..........................................................................................1000 Completing Work.......................................................................................1001 Disassembly...........................................................................................1002 Reassembly............................................................................................1005 Troubleshooting.......................................................................................1010 Solenoid Valve............................................................................................1011 Safety Instructions...................................................................................1015 General...............................................................................................1015 Specification.....................................................................................1015 Overview..........................................................................................1016 Parts List........................................................................................1018 Theory of Operation...............................................................................1019 Disassembly and Reassembly............................................................................1020 Troubleshooting.......................................................................................1021 EPPR Valve................................................................................................1023 Safety Instructions...................................................................................1027 General...............................................................................................1028 Specification.....................................................................................1028 Overview..........................................................................................1029 Hydraulic Circuit.................................................................................1030 Troubleshooting.......................................................................................1030 Accumulator...............................................................................................1031 Safety Instructions...................................................................................1035 General...............................................................................................1035 Specifications....................................................................................1037 Lower Structure and Chassis...................................................................................1039 Swing Bearing.............................................................................................1041 Safety Instructions...................................................................................1045 General...............................................................................................1046 General Description...............................................................................1046 Parts List........................................................................................1046 Maintenance Guidelines................................................................................1047 Disassembly...........................................................................................1048 Reassembly............................................................................................1050 Center Joint..............................................................................................1051 Safety Instructions...................................................................................1055 General...............................................................................................1055 General Description...............................................................................1055 Overview..........................................................................................1056 Section View..........................................................................................1058 Removal...............................................................................................1059 Installation..........................................................................................1063 Completing Work.......................................................................................1063 Disassembly...........................................................................................1064 Reassembly............................................................................................1067 Troubleshooting, Testing and Adjustment...............................................................1070 Inspection........................................................................................1070 Testing...........................................................................................1070 Travel Device.............................................................................................1071 Safety Instructions...................................................................................1075 General...............................................................................................1075 Specification.....................................................................................1075 Overview..........................................................................................1076 Theory of Operation...............................................................................1082 Cautions for Operation............................................................................1093 Precaution............................................................................................1096 Tools for Disassembly and Assembly................................................................1096 Tightening Torque.................................................................................1098 Removal...............................................................................................1099 Installation..........................................................................................1104 Completing Work.......................................................................................1104 Section View..........................................................................................1105 Disassembly...........................................................................................1108 Cautions on Disassembly...........................................................................1108 Disassembly Sequence..............................................................................1108 Reassembly............................................................................................1118 Cautions on Assembly..............................................................................1118 Assembly Sequence.................................................................................1118 Performance Test......................................................................................1137 Troubleshooting.......................................................................................1139 Track Assembly............................................................................................1141 Safety Instructions...................................................................................1145 General...............................................................................................1145 Track Tension.........................................................................................1146 Track Shoes and Links.................................................................................1148 Parts List........................................................................................1148 Track Removal.....................................................................................1149 Track Installation................................................................................1151 Wear Limits and Tolerances........................................................................1152 Sprocket..............................................................................................1154 Wear Limits and Tolerances........................................................................1154 Front Idler...........................................................................................1155 Overview..........................................................................................1155 Parts List........................................................................................1156 Front Idler Disassembly...........................................................................1157 Front Idler Reassembly............................................................................1159 Upper Roller..........................................................................................1160 Overview..........................................................................................1160 Parts List........................................................................................1161 Upper Roller Removal..............................................................................1162 Upper Roller Installation.........................................................................1162 Upper Roller Disassembly..........................................................................1162 Upper Roller Reassembly...........................................................................1164 Lower Roller..........................................................................................1165 Overview..........................................................................................1165 Parts List........................................................................................1166 Lower Roller Removal..............................................................................1167 Lower Roller Installation.........................................................................1167 Lower Roller Disassembly..........................................................................1167 Lower Roller Reassembly...........................................................................1168 Track Adjuster........................................................................................1170 Parts List........................................................................................1170 Disassembly.......................................................................................1171 Assembly..........................................................................................1172 Front.........................................................................................................1175 Boom and Arm..............................................................................................1177 Safety Instructions...................................................................................1181 Specifications........................................................................................1182 Removal...............................................................................................1184 Arm Removal.......................................................................................1184 Boom Removal......................................................................................1186 Installation..........................................................................................1187 Arm Installation..................................................................................1187 Boom Installation.................................................................................1187 Completing Work.......................................................................................1187 Bucket....................................................................................................1189 Safety Instructions...................................................................................1193 Bucket Tooth Inspection and Replacement...............................................................1194 Bucket O-ring Replacement.............................................................................1195 Bucket Replacement and Reversal.......................................................................1196 Replacement.......................................................................................1197 Reversal..........................................................................................1198 Cylinders.................................................................................................1199 Safety Instructions...................................................................................1203 General...............................................................................................1203 General Description...............................................................................1203 Specification.....................................................................................1203 Parts List........................................................................................1204 Theory of Operation...............................................................................1212 Seal of Cylinder..................................................................................1213 Special Tools and Materials........................................................................... 0 Rod Bushing (DD-bushing) Pushing-in Jig...........................................................1221 Disassembly...........................................................................................1222 Reassembly............................................................................................1227 Troubleshooting.......................................................................................1231 Hydraulic System..............................................................................................1233 Hydraulic System..........................................................................................1235 Safety Instructions...................................................................................1239 General Description...................................................................................1239 Hydraulic Schematic...................................................................................1240 General Description...............................................................................1240 Hydraulic Component and Oil Flow......................................................................1242 Hydraulic Component...............................................................................1242 Main Circuit......................................................................................1244 Pilot Circuit.....................................................................................1245 Return Circuit....................................................................................1246 Safety Cut-off Operation..............................................................................1247 Power Up Operation....................................................................................1248 Swing (Brake Release) Operation.......................................................................1250 Two Pump Operation....................................................................................1252 Travel Forward and Backward Operation.................................................................1253 Travel High-speed Operation...........................................................................1254 Travel Straight Operation.............................................................................1256 Boom Up Operation.....................................................................................1258 Boom Down Operation...................................................................................1260 Easy Boom Operation...................................................................................1262 Arm Dump Operation....................................................................................1264 Arm Crowd Operation...................................................................................1266 Bucket Dump Operation.................................................................................1268 Bucket Crowd Operation................................................................................1270 Combined Bucket Crowd and Boom Up Operation...........................................................1272 Combined Travel and Boom, Arm, Bucket or Swing Operation..............................................1274 Holding Valve Operation - Cylinder Locking............................................................1276 Holding Valve Operation - Cylinder Release............................................................1277 Main Relief & Over Load Relief Valve Operation........................................................1278 Hydraulic System Testing and Adjustment...................................................................1279 Safety Instructions...................................................................................1283 Procedural Troubleshooting Baseline Recommendations...................................................1284 Initial Checks and Tests to Establish Operating Condition of the Excavator........................1284 Pilot Pressure........................................................................................1286 Adjustment and Testing............................................................................1286 Power Mode Valve......................................................................................1287 Current Signal and Hydraulic Pressure Adjustments.................................................1287 Pressure Up Valve.....................................................................................1288 Checks and Adjustments............................................................................1288 Pump Input Power Control..............................................................................1290 Pump Regulator Adjustment.........................................................................1290 Installation and Testing of Flow Meter and Flow Meter Kit.............................................1293 Swing System Troubleshooting..........................................................................1295 Precautions/Initial Checks........................................................................1295 Swing Relief Valve Checking and Adjustment........................................................1296 Hydraulic System Troubleshooting..........................................................................1299 Safety Instructions...................................................................................1303 Hydraulic System......................................................................................1303 Unusual Noise Comes Out from Pump Connection......................................................1303 Engine Starts but Machine Does Not Operate........................................................1304 Hydraulic Oil is Cloudy...........................................................................1305 Hydraulic Oil Overheated..........................................................................1305 Hydraulic Pump Cavitation.........................................................................1306 Hydraulic Oil is Contaminated.....................................................................1306 Boom, Arm, Bucket Speed is Slow...................................................................1307 Boom, Arm or Bucket Power is Weak.................................................................1308 Cylinder Moves When Remote Control Valve is in the Neutral Position...............................1308 TR (L), TR (R) Swing Does Not Operate When Remote Control Valve Operated..........................1309 Swing Speed is Slow...............................................................................1310 Does Not Operate Boom Floating....................................................................1311 Machine Swings but Does Not Stop..................................................................1311 One Side Speed is Falls and the Machine Curves....................................................1312 Machine Does Not Stop on a Slope..................................................................1313 Travel Motor is Powerless (Travel Only)...........................................................1313 Machine Makes a Curved Travel, When Travel and Actuator Operation are Executed a the Same Time....1314 Does Not Travel is 2nd Speed or Auto Speed........................................................1314 Troubleshooting - Swing Gearbox.......................................................................1315 Troubleshooting - Hydraulic Problems..................................................................1316 Troubleshooting - Hydraulic Fan Drive System..........................................................1318 Troubleshooting - Main Pump...........................................................................1318 Troubleshooting - Control Valve.......................................................................1321 Troubleshooting - Travel Control Valve................................................................1322 Troubleshooting - Joystick Control Valve..............................................................1322 Electrical System.............................................................................................1323 Electrical System.........................................................................................1325 Safety Instructions...................................................................................1331 Introduction..........................................................................................1331 Electrical Supply System..............................................................................1332 Engine Starting Circuit...............................................................................1334 Start Operation...................................................................................1334 Engine Stop...........................................................................................1337 Monitoring System.....................................................................................1340 Instrument Panel..................................................................................1341 Functional Check..................................................................................1341 Monitoring System Schematic.......................................................................1342 Operation.............................................................................................1344 Instruments.......................................................................................1344 Warning and Indicator Lights.......................................................................... 0 Indication of Multifunction Gauge.................................................................1349 Initial Operation.....................................................................................1351 Graphic Information Area Display......................................................................1352 Overview..........................................................................................1352 Main Menus for the Graphic Display Area...........................................................1352 Menu Selector Buttons.............................................................................1352 User Menu.............................................................................................1353 User Menu - Access and Escape Methods.............................................................1353 Special Menu..........................................................................................1389 Entering/Accessing and Exiting/Escaping Menus.....................................................1389 Special Menu Selections...........................................................................1390 Failure Code..........................................................................................1406 Failure Code at Machine...........................................................................1406 Failure Code at Engine Side.......................................................................1409 Electronic Hydraulic Control System (EPOS)............................................................1426 Control System Schematic..........................................................................1426 Power Plus Mode Control...............................................................................1428 Operation.........................................................................................1430 Power Mode Control....................................................................................1432 Smart Power Control (SPC).............................................................................1434 Operation.........................................................................................1434 Engine Control System.................................................................................1437 Engine Control Dial...................................................................................1438 Engine Control........................................................................................1440 Automatic Deceleration Control (Auto Idle Control)....................................................1442 Engine Overheat Protection System.....................................................................1444 Power Boost Mode......................................................................................1447 Operation.........................................................................................1447 Power Boost Control...............................................................................1448 Automatic Travel Speed Control........................................................................1450 Water in Fuel Warning System..........................................................................1453 Operation.........................................................................................1453 Self-diagnostic Function..............................................................................1454 EPOS Controller...................................................................................1454 Air Conditioner System................................................................................1456 Outline...........................................................................................1456 Internal and External Filters.....................................................................1457 Air-Conditioning System Layout....................................................................1458 Air Conditioner/Heater Unit.......................................................................1460 Ambient Air Temperature Sensor....................................................................1465 Receiver Dryer....................................................................................1474 Troubleshooting.......................................................................................1475 Refrigerant System Repairs............................................................................1477 Refrigerant Safe Handling Procedures..............................................................1477 Repair and Replacement Procedure..................................................................1478 Refrigerant Recovery..............................................................................1480 Vacuuming Refrigerant System......................................................................1480 Leakage Check.....................................................................................1482 Refrigerant Charging..............................................................................1482 Inspecting System For Leakage.....................................................................1484 Wiper System.......................................................................................... 0 Wiper Operation...................................................................................1486 Lighting System....................................................................................... 0 Kind of Light.....................................................................................1489 Operation.........................................................................................1489 Overload Warning Device...............................................................................1490 Overload Warning Device Circuit Diagram...........................................................1490 Electrical System Troubleshooting.........................................................................1493 Safety Instructions...................................................................................1497 Electrical System.....................................................................................1497 When Starter Switch is Turn ON, Monitor Panel Display Does Not Appear.............................1497 Communication Error Flashes on the Panel..........................................................1498 Battery Charging Warning Light Lights, When Engine is Started.....................................1499 When Coolant Overheat Warning Light Lights, When Engine is Started................................1500 When Engine Oil Pressure Warning Light Lights, When Engine is Started.............................1500 When Water Separator Warning Light Lights, When Engine Is Started.................................1501 Does Not Control the Engine Control Dial..........................................................1501 Does Not Control the Engine Auto Idle (PA, PT)....................................................1502 When Pilot Cutoff Solenoid Does Not Operate.......................................................1502 When Does Not Operate Auto Travel Speed...........................................................1503 Wiper Does Not Operate When Wiper Switch Is Operated..............................................1504 All Actuators Speed are Slow (EPPR Valve).........................................................1505 Engine Stall (EPPR Valve).........................................................................1506 Options.......................................................................................................1507 One Way...................................................................................................1509 Safety Instructions...................................................................................1513 General...............................................................................................1513 General Description...............................................................................1513 Theory of Operation...............................................................................1513 Hydraulic Circuit.................................................................................1514 Caution for Installation..........................................................................1515 Installation Procedure................................................................................1516 Main Piping - One and Two-way.....................................................................1516 Main Piping - One Way.............................................................................1518 Pilot Piping - One Way............................................................................1522 Boom Piping - One and Two-way.....................................................................1524 Arm Piping - One and Two-way......................................................................1526 After Installation Precautions....................................................................1527 Air Bleeding......................................................................................1527 Completing Work.......................................................................................1528 Two-way...................................................................................................1529 Safety Instructions...................................................................................1533 General...............................................................................................1533 General Description...............................................................................1533 Theory of Operation...............................................................................1533 Structure.........................................................................................1534 Hydraulic Circuit.................................................................................1535 Caution for Installation..........................................................................1537 Installation Procedure................................................................................1538 Main Piping - One and Two-way.....................................................................1538 Main Piping - Two-way.............................................................................1540 Pilot Piping - Two-way............................................................................1544 Boom Piping - One and Two-way.....................................................................1548 Arm Piping - One and Two-way......................................................................1550 After Installation Precautions....................................................................1551 Air Bleeding......................................................................................1551 Completing Work.......................................................................................1552 Rotating..................................................................................................1553 Safety Instructions...................................................................................1557 General...............................................................................................1557 General Description...............................................................................1557 Theory of Operation...............................................................................1557 Structure.........................................................................................1558 Hydraulic Circuit.................................................................................1559 Caution for Installation..........................................................................1560 Installation Procedure................................................................................1562 Main Piping - Rotating............................................................................1562 Pilot Piping - Rotating...........................................................................1564 Boom Piping - Rotating............................................................................1566 Arm Piping - Rotating.............................................................................1568 After Installation Precautions....................................................................1569 Air Bleeding......................................................................................1569 Completing Work.......................................................................................1569 Quick Coupler.............................................................................................1571 Safety Instructions...................................................................................1575 General...............................................................................................1575 General Description...............................................................................1575 Theory of Operation...............................................................................1575 Hydraulic Circuit.................................................................................1576 Caution for Installation..........................................................................1577 Quick Coupler Operation...............................................................................1578 To Engage Attachment..............................................................................1578 To Release Attachment.............................................................................1581 Installation Procedure................................................................................1584 Main Piping - Quick Coupler.......................................................................1584 Electric Parts - Quick Coupler....................................................................1585 Boom Piping - Quick Coupler.......................................................................1586 Arm Piping - Quick Coupler........................................................................1588 After Installation Precautions....................................................................1589 Air Bleeding......................................................................................1589 Completing Work.......................................................................................1589 Schematic.....................................................................................................1591 Hydraulic Schematic / Electrical Schematic................................................................1593 Blank Page........................................................................................................1596 Blank Page........................................................................................................1598
DOOSAN DX490LC-5 DX530LC-5 EXCAVATOR SHOP MANUAL 950106-01005E-1 – PDF DOWNLOAD:
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