Doosan DX180LC, Shop Manual

Page 1: ...Shop Manual K1015439E Serial Number 5001 and Up DX225LC ...

Page 2: ...Product Label Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine DX225LC Serial Number 5001 and Up Pub No K1015439E Pub No K1015439E ...

Page 3: ...nce Procedures SP000016 Standard Torques SP000017 Upper Structure Cabin SP000943 Counterweight SP000940 Fuel Tank SP001005 Fuel Transfer Pump SP000021 Swing Bearing SP000022 Swing Reduction Gear SP000915 Lower Structure and Chassis Track Assembly SP000911 Engine and Drivetrain Air Conditioner SP000025 Drive Coupling Main Pump SP000912 Hydraulics Hydraulic System Troubleshooting Testing and Adjustm...

Page 4: ...iston Pump SP000932 PTO Server SP000933 Remote Control Valve Work Lever Joystick SP000069 Travel Control Valve with Damper SP000070 Solenoid Valve Assembly SP000445 Breaker EPPR Valve Opt SP000192 Hydraulic Schematic DX225LC SP000934 Electrical System Electrical System SP000935 Electrical Schematic DX180LC DX225LC DX225NLC DX255LC SP000936 Attachments Boom and Arm SP000937 Bucket SP000939 ...

Page 5: ...1Safety ...

Page 6: ...SP000014 Page 1 Track Excavator Safety SP000014 TRACK EXCAVATOR SAFETYSP000014 Track Excavator Safety Edition 1 ...

Page 7: ...Track Excavator Safety SP000014 Page 2 MEMO ...

Page 8: ...of a DOOSAN Excavator 6 General Safety Essentials 10 Location of Safety Labels 11 Summary of Safety Precautions for Lifting in Digging Mode 12 Unauthorized Modifications 13 General Hazard Information 13 Before Starting Engine 22 Machine Operation 26 Maintenance 33 Battery 42 Towing 44 Shipping and Transportation 45 Lifting With Sling 45 ...

Page 9: ...f this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling the load Remember that ultimately safety is your own responsibility MODEL SERIAL NUMBER RANGE DX180LC 5001 and Up DX225LC 5001 and Up DX225NLC 5001 and Up DX255LC 5001 and Up DX300LC 5001 and Up DX340LC 5001 and Up DX420LC ...

Page 10: ... page 1 12 4 Unauthorized Modifications on page 1 13 5 General Hazard Information on page 1 13 6 Before Starting Engine on page 1 22 7 Machine Operation on page 1 26 8 Maintenance on page 1 33 9 Battery on page 1 42 10 Towing on page 1 44 11 Shipping and Transportation on page 1 45 12 Lifting With Sling on page 1 45 DANGER Unsafe use of the excavator could lead to serious injury or death Operating...

Page 11: ...cautions given in this manual apply only to intended uses of the machine If you use your machine for any unintended uses that are not specifically prohibited you must be sure that it is safe for others In no event should you or others engage in prohibited uses or actions as described in this manual DOOSAN delivers machines that comply with all applicable regulations and standards of the country to...

Page 12: ...al injury or accidents Always observe safety precautions and follow recommended procedures CAUTION This word is used on safety messages and safety labels and indicates potential threat of a hazardous situation that if not avoided could result in minor or moderate injury It may also be used to alert against a generally unsafe practice WARNING This word is used on safety messages and safety labels a...

Page 13: ...ance Therefore the safety messages in this manual and on the machine may not include all possible safety precautions If any procedures or actions not specifically recommended or allowed in this manual are used you must be sure that you and others can do such procedures and actions safely and without damaging the machine If you are unsure about the safety of any procedures contact a DOOSAN distribu...

Page 14: ...pacity ratings that are printed at the end of this safety section are based on the machine being level on a firm supporting surface with hooks and slings attached in approved configuration Loads must be balanced and supported evenly Use tag lines to keep the load steady if wind conditions and large surface area are a problem Work crew hand signals individual tasks and safe procedures should all be...

Page 15: ...age 11 SP000014 LOCATION OF SAFETY LABELS Location of safety labels decals can vary from unit to unit Refer to appropriate Operation and Maintenance Manual and parts manual for your unit Always replace damaged or faded decals ...

Page 16: ...ifting work DANGER Unsafe use of the excavator while making rated lifts could cause serious potentially fatal injuries or extensive damage to the machine or nearby property Do not let anyone operate the machine unless they ve been properly trained and understand the information in the Operation and Maintenance Manual WARNING NEVER wrap a tag line around your hands or body NEVER rely on tag lines o...

Page 17: ... feeling well if you are taking medication that makes you feel sleepy if you have been drinking or if you are suffering from emotional problems These problems will interfere with your sense of judgment in emergencies and may cause accidents When working with another operator or with a person on work site traffic duty be sure that all personnel know the nature of the work and understand all hand si...

Page 18: ... ensure safety do not use the radio or music headphones when operating the machine There is a danger that this may lead to a serious accident When operating the machine do not put your hands or head out of the window When standing up from the operator s seat always place safety lock lever securely in the LOCK position If you accidentally touch the work equipment levers when they are not locked the...

Page 19: ...el Information Hands Arms The weighted root mean square acceleration to which the hands arms are subjected is less than 2 5 m s2 Whole body The weighted root mean square acceleration to which the whole body is subjected is less than 0 5 m s2 Measurements are obtained on a representative machine using measuring procedures as described in the following standard ISO 2631 1 ISO 5349 and SAE J1166 Reco...

Page 20: ...grease or mud on the handrails steps or track shoes wipe it off immediately Always keep these parts clean Repair any damage and tighten any loose bolts Never jump on or off the machine In particular never get on or off a moving machine These actions may lead to serious injury When getting on or off the machine always face the machine and maintain three point contact both feet and one hand or one f...

Page 21: ... of the fuel nozzle in constant contact with the neck of the fuel filling nozzle to provide a ground Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secured Precautions When Handling Fluids at High Temperature Immediately after operations are stopped the coolant engine oil and hydraulic oil are at highest temperatures and the radiator and hydraulic t...

Page 22: ...trol levers are operated the clearance between the machine and the work equipment will change and this may lead to serious damage or personal injury If going between movable parts is necessary always position and secure the work equipment so it cannot move Fire Extinguisher and First Aid Kit As a precaution if any injury or fire should occur always do the following Be sure that fire extinguishers ...

Page 23: ...Protective Structure FOPS or window guards Never attempt to alter or modify any protective structure reinforcement system by drilling holes welding remounting or relocating fasteners Any serious impact or damage to the system requires a complete integrity reevaluation Reinstallation recertification and or replacement of the system may be necessary Contact your DOOSAN distributor for available safe...

Page 24: ...bed in Handling of Accumulator in the Operation and Maintenance Manual The accumulator is charged with high pressure nitrogen gas so it is extremely dangerous if it is handled in the wrong way Always observe the following precautions Do not drill or make any holes in the accumulator or expose it to any flames fire or heat source Do not weld on the accumulator or try attaching anything to it When c...

Page 25: ...d the operator seat in the upper right corner of the cabin This tool can be used in case of an emergency situation that requires the breaking of glass to exit from the operator s cabin Grip the handle firmly and use the sharp point to break the glass FG000178 Figure 12 WARNING Protect your eyes when breaking the glass ...

Page 26: ...rk site Contact each utility and identify their locations Be careful not to damage or cut any of these lines Check the condition of the riverbed and the depth and flow of the water before operating in water or crossing a river NEVER work in water that is more than the permissible water depth Any object in vicinity of boom could represent a potential hazard or cause the operator to react suddenly a...

Page 27: ...per and other flammable materials accumulated in the engine compartment and around the battery They could cause a fire Remove any dirt from the window glass mirrors handrails and steps Do not leave tools or spare parts laying around in the operator s cabin The vibration of the machine when traveling or during operations may cause them to fall and damage or break the control levers or switches They...

Page 28: ...ain alert for other potentially hazardous conditions at the start of the work cycle Do not short circuit the starting motor to start the engine This is not only dangerous but may also damage the machine When starting the engine sound the horn as an alert Start and operate the machine only while seated Before Operating Machine If checks are not carried out properly after starting the engine it may ...

Page 29: ...chine Make sure that the horn the travel alarm if equipped and all other warning devices are working properly Fasten the seat belt securely Warm up the engine and hydraulic oil before operating machine Before moving the machine check undercarriage position The normal travel position is with idler wheels to the front under the cabin and the drive sprockets to the rear When the undercarriage is in t...

Page 30: ...re changing travel direction Sound the horn to warn people in the area Check that there is no one in the area around the machine There are blind spots behind the machine so if necessary swing the upper structure to check that there is no one behind the machine before traveling in reverse When operating in areas that may be hazardous or have poor visibility designate a person to direct work site tr...

Page 31: ...obstacle that causes the machine to tilt 10 or more to the right or left or 30 or more from front to rear Do not operate the steering suddenly The work equipment may hit the ground and cause the machine to lose its balance and this may damage the machine or structures in the area When traveling on rough ground travel at low speed and avoid sudden changes in direction Always keep to the permissible...

Page 32: ...ass fallen leaves or wet steel plates Even slight slopes may cause the machine to slip to the side so travel at low speed and make sure that the machine is always traveling directly up or down the slope Avoid changing travel direction on a slope This could result in tipping or sideslipping of the machine When possible operate the machine up slopes and downslopes Avoid operating the machine across ...

Page 33: ...k site beforehand to prevent the machine from falling and to prevent the ground stockpiles or banks from collapsing Precautions for Operation Be careful not to mistakenly travel too close to the edge of a cliff Use the machine only for its main purpose Using it for other purposes will cause failures To ensure a good view always do the following When working in dark areas attach working lights and ...

Page 34: ... 6 m 13 20 ft from the power line Very high voltage and rainy weather could further decrease that safety margin NOTE Before starting any operation near power lines either above ground or buried cable type you should always contact the power utility company directly and work out a safety plan with them Protecting Cabin from Falling Object Optional In a work site where falling objects or flying obje...

Page 35: ... working capacity The jolting shocks and impact loads caused by bumping or bottoming the boom or attachment are more likely to cause severe stress in very cold temperatures Reducing work cycle rate and workload may be necessary When the temperature rises frozen road surfaces become soft and machine travel becomes unstable In cold weather do not touch metal surfaces with your bare hands If you touc...

Page 36: ...oads provide fences signs flags or lights and put up any other necessary signs to ensure that passing traffic can see the machine clearly Park the machine so the machine flags and fences do not obstruct traffic After the front attachment has been lowered to an overnight storage position and all switches and operating controls are in the OFF position the safety lock lever must be set to the LOCKED ...

Page 37: ...nger that you may get dirt or mud in your eyes or that you may slip and injure yourself When washing the machine do the following Wear shoes with nonslip soles to prevent yourself from slipping and falling on wet places Wear safety glasses and protective clothing when washing the machine with high pressure steam Take action to prevent touching high pressure water and cutting your skin or having mu...

Page 38: ...vention All fuels most lubricants and some coolant mixtures are flammable Leaking fuel or fuel that is spilled onto hot surfaces or onto electrical components can cause a fire Store all fuels and all lubricants in properly marked containers and away from all unauthorized persons Store oily rags and other flammable material in a protective container Do not smoke while you refuel the machine or whil...

Page 39: ... alkali to contact the skin the eyes or the mouth Allow cooling system components to cool before you drain the cooling system Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Remove hydraulic tank filter plug only after the engine has been stopped Make sure that the hydraulic tank filter plug is cool before you remove it with your bare...

Page 40: ...atching fire To avoid this never subject these places to heat Do not weld on pipes or on tubes that contain flammable fluids Do not flame cut on pipes or on tubes that contain flammable fluids Before you weld on pipes or on tubes or before you flame cut on pipes or on tubes clean the pipes or tubes thoroughly with a nonflammable solvent If heat is applied directly to rubber hoses or piping under p...

Page 41: ...ect the battery terminal cables 8 Reassemble the undercover under the engine 9 Reassemble the cover over the battery 10 Close the cover of the battery Warning for Counterweight and Front Attachment Removal Figure 35 FG000312 Figure 36 FG00335 1 FG000371 Figure 37 DANGER DOOSAN warns any user that the removal of the counterweight from the machine front attachment or any other part may affect the st...

Page 42: ...point contact both feet and one hand or both hands and one foot to support yourself securely If the job requires it wear protective clothing To prevent injury from slipping or falling when working on the hood or covers never use any area except the area equipped with nonslip pads Lock Inspection Covers When carrying out maintenance with the inspection cover open lock the cover securely in position...

Page 43: ...semble the track adjuster or attempt to remove track tension grease valve assembly Keep your face and body away from the valve Refer to the track adjustment procedure in the Operator and Maintenance Manual or Shop Manual Supports and Blocking for Work Equipment Do not allow weight or equipment loads to remain suspended Lower everything to the ground before leaving the operator s seat Do not use ho...

Page 44: ...pose your fingers Do not bend high pressure lines Do not strike high pressure lines Do not install lines tubes or hoses that are bent or damaged Make sure that all clamps guards and heat shields are installed correctly to prevent vibration rubbing against other parts and excessive heat during operation If any of the following conditions are found replace the part Damage or leakage from hose end We...

Page 45: ...ntaminant and may only be disposed of at approved collection facilities To prevent pollution of the environment always do the following Never dump waste oil in a sewer system rivers etc Always put oil drained from your machine in containers Never drain oil directly onto the ground Obey appropriate laws and regulations when disposing of harmful materials such as oil fuel solvent filters and batteri...

Page 46: ...tities of water and see a doctor at once If you accidentally drink battery electrolyte drink a large quantity of water or milk raw egg or vegetable oil Call a doctor or poison prevention center immediately When cleaning the top surface of the battery wipe it with a clean damp cloth Never use gasoline thinner or any other organic solvent or detergent Tighten the battery caps securely If the battery...

Page 47: ...two series connected twelve volt batteries have a cable connecting one positive terminal on one of the 12 volt batteries to a negative terminal on the other battery Booster or charger cable connections must be made between the nonseries connected positive terminals and between the negative terminal of the booster battery and the metal frame of the machine being boosted or charged Refer to the proc...

Page 48: ...left and right hooks and secure in position If the engine on the problem machine will not start or there is a failure in the brake system always contact your DOOSAN distributor Never go between the towing machine and the towed machine during the towing operation It is dangerous to carry out towing on slopes so select a place where the slope is gradual If there is no place where the slope is gradua...

Page 49: ...formation on partial disassembly Refer to the Transportation and Shipping section of this Operation and Maintenance Manual for information on loading unloading and towing LIFTING WITH SLING 1 Refer to Specification section of Operation and Maintenance Manual for information on weight and dimensions 2 Use properly rated cables and slings for lifting 3 Position machine for a level lift 4 Lifting cab...

Page 50: ...1Specifications ...

Page 51: ...Specification for DX225LC Page 1 SP000908 C o u n t e r w e i g h t s SP000908 SPECIFICATION FOR DX225LCSP000908 Specification for DX225LC Edition 1 ...

Page 52: ...General Dimensions 11 Working Range 12 General Specifications 14 Engine Performance Curves Per DIN 6270 Standard 16 Approximate Weight of Workload Materials 18 Performance Tests 20 Excavator Performance Standards 21 Test Conditions 21 Travel Speed and Travel Motor Balance Steering Deviation Tests 21 Swing Speed and Deceleration Force Test 23 Cylinder Performance Tests 25 ...

Page 53: ... Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling the load Remember that ultimately safety is your own responsibility MODEL SERIAL NUMBER RANGE DX225LC 5001 and Up ...

Page 54: ...ESCRIPTION The excavator has three main component sections The Upper Swing Body The Lower Undercarriage and Track Frames The Excavator Front end Attachment The following illustration identifies main components and their locations See Figure 1 on page 8 ...

Page 55: ...Specification for DX225LC SP000908 Page 8 COMPONENT LOCATIONS 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 38 37 36 35 34 33 32 31 30 29 28 27 19 25 26 24 23 22 21 20 FG007028 Figure 1 ...

Page 56: ...leaner 12 Swing Bearing 13 Cabin 14 Seat 15 Boom Cylinder 16 Work Lever Joystick Controls 17 Arm Cylinder 18 Boom 19 Travel Lever 20 Arm 21 Bucket Cylinder 22 Guide Link 23 Bucket 24 Push Link 25 Tooth Point 26 Side Cutter 27 Idler 28 Track Adjuster 29 Track Guide 30 Battery 31 Lower Roller 32 Center Joint 33 Upper Roller 34 Travel Motor 35 Track Link and Shoe 36 Suction Filter 37 Return Filter 38...

Page 57: ... ARM 3 5 M 11 5 ft ARM A 9 080 mm 29 9 8 990 mm 29 6 9 500 mm 31 2 9 485 mm 31 1 9 500 mm 31 2 B 2 750 mm 9 0 C 6 330 mm 20 9 6 240 mm 20 6 6 750 mm 22 2 6 735 mm 22 1 6 750 mm 22 2 D 3 650 mm 11 12 E 4 445 mm 14 7 F 1 055 mm 3 6 G 3 210 mm 10 6 3 050 mm 10 0 3 110 mm 10 2 3 005 mm 9 10 3 290 mm 10 10 H 2 710 mm 8 11 I 1 400 mm 4 7 J 1 310 mm 4 4 K 2 390 mm 7 10 L 2 990 mm 9 10 M 600 mm 1 12 N 480...

Page 58: ...e stability and support provided by ground conditions Digging too far underneath the excavator if soil conditions are wet loose or unstable can collapse ground support which could cause injury and or equipment damage 0 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 C D F A E I L B H G G L 0 1 2 4 3 5 6 7 8 9 10 11 FG007029 Figure 3 ...

Page 59: ... 6 990 mm 22 11 7 150 mm 23 5 6 085 mm 19 12 6 300 mm 20 8 E Min Swing Radius 3 675 mm 12 1 3 410 mm 11 2 3 410 mm 11 2 3 440 mm 11 3 3 370 mm 11 1 3 195 mm 10 6 F Max Digging Height 9 395 mm 30 10 9 630 mm 31 7 9 750 mm 31 12 9 870 mm 32 5 8 845 mm 29 0 9 065 mm 29 9 G Max Bucket Pin Height 8 080 mm 26 6 8 300 mm 27 3 8 455 mm 27 9 8 610 mm 28 3 7 555 mm 24 9 7 770 mm 25 6 H Max Vertical Wall 4 9...

Page 60: ...eight and Front Lower 7 730 kg 17 041 lb Including Swing Bearing Digging Forces At Power Boost Bucket Cylinder 13 300 kg 29 321 lb with either 3 500 mm 11 6 or 2 400 mm 7 10 arm Arm Cylinder 10 500 kg 23 149 lb with 2 900 mm 9 6 arm Fuel Tank Capacity 400 liters 105 7 U S gal Hydraulic System Capacity 240 liters 63 4 U S gal Hydraulic Reservoir Capacity 140 liters 37 U S gal Bucket Heaped Capacity...

Page 61: ...0 Overall Shipping Height to top of cylinder hose 3 005 mm 9 10 Track Shipping Length 4 445 mm 14 7 Transport Trailer Capacity 30 metric tons 33 tons minimum load capacity Transport Loading Ramp Allowable Slope 15 angle CAUTION Refer to Transport Maximum Procedure for Safe Shipping Instructions ...

Page 62: ...tion for DX225LC SP000908 Page 16 ENGINE PERFORMANCE CURVES PER DIN 6270 STANDARD FG007031 POWER OUTPUT ps TORQUE kg m FUEL CONSUMPTION g ps h REVOLUTION rpm 1000 100 2000 1500 160 60 150 50 150 70 140 Figure 4 ...

Page 63: ...ic Pressure 760 mmHg 20 C 68 F Cooling Fan 660 4 mm SUCKER 26 in Alternator 24V x 50A Air Cleaner Installed Muffler Installed Performance Standard DIN 6270 Power 150 ps 1 900 rpm 148 hp 1 900 rpm Max Torque 68 kg m 1 400 rpm 492 lb ft 1 400 rpm Fuel Consumption Min Rated 165 g ps h 5 47 oz hp h ...

Page 64: ...ity 1 600 kg m3 2 700 lb yd3 or Less High Weight or Density 2 000 kg m3 3 370 lb yd3 or Less Charcoal 401 kg m3 695 lb yd3 Coke blast furnace size 433 kg m3 729 lb yd3 Coke foundry size 449 kg m3 756 lb yd3 Coal bituminous slack piled 801 kg m3 1 350 lb yd3 Coal bituminous r of m piled 881 kg m3 1 485 lb yd3 Coal anthracite 897 kg m3 1 512 lb yd3 Clay DRY in broken lumps 1 009 kg m3 1 701 lb yd3 C...

Page 65: ...ed 1 1 2 or 2 1 362 kg m3 2 295 lb yd3 Limestone crushed 1 522 kg m3 2 565 lb yd3 Limestone fine 1 602 kg m3 2 705 lb yd3 Phosphate rock 1 282 kg m3 2 160 lb yd3 Salt 929 kg m3 1 566 lb yd3 Snow light density 529 kg m3 891 lb yd3 Sand DRY loose 1 522 kg m3 2 565 lb yd3 Sand WET packed 1 922 kg m3 3 240 lb yd3 Shale broken 1 362 kg m3 2 295 lb yd3 Sulfur broken 529 kg m3 1 620 lb yd3 Material Low W...

Page 66: ... Up sec 3 3 0 4 2 9 0 4 Down sec 2 6 0 3 2 5 0 3 Arm Crowd sec 4 1 0 4 3 8 0 4 Dump sec 2 6 0 3 2 4 0 3 Bucket Crowd sec 3 8 0 4 3 5 0 4 Dump sec 2 3 0 3 2 2 0 3 Swing 3 Revolutions sec 17 5 1 5 16 5 1 5 Jack up Speed 3 Turns Low sec 34 5 2 0 33 1 2 0 High sec 18 9 1 5 18 0 1 5 Travel Speed 20 m 66 ft Low sec 25 1 5 24 1 5 High sec 13 7 1 0 13 1 1 0 Travel Deviation 20 m 66 ft Low mm in 150 6 150 ...

Page 67: ...le maintenance and adjustment service should be completed before testing 3 Hydraulic fluid and engine oil should be of appropriate viscosity for ambient weather Warm up hydraulic oil to standard operating temperature between 45 55 C 112 135 F 4 Run all tests with the engine speed control set to maximum rpm 5 Repeat tests with Power Mode engine control settings at both Standard Mode standard work m...

Page 68: ...es are parallel with the test course Operate both travel levers at the fully engaged position and measure the time it takes to cross 20 m 65 7 1 2 Compare measured results against the standard for new machines Rotate the turntable 180 Both tests should be repeated three times Average all results to obtain a final value 0 3 M 0 5 M 1 2 FG007032 Figure 5 Rate of Travel Time Standard Mode Power Mode ...

Page 69: ...tion is allowed with the travel control set for high speed Swing Speed and Deceleration Force Test Swing Speed Test Extend the bucket cylinder completely and retract the arm cylinder as shown in Figure 7 to test swing speed The lowest point of the bucket will be approximately 1 5 m 3 off the ground Use paint marks at the same point on the swing body and undercarriage or select alternate measuring ...

Page 70: ...le and undercarriage with paint at the 90 point Make several attempts to rotate the turntable exactly 90 starting from the boom straight ahead position Engage the swing lever and brake at the 90 point shown as swing stop in Figure 8 Record how far the turntable drifts past the stop point measuring the distance between paint marks Maximum distance should be less than 1200 mm 47 1 4 in both Power Mo...

Page 71: ...d the teeth of the bucket hanging vertically 500 mm 1 1 2 2 above the ground Dump and crowd the bucket several times and average results for both standard and extraduty power modes Hydraulic Cylinder Natural Drop Test To check boom and arm cylinder tightness against the specified performance standard for new cylinders put a full load of dirt in the bucket and move the attachment cylinders so the a...

Page 72: ... corresponding mark on the travel frame Use the attachment to jack up one side of the machine and operate the raised travel motor Record the number of seconds it takes the crawler shoe to make 3 full rotations during both high speed and low speed operation Operation Standard Mode Power Mode High speed 17 4 20 4 sec 16 5 19 5 sec Low Speed 32 5 36 5 sec 31 1 35 1 sec ...

Page 73: ...1General Maintenance ...

Page 74: ...General Maintenance Procedures Page 1 SP000016 SP000016 GENERAL MAINTENANCE PROCEDURES SP000016 General Maintenance Procedures Edition 1 ...

Page 75: ...elding Precautions and Guidelines 6 Hydraulic System General Precautions 7 Maintenance Service and Repair Procedure 9 General Precautions 9 Hydraulic System Cleanliness and Oil Leaks 10 Maintenance Precautions for Hydraulic System Service 10 Oil Leakage Precautions 11 Cleaning and Inspection 12 General Guidelines 12 Bearing Inspection 13 ...

Page 76: ...N Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling the load Remember that ultimately safety is your own responsibility MODEL SERIAL NUMBER RANGE ALL MODELS ALL RANGES ...

Page 77: ...ese types of steel are performed with the proper procedures and equipment If repairs are performed incorrectly structural weakening or other damage to the machine that is not always readily visible could be caused Always consult DOOSAN After Sales Service Distributor before welding on integral components loader arm frames car body track frames turntable attachment etc of the machine It is possible...

Page 78: ... precautions 1 Use extra caution and adequate safety shielding when welding near fuel and oil tanks batteries hydraulic piping lines or other fire hazards 2 Never weld when the engine is running Battery cables must be disconnected before the welding procedure is started 3 Never weld on a wet or damp surface The presence of moisture causes hydrogen embrittlement and structural weakening of the weld...

Page 79: ...ation of air in the system and many other types of problems As a general precaution and to help lessen the risk of potential long term damage allow the engine to run at no load idle speed immediately after initial start up Hydraulic fluid will circulate releasing any air that may have been trapped in the system before load demands are imposed A daily walk around prestart equipment safety inspectio...

Page 80: ...he hydraulic circuit may be imminent or have already occurred Open the drain plugs on the main pump casings and check and compare drain oil in the pumps Look for evidence of grit or metallic particles Vibration or unusual noise during operation could be an indication of air leaking into the circuit Refer to the appropriate Troubleshooting section for component or unit for procedures or it may be e...

Page 81: ...sidue solvent and thoroughly clean exterior surfaces of assemblies before any part of the circuit is opened or disassembled NOTE It s just as important to clean the cap and reservoir top before routine fluid changes or quick checks as it is before major repairs Accumulated dirt attracts moisture oil and other fluids and more dirt Keep dismantled parts covered during disassembly Use clean caps plug...

Page 82: ...full of fine dust are especially hazardous Clogging of valve spools or external piping especially pilot circuit piping can gradually diminish or suddenly put a stop to normal hydraulic function You can prevent having to make these types of repairs by following recommended assembly procedures 1 Use new O rings and oil seals whenever hydraulic assemblies are rebuilt 2 Prepare joint surfaces before a...

Page 83: ...not lubricated DO NOT SPIN BEARINGS WHEN DRYING bearings may be rotated slowly by hand to facilitate drying process 3 Carefully inspect all bearing rollers cages and cups for wear chipping or nicks to determine condition Do not replace a bearing cone or cup individually without replacing mating cup or cone at the same time After inspection dip bearings in lightweight oil and wrap in clean lintless...

Page 84: ...nd dirt Remove any scratches and burrs with crocus cloth Remove foreign material Replace any parts that are deeply grooved or scratched which would affect their operation Bearing Inspection The condition of the bearings are vital to the smooth and efficient operation of the machinery When any component containing bearings is disassembled always carefully examine the condition of the bearings and a...

Page 85: ...as been turning in its housing or on its shaft If available use magna flux or similar process for checking for cracks that are not visible The following illustrations will aid in identifying and diagnosing some of the bearing related problems NOTE The illustrations will only show tapered roller bearings but the principles of identifying diagnosing and remedying the defects are common to all styles...

Page 86: ...erheating lubricant failure or overload Replace bearing check seals and check for proper lubrication Abrasive Step Wear Pattern on roller ends caused by fine abrasives Clean all parts and housings check all parts and housings check seals and bearings and replace if leaking rough or noisy Figure 4 Figure 5 Figure 6 ...

Page 87: ...s check seals and check for proper lubrication Misalignment Outer race misalignment because of foreign object Clean related parts and replace bearing Make sure races are properly seated Indentations Surface depressions on race and rollers caused by hard particles of foreign materials Clean all parts and housings check seals and replace bearings if rough or noisy Figure 7 Figure 8 Figure 9 ...

Page 88: ...s Brinelling Surface indentations in raceway caused by rollers either under impact loading or vibration while the bearing is not rotating Replace bearing if rough or noisy Cage Wear Wear around outside diameter of cage and roller pockets caused by abrasive material and inefficient lubrication Replace bearings check seals Figure 10 Figure 11 Figure 12 ...

Page 89: ...Cracked Inner Race Race cracked because of improper fit cocking or poor bearing seat Replace all parts and housings check seals and bearings and replace if leaking Smears Smearing of metal because of slippage caused by poor fitting lubrication overheating overloads or handling damage Replace bearings clean related parts and check for proper fit and lubrication Replace shaft if damaged Figure 13 Fi...

Page 90: ...r loss of temper on races or rollers a simple file test may be made A file drawn over a tempered part will grab and cut metal whereas a file drawn over a hard part will glide readily with no metal cutting Replace bearing if overheating damage is indicated Check seals and other related parts for damage Stain Discoloration Discoloration can range from light brown to black caused by incorrect lubrica...

Page 91: ...SP000017 Page 1 Standard Torques SP000017 STANDARD TORQUESSP000017 Standard Torques Edition 1 ...

Page 92: ...or Standard Metric Fasteners 6 Torque Values for Standard U S Fasteners 7 Type 8 Phosphate Coated Hardware 9 Torque Values for Hose Clamps 10 Torque Values for Split Flanges 11 Torque Wrench Extension Tools 12 Torque Multiplication 12 Other Uses for Torque Wrench Extension Tools 13 Tightening Torque Specifications Metric 13 ...

Page 93: ...w all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling the load Remember that ultimately safety is your own responsibility MODEL SERIAL NUMBER RANGE ALL MODELS ALL RANGES ...

Page 94: ... 12 00 86 79 17 00 122 96 20 00 144 66 M14 x 1 5 4 10 29 65 4 30 31 10 6 60 47 73 5 70 41 22 8 30 60 03 7 50 54 24 11 10 80 28 12 50 90 41 13 00 94 02 18 50 133 81 22 00 159 12 M16 x Std 5 60 40 50 6 00 43 39 9 00 65 09 8 00 57 86 11 50 83 17 10 50 75 94 15 50 112 11 17 90 129 47 18 50 133 81 26 00 188 05 31 00 224 22 M16 x 1 5 6 20 44 84 6 50 47 01 9 70 70 16 8 60 62 20 12 50 90 41 11 30 81 73 17...

Page 95: ...sed 0 70 When Molykote white lead or similar mixtures are used as lubricants 0 75 When Parkerized bolts or nuts are used 0 85 When cadmium plated bolts or nuts and zinc bolts w waxed zinc nuts are used 0 90 When hardened surfaces are used under the nut or bolt head NOTE When reusing bolts and nuts in service use minimum torque values Type S A E Grade Description Bolt Head Marking 1 1 OR 2 WILL HAV...

Page 96: ...s ft lb Newton Meter Nm Foot pounds ft lb Newton Meter Nm 1 4 20 6 8 9 12 1 4 28 7 9 11 15 5 16 18 13 18 18 24 5 16 24 15 20 21 28 3 8 16 24 33 34 46 3 8 24 27 37 38 52 7 16 14 38 52 54 73 7 16 20 42 57 60 81 1 2 13 58 79 82 111 1 2 20 65 88 90 122 9 16 12 84 114 120 163 9 16 18 93 126 132 179 5 8 11 115 156 165 224 5 8 18 130 176 185 251 3 4 10 205 278 290 393 3 4 16 240 312 320 434 7 8 9 305 414...

Page 97: ...ues shown below also apply to the following 1 Phosphate coated bolts used in tapped holes in steel or gray iron 2 Phosphate coated bolts used with phosphate coated prevailing torque nuts nuts with distorted threads or plastic inserts 3 Phosphate coated bolts used with copper plated weld nuts Markings on bolt heads or nuts indicate material grade ONLY and are NOT to be used to determine required to...

Page 98: ... boots hydraulic system etc Clamp Type And Size Torque Radiator Air Cleaner Boots Etc Hydraulic System Kilogram meter kg m Inch Pounds in lb Kilogram meter kg m Inch Pounds in lb T Bolt Any Diameter 0 68 0 72 59 63 Worm Drive Under 44 mm 1 3 4 in Open Diameter 0 2 0 3 20 30 0 5 0 6 40 50 Worm Drive Over 44 mm 1 3 4 in Open Diameter 0 5 0 6 40 50 Worm Drive All Ultra Tite 0 6 0 7 50 60 0 5 0 6 40 5...

Page 99: ...g bolts will damage the flanges and or bolts which may cause leakage Inside diameter of flange on end of hydraulic tube or hose fitting NOTE Values stated in chart are for Standard Pressure Series Code 61 Split Flanges Flange Size Bolt Size Bolt Torque Kilogram meter kg m Foot pounds ft lb 1 2 5 16 2 1 2 5 15 18 3 4 3 8 3 0 3 7 22 27 1 3 8 3 7 4 8 27 35 1 1 4 7 16 4 8 6 2 35 45 1 1 2 1 2 6 4 8 0 4...

Page 100: ...or situations if the right extension tool is used or fabricated Torque Multiplication A wrench extension tool can be used to increase the tightening force on a high capacity nut or bolt For example doubling the distance between the bolt and the back handle end of the torque wrench doubles the tightening force on the bolt It also halves the indicated reading on the scale or dial of the torque wrenc...

Page 101: ...tension can be used to measure adjustment tightness of a linkage or assembly Specially fabricated extensions can be used to make very precise checks of the force required to engage or disengage a clutch mechanism release a spring applied brake assembly or take up free play in most any movable linkage Once the value of the adjustment force is established repeated checks at regular intervals can hel...

Page 102: ...e as a general guide in selecting specific formulas that will meet the particular requirements of individual assembly installations DOOSAN does not specifically endorse a specific manufacturer or brand name but the following table of Loctite applications is included for which cross references to other makers products should also be widely available IMPORTANT Use primer T or N for all cold weather ...

Page 103: ...C 500 F Remove HOT 210 Product Application Color Removal Required Setup 545 No filler nonclog formula for high pressure hydraulic systems Over application will not restrict or foul system components Purple Hand tools 4 Hours or 1 2 hour with Locquic T Primer 656 Solvent resistant higher viscosity tapered thread sealer White Hand tools 4 Hours or 1 2 hour with Locquic T Primer Product Application C...

Page 104: ... cold temperature applications 620 For high temperatures to 232 C 450 F Green Same as 609 above 680 For high strength bonds and tight clearance gaps to 0 00008 mm 0 002 Green Same as 609 above Product Application Color Notes 380 Black Max instant adhesive for shock and vibration resistant bonds Black May take 120 hours to reach full cure strength 454 Adhesive for porous surfaces Clear Full strengt...

Page 105: ...1Upper Structure ...

Page 106: ...Cabin Page 1 SP000943 SP000943 CABIN SP000943 Cabin Edition 1 ...

Page 107: ...Cabin Page 3 SP000943 Table of Contents Cabin Safety Precautions 5 Applicable Models 5 Removal 7 Installation 11 ...

Page 108: ...ose contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling the load Remember that ultimately safety is your own responsibility MODEL SERIAL NUMBER RANGE DX180LC 5001 and Up DX225LC 5001 and Up DX225NLC 5001 and Up DX255LC 5001 and Up DX300LC 5001 and Up DX300LL 5001 and Up DX340LC 5001 and Up DX420LC...

Page 109: ...r A Cabin interior lighting B External light wiring C Radio antenna and connections D Wiper washer connections NOTE Control console wiring harnesses and hydraulic piping lines that pass through the floor of the cabin do not need to be disassembled NOTE If unit is equipped with a cabin protective structure for forestry or hazardous working conditions it must be removed CAUTION Avoid disassembling c...

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