Doosan DX180LC Shop Manual
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Doosan DX180LC Shop Manual

Serial number 5001 and up
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DX225LC
Shop Manual
K1015439E
Serial Number 5001 and Up

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Summary of Contents for Doosan DX180LC

  • Page 1 DX225LC Shop Manual K1015439E Serial Number 5001 and Up...
  • Page 2 Product Label Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine Pub. No. K1015439E...

  • Page 3: Specifications

    Table of Contents Publication Request for Proposed Revision Safety Track Excavator Safety................. SP000014 Specifications Specification for DX225LC..............SP000908 General Maintenance General Maintenance Procedures ............SP000016 Standard Torques ................. SP000017 Upper Structure Cabin ....................SP000943 Counterweight..................SP000940 Fuel Tank....................SP001005 Fuel Transfer Pump ................SP000021 Swing Bearing..................
  • Page 4 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 Table of Contents Page 2...
  • Page 5 Safety...

  • Page 6: Track Excavator Safety

    SP000014 TRACK EXCAVATOR SAFETYSP000014 Track Excavator Safety Edition 1 Track Excavator Safety SP000014 Page 1...
  • Page 7 MEMO Track Excavator Safety SP000014 Page 2...

  • Page 8: Table Of Contents

    Table of Contents Track Excavator Safety Safety Precautions..........5 Applicable Models..........5 To the Operator 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 ........

  • Page 9: Safety Precautions

    Remember, that ultimately safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX180LC 5001 and Up DX225LC 5001 and Up DX225NLC 5001 and Up...

  • Page 10: To The Operator Of A Doosan Excavator

    TO THE OPERATOR OF A DOOSAN EXCAVATOR DANGER! Unsafe use of the excavator could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.

  • Page 11: Specifications

    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 which it has been sent. If this machine has been purchased in another...
  • Page 12 SAFETY ALERT SYMBOL Be Prepared - Get to Know All Operating and Safety Instructions This is the Safety Alert Symbol. Wherever it appears in this manual or on safety signs on the machine you must be alert to the potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures.
  • Page 13 Safety precautions are described in SAFETY from page -11 on. DOOSAN cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or...
  • Page 14 The excavator has been primarily designed for moving earth with a bucket. For use as a grapple or for other object handling, contact DOOSAN for proper installation and application. Lifting-work applications (unless restricted or prohibited by local regulations) are permitted in approved lift configuration, to rated capacity only, with no side-loading.

  • Page 15: Location Of Safety Labels

    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. Track Excavator Safety SP000014 Page 11...

  • Page 16: Summary Of Safety Precautions For Lifting In Digging Mode

    If you need more information or have any questions or concerns about safe operating procedures or working the excavator correctly in a particular application or in the specific conditions your individual operating environment, please consult your local DOOSAN representative. Track Excavator Safety SP000014 Page 12...

  • Page 17: Unauthorized Modifications

    UNAUTHORIZED MODIFICATIONS Any modification made without authorization or written approval from DOOSAN can create a safety hazard, for which the machine owner will be held responsible. For safety's sake, replace all OEM parts with the correct authorized or genuine DOOSAN part. For example, not taking...

  • Page 18: Cabin

    Inside Operator's Cabin When entering the operator's cabin, always remove all mud and oil from the soles of your shoes. If you operate the travel pedal with mud or oil stuck to your shoes, your foot may slip and this may cause a serious accident.
  • Page 19 Recommendations for Limiting Vibrations Select the right machine, equipment and attachments for a particular application. Replace any damaged seat by a genuine DOOSAN part. Keep the seat maintained and adjusted. • Adjust the seat and suspension for the weight and size of the operator.
  • Page 20 Adjust the machine speed and travel path to reduce the vibration level. • Slow down if it is necessary when traveling through rough terrain. • When driving machine, avoid obstacles excessive rough terrain. Keep the machine on terrain where working and traveling conditions are good.
  • Page 21 Fuel, Oil and Hydraulic Fluid Fire Hazards Fuel, oil and antifreeze will catch fire if it is brought close to a flame. Fuel is particularly flammable and can be hazardous. Always strictly observe the following. Add fuel, oil, antifreeze and hydraulic fluid to the machine only in a well ventilated area.
  • Page 22 Asbestos Dust Hazard Prevention Asbestos dust can be HAZARDOUS to your health if it is inhaled. Materials containing asbestos fiber can be present on work site. Breathing air that contains asbestos fiber can ultimately cause serious or fatal lung damage. To prevent lung damage from asbestos fiber, observe following precautions: •...
  • Page 23 Reinstallation, recertification and/or replacement of the system may be necessary. Contact your DOOSAN distributor for available safety guards and/or recommendations to prevent danger of getting hit by objects that could strike the operator's cabin. Make sure that all other work site crew members are kept well away from the excavator and safe from possible hazards.
  • Page 24 Attachment Precautions Option kits are available through your dealer. Contact DOOSAN for information on available one-way (single-acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because DOOSAN cannot anticipate, identify or test all the attachments that owners may wish to install on their machines, please contact DOOSAN for authorization and approval of attachments, and their compatibility with optional kits.

  • Page 25: Emergency Exit

    Emergency Exit This machine is equipped with a glass breaking tool. It is behind 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.

  • Page 26: Before Starting Engine

    BEFORE STARTING ENGINE Work Site Precautions Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. Check the terrain and condition of the ground at the work site, and determine the best and safest method of operation. Make sure the ground surface is as hard and horizontal as possible before carrying out operations.
  • Page 27 Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground collapses, the machine could fall or tip over resulting in serious injury or death. Remember that soil after heavy rain, blasting or after earthquakes, is weakened.
  • Page 28 Engine Starting Walk around your machine before getting in the operator's cabin. Look for evidence of leaking fluid, loose fasteners, misaligned assemblies or any other indications of possible equipment hazard. All equipment covers and machinery safety guards must be in place, to protect against injury while the machine is being operated.
  • Page 29 • Clear all obstacles from the machine's path. Beware of hazards. • Be sure that all windows are clean. Secure the doors and the windows in the open position or in the shut position. • Adjust the rearview mirrors for best visibility close to the machine.

  • Page 30: Machine Operation

    MACHINE OPERATION When Swinging or Changing Direction of Travel Before operating the machine or the work equipment, always observe the following precautions to prevent serious injury or death. • Start and operate the machine only while seated. • When changing travel direction from forward to reverse or from reverse to forward, reduce speed early and stop the machine before changing travel HAOA190L...
  • Page 31 Travel Precautions T R A V E L P O S T U R E Never turn the starting switch to the "O" (OFF) position when traveling. It is dangerous if the engine stops while the machine is traveling. It will be impossible to operate the steering. Attachment control levers should not be operated while traveling.

  • Page 32: Traveling On Slopes

    Traveling on Slopes Never jump onto a machine that is running away to stop it. There is a danger of serious injury. Traveling on slopes could result in the machine tipping over or slipping. On hills, banks or slopes, carry the bucket approximately 20 - 30 cm (8 - 12 in) above the ground.
  • Page 33 Do not carry out deep digging under the front of the machine. The ground under the machine may collapse and cause the machine to fall. Working heavy loads over loose, soft ground or uneven, broken terrain can cause dangerous side load conditions and possible tipover and injury.
  • Page 34 Avoid High-voltage Cables Serious injury or death can result from contact or proximity to high-voltage electrical lines. The bucket does not have to make physical contact with power lines for current to be transmitted. Use a spotter and hand signals to stay away from power lines not clearly visible to the operator.
  • Page 35 In a work site where falling rocks can cause damage and possibly crush personnel, or in a mining operation, be sure to install the falling object protective structure (Figure 25). Be sure to install any other additional protective structures required for work site conditions. When the falling object protective structure is installed, and the front window needs to be cleaned, loosen the bolts marked with an arrow.

  • Page 36: Parking Machine

    Parking Machine Avoid making sudden stops, or parking the machine wherever it happens to be at the end of the workday. Plan so the excavator 1 2 0 will be on firm, level ground away from traffic and away from high walls, cliff edges and any area of potential water accumulation or runoff.

  • Page 37: Maintenance

    DO NOT OPERATE a length of chain or cable to keep the safety lever in the fully when performing inspection lowered, nonactive position. or maintenance Warning tags, for controls are available from DOOSAN 190-00695 distributors. ARO1320L Figure 29 Clean Before Inspection or Maintenance Clean the machine before carrying out inspection and maintenance.

  • Page 38: Specifications

    Proper Tools Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools could cause personal injury. There is potential danger of pieces from chisels with crushed heads, or hammers, may get into your eyes and cause blindness. HDO1037L Figure 31 Use of Lighting...
  • Page 39 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. Burn Prevention When checking the radiator coolant level, shut down engine, let the engine and radiator cool down, then check the coolant recovery tank.
  • Page 40 Welding Repairs CAUTION! When you connect or disconnect connectors between ECU and Engine or connector between ECU and the machine, always disconnect the source power to protect damage of the ECU. If you don't observe this procedure, the ECU would be damaged or the engine would operate abnormally.
  • Page 41 Warning for Counterweight and Front Attachment Removal DANGER! DOOSAN warns any user, that the removal of the counterweight from the machine, front attachment or any other part, may affect the stability of the machine. This could cause unexpected movement, resulting in death or serious injuries.
  • Page 42 Precautions for Removal, Installation and Storage of Attachments Before starting removal and installation of attachments, decide on the team leader. Do not allow anyone except the authorized workers close to the machine or attachment. Place attachments that have been removed from the machine in a safe place so they do not fall.
  • Page 43 In particular, if the machine is used when there are still problems with the brake or work equipment systems, it may lead to serious injury. If necessary depending on the type of failure, please contact your DOOSAN distributor for repairs. Track Excavator Safety SP000014 Page 39...
  • Page 44 Precautions with High-pressure Lines, Tubes and Hoses When inspecting or replacing high-pressure piping or hoses, check to verify that the pressure has been released from the circuit. Failure to release the pressure may lead to serious injury. Always do the following: •...
  • Page 45 Waste Materials Physical contact with used motor oil may pose a health risk. Wipe oil from your hands promptly and wash off any remaining residue. Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities. To prevent pollution of the environment, always do the following: •...

  • Page 46: Battery

    BATTERY Battery Hazard Prevention Battery electrolyte contains diluted sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is highly explosive, and mistakes in handling them can cause serious injury or fire. To prevent problems, always do the following: • Do not smoke or bring any flame near the battery. •...
  • Page 47 Boost Starting or Charging Engine Batteries If any mistake is made in the method of connecting the booster cables, it may cause an explosion or fire. Always do the following: • Turn off all electrical equipment before connecting leads to the battery. This includes electrical switches on the battery charger or boost starting equipment.

  • Page 48: Towing

    Shackle • If the engine on the problem machine will not start or there is a failure in the brake system. always contact your DOOSAN distributor. Towing Wire FG000669 • Never go between the towing machine and the towed Figure 46 machine during the towing operation.

  • Page 49: Shipping And Transportation

    SHIPPING AND TRANSPORTATION Obey State and Local Over-the-Road Regulations Check state and local restrictions regarding weight, width and length of a load before making any other preparation for transport. The hauling vehicle, trailer and load must all be in compliance with local regulations governing the intended shipping route.

  • Page 50: Specifications

    Specifications...
  • Page 51 SP000908 SPECIFICATION FOR DX225LCSP000908 Specification for DX225LC Edition 1 SP000908 Specification for DX225LC Page 1...

  • Page 52: Specifications

    Table of Contents Specification for DX225LC Safety Precautions..........5 Applicable Models..........5 General Description..........7 Component Locations........... 8 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 ..........

  • Page 53: Safety Precautions

    SAFETY PRECAUTIONS CAUTION! 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.

  • Page 54: General Description

    GENERAL DESCRIPTION The excavator has three main component sections: • Swing Body The Upper • 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.) Specification for DX225LC SP000908 Page 7...

  • Page 55: Component Locations

    COMPONENT LOCATIONS FG007028 Figure 1 SP000908 Specification for DX225LC Page 8...

  • Page 56: Swing Bearing

    Reference Reference Description Description Number Number Counterweight Hood Bucket Cylinder Muffler Guide Link Hydraulic Oil Tank Bucket Fuel Tank Push Link Engine Tooth Point Fuel Tank Fill Cap Side Cutter Radiator and Oil Cooler Idler Control Valves Track Adjuster Swing Motor Track Guide Air Cleaner Battery...

  • Page 57: General Dimensions

    GENERAL DIMENSIONS FG005887 Figure 2 5.2 M (17.1 ft) BOOM 5.7 M (18.7 ft) BOOM DIMENSION 2.0 M (6.6 ft) 2.4 M (7.9 ft) 2.4 M (7.9 ft) 2.9 M (9.5 ft) 3.5 M (11.5 ft) 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") 2,750 mm (9' 0") 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") 3,650 mm (11' 12")

  • Page 58: Working Range

    WORKING RANGE WARNING! The actual value for dimension "L" Digging Reach, depends on the 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. FG007029 Figure 3 SP000908...
  • Page 59 Boom Type One Piece 5.7 m (18.7 ft) One Piece 5.2 m (18.1 ft) 2.0 m 2.4 m 2.9 m 3.5 m 2.0 m 2.4 m Arm Type (6.56 ft) (7.87 ft) (9.51 ft) (11.48 ft) (6.56 ft) (7.87 ft) Dim.

  • Page 60: General Specifications

    GENERAL SPECIFICATIONS Shipping Weight 21.5 metric tons (47,399 lb), includes fuel 10%, boom, 5,700 mm (18' 8"), arm 2,900 mm (9' 6"), standard bucket and standard shoes Operating Weight Add weight of full fuel tank and operator. Shipping Weights with Optional Track Add 285 kg (628 lb) for 700 mm (28") shoes Shoe Add 560 kg (1,235 lb) for 800 mm (32") shoes...
  • Page 61 Overall Shipping Width 2,990 mm (9' 10") (standard shoes) Overall Shipping Height (to top 3,005 mm (9' 10") of cylinder hose) Track Shipping Length 4,445 mm (14' 7") Transport Trailer Capacity 30 metric tons (33 tons), minimum load capacity Transport Loading Ramp Allowable 15°...

  • Page 62: Engine Performance Curves (Per Din 6270 Standard)

    ENGINE PERFORMANCE CURVES (PER DIN 6270 STANDARD) 1000 2000 1500 REVOLUTION (rpm) FG007031 Figure 4 SP000908 Specification for DX225LC Page 16...
  • Page 63 Condition Specification Engine Model DL06 Barometric Pressure 760 mmHg (20°C (68°F)) 660.4 mm, SUCKER Cooling Fan (26 in) Alternator 24V x 50A Air Cleaner Installed Muffler Installed Performance Standard DIN 6270 150 ps @ 1,900 rpm Power (148 hp @ 1,900 rpm) 68 kg•m @ 1,400 rpm Max.

  • Page 64: Approximate Weight Of Workload Materials

    APPROXIMATE WEIGHT OF WORKLOAD MATERIALS IMPORTANT Weights are approximations of estimated average volume and mass. Exposure to rain, snow or groundwater; settling or compaction because of overhead weight, chemical or industrial processing or changes because of thermal or chemical transformations could all increase the value of weights listed in the table.
  • Page 65 Medium Weight or Low Weight or Density High Weight or Density Density Material 1,100 kg•m 2,000 kg•m 1,600 kg•m (1,850 lb/yd ), or Less (3,370 lb/yd ), or Less (2,700 lb/yd ), or Less 1,762 kg•m Earth, WET, muddy --------------------- --------------------- (2,970 lb/yd Gypsum, calcined,...

  • Page 66: Performance Tests

    PERFORMANCE TESTS Main Relief Pressure Normal Operation : 330 kg•cm (4,689 psi) with "Pressure Up" : 350 kg•cm (4,970 psi) Actuator Speeds Operation Unit Standard Mode Power Mode 3.3 ± 0.4 2.9 ± 0.4 Boom Down 2.6 ± 0.3 2.5 ± 0.3 Crowd 4.1 ±...

  • Page 67: Excavator Performance Standards

    EXCAVATOR PERFORMANCE STANDARDS Evaluation of equipment performance and operating condition can be made by running the excavator through a series of different tests, and recording results with a stopwatch and tape measure. Compare results of performance tests against the specifications and standards that follow, which are for equipment in new or renewed condition.
  • Page 68 0.3 M - 0.5 M (1' - 2') FG007032 Figure 5 The lowest part of the bucket linkage should be 0.3 - 0.5 m (1' - 2') off the ground. Mark off a 20 m (65' 7-1/2") test distance, with a 3 - 5 m (10' - 15') run-up area, and a 3 - 5 m (10' - 15', or longer) speed runoff distance.

  • Page 69: Swing Speed And Deceleration Force Test

    Travel Deviation To check steering deviation (travel motor balance), use a long tape or rope, or the edge of an undeviating straight road curb or other marker to verify side to side travel motor uniformity. Deviation distance should always be measured at the 20 m (65' 7-1/2") "finish line."...
  • Page 70 Swing Deceleration Force Test With the boom, arm and bucket in the same position as for the swing speed test, rotate the turntable so the boom is evenly centered between the side frames, pointing straight ahead. Locate the 90° reference point, perpendicular to the boom. Mark the turntable and undercarriage with paint at the 90°...

  • Page 71: Cylinder Performance Tests

    Cylinder Performance Tests All tests are performed with standard boom, arm and NOTE: bucket configuration. The bucket should be empty. Boom Cylinders Test The starting points for the test are with the boom and arm extended away from the excavator, and the bucket curled inward.
  • Page 72 Travel Motor Jack-up Test Test travel motor operation on each side by painting or chalking a mark on one crawler shoe, with a 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.
  • Page 73 General Maintenance...
  • Page 74 SP000016 GENERAL MAINTENANCE PROCEDURES SP000016 General Maintenance Procedures Edition 1 SP000016 General Maintenance Procedures Page 1...
  • Page 75 Table of Contents General Maintenance Procedures Safety Precautions..........5 Applicable Models..........5 Welding 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 .............

  • Page 76: Safety Precautions

    SAFETY PRECAUTIONS CAUTION! 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.

  • Page 77: Welding Precautions And Guidelines

    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.

  • Page 78: Hydraulic System - General Precautions

    CAUTION! Observe the following safety precautions: Use extra caution and adequate safety shielding when welding near fuel and oil tanks, batteries, hydraulic piping lines or other fire hazards. Never weld when the engine is running. Battery cables must be disconnected before the welding procedure is started.
  • Page 79 circuits are in neutral, or "OFF." This will prevent pumps or other components that may be temporarily being starved of oil from being run under a load. Replacement of any hydraulic system component could require thorough cleaning, flushing, and some amount of prefilling with fresh, clean oil if the protective seal on replacement parts has obviously been broken or if seal integrity may have been compromised.

  • Page 80: Maintenance Service And Repair Procedure

    MAINTENANCE SERVICE AND REPAIR PROCEDURE General Precautions Fluid level and condition should always be checked whenever any other maintenance service or repair is being performed. If the unit is being used in an extreme temperature NOTE: environment (in subfreezing climates or in high temperature, high humidity tropical conditions), frequent purging of moisture condensation from the hydraulic reservoir drain tap should be a regular and...

  • Page 81: Hydraulic System Cleanliness And Oil Leaks

    HYDRAULIC SYSTEM CLEANLINESS AND OIL LEAKS Maintenance Precautions for Hydraulic System Service Whenever maintenance, repairs or any other troubleshooting or service is being performed, it's important to remember that the hydraulic system - including both the interior and exterior surfaces of assemblies, and every drop of operating fluid - must be protected from contamination.

  • Page 82: Oil Leakage Precautions

    Oil Leakage Precautions Oil that is visibly seeping from joints or seals should always serve as a "red flag" alarm. Leaks must alert the machine operator and maintenance crew that air, water and dirt have an open, free passageway through which to enter the circuit.

  • Page 83: Cleaning And Inspection

    CLEANING AND INSPECTION General Guidelines All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or foreign material enters unit being assembled. Even minute particles can cause malfunction of close fitting parts such as thrust bearing, matched parts, etc.

  • Page 84: Bearing Inspection

    seriously impair its efficiency. Apply a thin coat of Loctite #120 to outer diameter, of metal casing, on oil seals to assure an oil tight fit into retainer. Use extreme care not to get Loctite on lips of oil seals. If this happens, that portion of the seal will become brittle and allow leakage.
  • Page 85 After inspection lightly coat the bearing and related parts with oil and wrap in a clean lintless cloth or paper and protect them from moisture and other foreign materials until installation. It is also important to inspect the bearing housing and/or shaft for grooved, galled or burred conditions that indicate the bearing has been turning in its housing or on its shaft.
  • Page 86 Replace bearing. Figure 4 Galling Metal smears on roller ends because of overheating, lubricant failure or overload. Replace bearing - check seals and check for proper lubrication. Figure 5 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.
  • Page 87 Etching Bearing surfaces appear gray or grayish black in color with related etching away of material usually at roller spacing. Replace bearings - check seals and check for proper lubrication. Figure 7 Misalignment Outer race misalignment because of foreign object. Clean related parts and replace bearing.
  • Page 88 Fatigue Spalling Flaking of surface metal resulting from fatigue. Replace bearing - clean all related parts. Figure 10 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. Figure 11 Cage Wear Wear around outside diameter of cage and roller pockets...
  • Page 89 Abrasive Roller Wear Pattern on races and rollers caused by fine abrasives. Clean all parts and housings, check seals and bearings and replace if leaking, rough or noisy. Figure 13 Cracked Inner Race Race cracked because of improper fit, cocking or poor bearing seat.
  • Page 90 Frettage Corrosion set up by small relative movement of parts with no lubrication. Replace bearing. Clean all related parts. Check seals and check for proper lubrication. Figure 16 Heat Discoloration Heat discoloration can range from faint yellow to dark blue resulting from overload or incorrect lubrication.
  • Page 91 SP000017 STANDARD TORQUESSP000017 Standard Torques Edition 1 Standard Torques SP000017 Page 1...
  • Page 92 Table of Contents Standard Torques Safety Precautions..........5 Applicable Models..........5 Torque Values for 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 ......

  • Page 93: Standard Torques

    SAFETY PRECAUTIONS CAUTION! 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.

  • Page 94: Torque Values For Standard Metric Fasteners

    TORQUE VALUES FOR STANDARD METRIC FASTENERS The units for the torque values are kg•m (ft lb). NOTE: Grade Dia. x Pitc h (mm) 10.9 12.9 (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K) 0.15 0.16 0.25 0.22 0.31 0.28 0.43...

  • Page 95: Torque Values For Standard U.s. Fasteners

    TORQUE VALUES FOR STANDARD U.S. FASTENERS S.A.E. Bolt Head Type Description Grade Marking WILL HAVE NO MARKINGS IN THE CENTER OF THE HEAD. 1 OR 2 Low or Medium Carbon Steel Not Heat-treated. WILL HAVE THREE RADIAL LINES. Quenched and Tempered Medium Carbon Steel. WILL HAVE 6 RADIAL LINES.
  • Page 96 The following General Torque Values must be used where SPECIAL TORQUE VALUES are not given. Torque values listed throughout this manual are lubricated (wet) threads; values should be NOTE: increased 1/3 for nonlubricated (dry) threads. Heat-treated Material Grade 5 and Grade 8 Grade 5 Grade 8 Thread Size...

  • Page 97: Type 8 Phosphate Coated Hardware

    TYPE 8 PHOSPHATE COATED HARDWARE This chart provides tightening torque for general purpose applications using original equipment standard hardware as listed in the Parts Manual for the machine involved. DO NOT SUBSTITUTE. In most cases, original equipment standard hardware is defined as Type 8, coarse thread bolts and nuts and thru hardened flat washers (Rockwell "C"...

  • Page 98: Torque Values For Hose Clamps

    TORQUE VALUES FOR HOSE CLAMPS The following chart provides the tightening torques for hose clamps used in all rubber applications (radiator, air cleaner, operating lever boots, hydraulic system, etc.). Torque Radiator, Air Cleaner, Boots, Etc. Hydraulic System Clamp Type And Size Kilogram-meter Inch Pounds Kilogram-meter...

  • Page 99: Torque Values For Split Flanges

    TORQUE VALUES FOR SPLIT FLANGES The following chart provides the tightening torques for split flange connections used in hydraulic systems. Split flanges and fitting shoulders should fit squarely. Install all bolts, finger tight and then torque evenly. Over torquing bolts will damage the flanges and/or NOTE: bolts, which may cause leakage.

  • Page 100: Torque Wrench Extension Tools

    TORQUE WRENCH EXTENSION TOOLS Very large diameter, high-grade fasteners (nuts, bolts, cap screws, etc.) require a great deal of turning force to achieve recommended tightening torque values. Common problems that could occur as a result are: • Recommended torque exceeds the measuring capacity of the torque wrench.

  • Page 101: Other Uses For Torque Wrench Extension Tools

    The formula assumes that there is no added NOTE: deflection or "give" in the joint between the extension torque wrench. Readings also inaccurate: • If the extension itself absorbs some of the tightening force and starts to bend or bow out. •...
  • Page 102 Use the information on this page 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.
  • Page 103 I. "Loctite" Fastener Adhesives Breakaway Cure Product Application Color Removal Strength (in lb) of Sealer Alone Low strength for 6 mm (1/4") or Purple Hand tools smaller fasteners. Medium strength for 6 mm (1/4") and 242 or 243 Blue Hand tools larger fasteners.
  • Page 104 IV. "Loctite" retaining compounds Product Application Color Notes For bushings, sleeves, press fit Use Locquic "N" primer for increased bond bearings, splines and collars. For Green strength and all cold temperature gaps to 0.0002 mm (0.005"), applications. temperatures to 121°C (250°F). For high temperatures to 232°C Green Same as 609, above.
  • Page 105 Upper Structure...
  • Page 106 SP000943 CABIN SP000943 Cabin Edition 1 SP000943 Cabin Page 1...
  • Page 107 Table of Contents Cabin Safety Precautions..........5 Applicable Models..........5 Removal..............7 Installation ............11 SP000943 Cabin Page 3...
  • Page 108 Remember, that ultimately safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX180LC 5001 and Up DX225LC 5001 and Up DX225NLC 5001 and Up...

  • Page 109: Bucket

    REMOVAL CAUTION! Avoid disassembling cabin if there are strong wind gusts, which could catch large surface area of cabin shell and push it sideways during lift. Park on firm and level ground. Lower front attachment (bucket) to ground. Shut down engine. Set safety lever on "RELEASED"...
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