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Doosan DX225LC-3 Shop Manual

Doosan DX225LC-3 Shop Manual

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EXCAVATOR

Shop

Manual

DX225LC-3

Serial Number 1001 and Up

Serial Number 50001 and Up (Europe Only)

Doosan Infracore

Construction Equipment

950106-00364E

March 2012

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Summary of Contents for Doosan DX225LC-3

Page 1 950106-00364E March 2012 EXCAVATOR Shop Manual DX225LC-3 Serial Number 1001 and Up Serial Number 50001 and Up (Europe Only) Doosan Infracore Construction Equipment...
Page 2 WARNING CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects and other reproductive harm. WARNING CALIFORNIA PROPOSITION 65 WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
Page 3 Shop Manual DX225LC-3 EXCAVATOR Serial Number 1001 and Up Serial Number 50001 and Up (Europe Only) DOOSAN and the DOOSAN logo are registered trademarks of DOOSAN Corporation in the United States and various other countries around the 950106-00364E world. March 2012...
Page 5 Product Label Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine Pub. No. 950106-00364E...
Page 7 Table of Contents Safety Track Excavator Maintenance Safety ........... SP002322 Specifications Specifications for DX225LC-3............... SP002491 General Maintenance General Maintenance Instructions ............SP002454 Standard Torques ................. SP002404 Upper Structure Cabin ....................SP002324 Counterweight..................SP002492 Fuel Tank....................SP002493 Fuel Transfer Pump (Option) ..............SP002534 Swing Bearing..................
Page 8 Remote Control Valve (Work Lever / Joystick) ........SP002395 Travel Control Valve (with Damper)............SP002381 Solenoid Valve Assembly ..............SP002406 Breaker EPPR Valve (Option) .............. SP002458 Dozer Valve ..................SP002529 Hydraulic Schematic (DX225LC-3)............SP002507 Electrical System Electrical System .................. SP002337 Electrical Schematic ................SP002508 Attachments Boom and Arm..................
Page 9 Safety...
Page 11 SP002322 TRACK EXCAVATOR MAINTENANCE SAFETY SP002322 Track Excavator Maintenance Safety Edition 2 Track Excavator Maintenance Safety SP002322 Page 1...
Page 12 MEMO Track Excavator Maintenance Safety SP002322 Page 2...
Page 13: Table Of Contents
Table of Contents Track Excavator Maintenance Safety Safety Instructions ..........5 Applicable Models ..........5 Safety Messages ..........6 Safety Decals ............7 General ..............7 Transportation ............ 20 Operation ............22 Maintenance ............39 Environment and Circumstances......56 Track Excavator Maintenance Safety SP002322 Page 3...
Page 14 MEMO Track Excavator Maintenance Safety SP002322 Page 4...
Page 15: Track Excavator Maintenance Safety
MODEL SERIAL NUMBER RANGE DX140LC-3 1001 and Up, 50001 and Up DX180LC-3 1001 and Up, 50001 and Up DX225LC-3 1001 and Up, 50001 and Up DX255LC-3 1001 and Up, 50001 and Up DX300LC-3 1001 and Up, 50001 and Up DX340LC-3...
Page 16: Safety Messages
SAFETY MESSAGES Safety messages and safety decals included in this manual and on the machine provide instructions how to operate, service and maintain the machine. Safety messages and safety decals indicate potential hazards and describe safety precautions required to avoid hazards. Operator and maintenance personnel should read and understand these safety messages and decals before beginning operation or maintenance.
Page 17: Safety Decals
SAFETY DECALS 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. GENERAL Safe Operation is Operator's Responsibility Only trained and authorized personnel should operate and maintain the machine.
Page 18 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...
Page 19 Additional protection for operator's cabin could be required such as an Operator Protection Guard (OPG) or window guards. Contact your DOOSAN distributor for information on available protective guards. HAOA110L Figure 2 To prevent personnel from being struck by flying objects, keep personnel out of work area.
Page 20 Personal Protective Equipment (PPE) Do not wear loose clothing and accessories. Secure long hair. These items can snag on controls or on other parts of equipment. Do not wear oily clothes. They are highly flammable. Some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause disabling or permanent injuries.
Page 21 Do not depend on hydraulic cylinders to support raised equipment. Equipment can fall if a control is moved, or if a hydraulic line breaks or is loosened or disconnected. If it is necessary to remove guards to perform maintenance, always install guards after maintenance is completed. HDO1010L Figure 5 Hot Coolant and Oils - Burn Prevention...
Page 22 Fire and Explosion Prevention All fuels, most lubricants and some coolant mixtures are flammable and can cause a fire resulting in death or serious injury, and property damage. Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause fire.
Page 23 Electrical Check all electrical wiring and connections for damage daily. Keep battery terminals clean and tight. Repair or replace any damaged part or wires that are loose or frayed. Clean all electrical connections and tighten all electrical connections. Never check battery charge by placing a metal object across terminal posts.
Page 24 Fueling Use caution when you are refueling a machine. Fuel is flammable and can catch fire if it is brought close to a flame. Stop engine and let it cool before adding fuel. Do not smoke while you are refueling a machine. Do not refuel a machine near flames or sparks.
Page 25 If a Fire Occurs If a fire occurs: • Do not attempt to move machine or continue operations. • Turn starter switch to "O" (OFF) position to stop engine. • Use handrails, guardrails and steps to get off machine. • Immediately call for help or fire station.
Page 26 Never modify the operator's cabin by welding, grinding, drilling holes or adding attachments unless instructed by DOOSAN in writing. Changes to the cabin can cause loss of operator protection from rollover and falling objects, and result in death or serious injury.
Page 27 Never modify the operator cabin by welding, grinding, drilling holes or adding attachments unless instructed in writing by DOOSAN. Changes to the cabin can cause loss of operator protection from rollover and falling objects, and can result in death or serious injury.
Page 28 Reinstallation, recertification and/or replacement of system may be necessary. Contact your DOOSAN distributor for available safety guards and/or recommendations to protect against objects that could strike operator's cabin. Make sure that all other work site crew members are kept away from excavator when operating.
Page 29 Emergency Exit from Operator's Station This machine is equipped with a glass breaking tool. It is found on left pillar of cabin. This tool can be used to break the glass to exit from cabin in an emergency. Grip handle firmly and use sharp point to break glass.
Page 30: Transportation
Manual for information on partial disassembly. Refer to Operation and Maintenance Manual, for information on loading, unloading and towing. The machine can be disassembled into parts for transporting. Contact your DOOSAN distributor assistance with disassembly. Loading and Unloading To prevent machine tipping or rollover when loading or unloading machine, always do the following: •...
Page 31 • When driving up or down ramps, the center of gravity of machine will change suddenly causing the tracks to drop down to the ramps or trailer. This will occur at the joint between the ramps and trailer. Travel slowly over this point.
Page 32: Operation
OPERATION Always make sure that machine is properly maintained. Before Engine Starting Machine Condition Every day before starting engine for first time, perform the following checks and repair machine before operating, as necessary. If these checks are not properly done death or serious injury could result.
Page 33 Work Site Before starting operations, thoroughly check work area for any hazards, such as underground utility lines, overhead electrical lines, unstable ground, excessive slopes, etc. Before starting engine and moving machine, make sure that no one is underneath machine, around machine, or on machine. Know width and length of your machine and work equipment to maintain proper clearance when you operate machine or work equipment near fences or near boundary obstacles.
Page 34 Mounting/Dismounting Before getting on or off machine, if there is any oil, grease, or mud on handrails, guardrails, 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 machine. In particular, never get on or off a moving machine.
Page 35 Cleaning Remove all straw, wood chips, leaves, grass, paper and other flammable debris accumulated in engine compartment, Diesel Particulate Filter (DPF), mufflers and around battery. Remove any dirt from window glass, mirrors, handrails, and steps. Do not leave tools or spare parts in operator's cabin. Vibration of machine during operation can cause tools or spare parts to fall and damage or break control levers or switches.
Page 36 If original color of webbing in these areas is extremely faded and/or webbing is packed with dirt, webbing strength may be reduced. NOTE: Contact your DOOSAN distributor for seat belt system replacement parts. WARNING AVOID DEATH OR SERIOUS INJURY...
Page 37 Inspect equipment and repair immediately if there are problems with visual aids. If machine cannot be fixed immediately, DO NOT use the machine. Contact your DOOSAN distributor and arrange for repairs. Work Site Rules •...
Page 38 • Check mirrors and rear view camera (if equipped) on machine before starting operations. Clean off any dirt and adjust view for good visibility. When operating or traveling during poor visibility conditions, follow the preceding work site rules. It may not be possible to adjust all visual aids to see all the way around the machine.
Page 39 Starting Engine Only operate the machine from the operator's seat with your seat belt fastened. Only operate controls while engine is running. Check for proper operation of all controls and all protective WARNING devices while you operate the machine slowly in an open area. •...
Page 40 Swinging or Traveling As a machine operator, you should know and follow local, state and federal laws and regulations when operating on public roads or highways. It is important to keep in mind that machine, in comparison with the rest of traffic, is a slow moving and wide vehicle which can cause traffic delays.
Page 41 Never turn starter switch to "O" (OFF) position when traveling. Travel Position This can lead to a loss of steering control. Do not operate attachments while traveling. Do not change selected travel mode (FAST/SLOW) while traveling. Never travel over obstacles or excessive slopes that will cause machine to tilt severely.
Page 42 Lifting and Digging The operator is responsible for any load carried when traveling on public roads and while working with the machine. • Keep loads secure so they do not fall off while operating. • Do not exceed maximum load for the machine. Machine operation will be affected when center of gravity changes, caused by extended loads and different attachments.
Page 43 Operation on Slopes If the machine has to be used on a slope, pile soil to make a platform that will keep the machine as horizontal as possible. Improper traveling on steep slopes could result in machine tipping, rollover or sliding down the slope. Always fasten your seat belt.
Page 44 Always attach wire rope onto left and right hooks and secure in position. • If engine on machine with problem will not start or there is a failure in brake system, always contact your DOOSAN distributor. • Never go between towing machine and towed machine during towing operation.
Page 45 Attachment Never let anyone ride on any work attachment, such as bucket, crusher, grapple, or clamshell (grab bucket). This creates a falling and crushing hazard, and can result in death or serious injury. The clamshell, grapple, or magnet can swing in all directions. Move work levers (joysticks) in a continuous motion.
Page 46 After the machine is parked, allow engine to run for five minutes before stopping the engine. This allows hot areas of engine to cool gradually. • Do not leave operator's seat when there is a raised load. Parking Machine Avoid making sudden stops, or parking machine wherever it happens to be at end of workday.
Page 47 Preservation/Storing Machine Perform the following if storing excavator for more than one month. Conditions Maintenance Required Cleaning Pressure wash undercarriage and track assemblies. Inspect for damage or loose or missing parts. Lubrication Perform all daily lubrication procedures. Apply a coating of light oil to exposed plated metal surfaces, such as hydraulic cylinder rods, etc.
Page 48 Check After Long-term Parking • All oil and fluid levels. • Tension of all belts. • Air pressure. • Air cleaner. • Batteries and electrical connections. • Lubricate all greasing points. • Wipe off grease from piston rods. • Inspect for signs of nests (i.e. birds, rodents, etc.) Track Excavator Maintenance Safety SP002322 Page 38...
Page 49: Maintenance
Untrained operators and failure to follow instructions can result in death or serious injury. • Never service DOOSAN equipment without instructions. • Always lower bucket and blade to ground before doing any maintenance. Use correct procedure to lift and support excavator.
Page 50 Maintenance procedures which are not in this manual must be performed ONLY BY QUALIFIED SERVICE PERSONNEL. Always use genuine DOOSAN replacement parts. • Only authorized personnel should service and repair the machine. Do not allow unauthorized personnel into work area.
Page 51 • When performing maintenance of engine and you are exposed to engine noise for long periods of time, wear hearing protection while working. • If noise from the machine is too loud, it can cause temporary or permanent hearing problems. •...
Page 52 950205-01451 FG018690 Figure 34 "DO NOT OPERATE" warning tags, are available from your DOOSAN distributor. • Always attach "DO NOT OPERATE" warning tag to work equipment control lever in the operator's cabin to alert others that you are performing service or maintenance on the machine.
Page 53 Cleaning Clean machine before performing inspection and maintenance. If inspection and maintenance are done when machine is dirty, it will become more difficult to locate problems, and you could slip on steps and work platform areas and injure yourself. When washing machine, do the following: •...
Page 54 Use of Lighting When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use proper lighting equipment to prevent arcs or sparks that could cause a fire or explosion resulting in death or serious injury. HDO1040L Figure 38 Fire and Explosion Prevention Fuels, most lubricants and some coolant mixtures are flammable.
Page 55 Burn Prevention When checking radiator coolant level, stop engine, let engine and radiator cool down, then check coolant recovery tank. If coolant level in coolant recovery tank is near upper limit, there is enough coolant in radiator. Using gloves, loosen radiator cap slowly to release internal pressure before removing radiator cap.
Page 56 Rubber That Contains Fluorides Observe extra great care when it is suspected that you may have to handle rubber that contains fluorides. Certain seals which have to withstand high operating temperatures (e.g. in engines, transmissions, axles, hydraulic motors and pumps) may be made from rubber that contains fluorides, which, when exposed to high heat (fire), forms hydrogen fluoride and hydrofluoric acid.
Page 57 Rubber and Plastics Polymer materials when heated, can form compounds that create a health hazard and can harm the environment. Scrapped rubber and plastic must never be burned. Extra precautions should be taken when servicing machines that have been in a fire or exposed to extreme heat. If gas cutting or welding is to be done near such materials, the following safety instructions must be followed: •...
Page 58 Welding Repairs IMPORTANT When disconnecting or connecting connectors between ECU and engine, or connector between ECU and the machine, always disconnect the battery to prevent damage to ECU. If you do not follow this procedure, the ECU will be damaged and/or the engine will not operate properly. When performing welding repairs, perform welding in a properly equipped place.
Page 59 Preparation for Electrical Welding On Body Structure To prevent damage to ECU by electrical welding, observe the following procedures: Turn battery disconnect switch to "OFF" position. Disconnect the connector between ECU and machine, and the connector between ECU and engine. Proceed with welding.
Page 60 Lock Inspection Covers When performing maintenance with inspection cover open, use lock bar to secure cover and prevent accidental lowering of the cover caused by wind or movement of the machine. If maintenance work is done with the inspection cover open but not locked, it could suddenly close because of the wind or movement of the machine and cause injury.
Page 61 Contact your DOOSAN distributor for assistance. • Wear safety goggles and leather gloves when working on an accumulator. Hydraulic oil under pressure can penetrate skin and result in death or serious injury. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.
Page 62 Track Tension Adjustments Track adjusting systems use grease under high-pressure to keep track under tension. Grease under high-pressure can penetrate body and result in death or serious injury. Watch track or track spring to see if track is being loosened. NEVER LOOSEN track tension grease valve.
Page 63 If any loose bolts are found, stop work and tighten to specified torque. If any damaged hoses are found, stop operations immediately contact your DOOSAN distributor replacement parts. Track Excavator Maintenance Safety SP002322 Page 53...
Page 64 Battery Battery Hazard Prevention Battery electrolyte contains diluted sulfuric acid and generates hydrogen gas. Hydrogen gas is highly explosive, and improper handling can cause death or serious injury, or fire. Do not allow electrolyte to contact skin or eyes. Always wear safety goggles and protective clothing when servicing batteries.
Page 65 Since there is a potential hazard that sparks could be generated, always do the following: • Do not let tools, rings or other metal objects make any contact between battery terminals. Do not leave tools or other metal objects lying near battery. •...
Page 66 ENVIRONMENT AND CIRCUMSTANCES Work Site Areas Requiring Extra Caution • Do not operate too close to edge of a quay, ramp, etc. • Do not operate too close to edge of a steep slope or drop-off. Take care when working in a place where machine may tip over.
Page 67 Drop-off or Edge When working at edge of an excavation or near a drop-off, the machine could tip over, which can result in death or serious injury. Always fasten your seat belt. Check ground conditions of work site before operating to prevent the machine from falling or rollover, and to prevent ground, stockpiles, or banks from collapsing.
Page 68 When working on loose or unstable ground, it is important not to dig too deep and to carefully reposition the machine. Do not panic and do not raise bucket, if ground should begin to collapse. Lower work equipment to improve stability of machine. Never dig under machine, if there is a potential of causing a landslide.
Page 69 Working in Contaminated Environment When working within area which is contaminated or where there is a health risk, check local regulations and contact your DOOSAN distributor for assistance with identifying what additional safety precautions need to be taken. Track Excavator Maintenance Safety...
Page 70 Operation in Extreme Conditions Operation In Extreme Cold In extremely cold weather, avoid sudden travel movements and stay away from even slight slopes. The machine could slide down the slope. Snow accumulation could hide potential hazards and slippery surfaces. Warming up engine for a short period may be necessary to avoid operating with sluggish or reduced working capacity.
Page 71 An extra outer air filter should be kept in operator's cabin to replace element that could become iced and cause restricted airflow to engine. Clean off all mud, snow and ice to prevent freezing. Cover machine with a tarp if possible, keep ends of tarp from freezing to ground.
Page 72 In hot, damp climates, corrosion will occur on all parts of machine and will be accelerated during rainy season. Rust and paint blisters will appear on metal surfaces and fungus growth on other surfaces. Protect all unfinished, exposed surfaces with a film of preservative lubricating oil.
Page 73 Operation in Saltwater Areas Saltwater and saltwater spray is very corrosive. When operating in saltwater areas, or in or around snow, observe the following precautions: When exposed to saltwater, dry machine thoroughly and rinse with freshwater, as soon as possible. Keep all exposed surfaces coated with preservative lubricating oil.
Page 74 Exhaust Ventilation Engine exhaust gases can cause unconsciousness, loss of alertness, judgment and motor control. This can result in death or serious injury. Make sure there is adequate ventilation before starting engine in any enclosed area. Check for and be aware of any open windows, doors or ductwork where exhaust may be carried, or blown by wind, exposing others to hazardous exhaust gases.
Page 75 • Stay away from areas that might have asbestos particles in air. Silica Dust Information WARNING AVOID DEATH OR SERIOUS INJURY Avoid exposure to dust containing crystalline silica particles as it can cause serious injury to the lungs (silicosis). ARO1770L Figure 57 Cutting or drilling concrete containing sand or rock containing quartz can result in exposure to silica dust.
Page 76 ISO 2631/1. ISO 5349, and SAE J1166. Recommendations for Reducing Vibrations: Select proper machine, equipment and attachments for a particular application. Replace any damaged seat with a genuine DOOSAN seat. Keep seat properly maintained and adjusted. • Adjust seat and suspension for weight and size of operator.
Page 77 Specifications...
Page 79 SP002491 SPECIFICATIONS FOR DX225LC-3SP002491 Specifications for DX225LC-3 Edition 1 Specifications for DX225LC-3 SP002491 Page 1...
Page 80 MEMO Specifications for DX225LC-3 SP002491 Page 2...
Page 81 Table of Contents Specifications for DX225LC-3 Safety Instructions ..........5 Applicable Models ..........5 General Description ..........7 Component Locations........... 8 General Dimensions ........... 10 One - Piece Boom ............10 Two - Piece Boom ............11 Working Range ........... 12 One - Piece Boom ............
Page 82 MEMO Specifications for DX225LC-3 SP002491 Page 4...
Page 83: Specifications For Dx225Lc-3
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX225LC-3 1001 and Up, 50001 and Up Specifications for DX225LC-3 SP002491 Page 5...
Page 84 Specifications for DX225LC-3 SP002491 Page 6...
Page 85: General Description
The excavator has three main component sections: • The Upper Structure • 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.) Specifications for DX225LC-3 SP002491 Page 7...
Page 86: Component Locations
COMPONENT LOCATIONS 9 10 11 12 13 14 15 16 FG019399 Figure 1 Specifications for DX225LC-3 SP002491 Page 8...
Page 87 Lower Roller Air Cleaner Battery Swing Bearing Center Joint Seat Upper Roller Cabin Sprocket Boom Cylinder Travel Motor Work Lever (Joystick) Track Link and Shoe Travel Lever Suction Filter Arm Cylinder Return Filter Boom Pumps Specifications for DX225LC-3 SP002491 Page 9...
Page 88: General Dimensions
3,275 mm (10' 11") 2,710 mm (8' 10") 1,400 mm (4' 7") 1,310 mm (4' 4") 2,390 mm (7' 10") 2,990 mm (9' 10") 600 mm (1' 12") 480 mm (1' 7") 2,975 mm (9' 9") Specifications for DX225LC-3 SP002491 Page 10...
Page 89: Two - Piece Boom
3,080 mm (10' 1") 2,710 mm (8' 10") 1,400 mm (4' 7") 1,310 mm (4' 4") 2,390 mm (7' 10") 2,990 mm (9' 10") 600 mm (1' 12") 480 mm (1' 7") 2,975 mm (9' 9") Specifications for DX225LC-3 SP002491 Page 11...
Page 90: Working Range
Digging too far underneath the excavator if soil conditions are wet, loose or unstable can collapse ground support, which could cause death or serious injury and/or equipment damage. One - Piece Boom FG022236 Figure 4 Specifications for DX225LC-3 SP002491 Page 12...
Page 91 2,825 mm 4,875 mm Min. Radius 2.5 m Line (9' 5") (9' 4") (9' 3") (15' 12") 1,685 mm 510 mm -230 mm 155 mm Min. Digging Reach (5' 6") (1' 8") (-9") (6") Specifications for DX225LC-3 SP002491 Page 13...
Page 92: Two - Piece Boom
Two - Piece Boom FG022237 Figure 5 Specifications for DX225LC-3 SP002491 Page 14...
Page 93 Max. Depth to 2.5 m Line 5,865 mm (19' 3") 6,350 mm (21' 10") Min. Radius 2.5 m Line 1,735 mm (5' 8") 1,735 mm (5' 8") Min. Digging Reach 2,155 mm (7' 1") 1,245 mm (4' 1") Specifications for DX225LC-3 SP002491 Page 15...
Page 94: General Specifications
Standard 600 mm (24") shoe 0.46 kg/cm (6.54 psi) Optional 700 mm (28") shoe 0.40 kg/cm (5.73 psi) Optional 800 mm (32") shoe 0.36 kg/cm (5.12 psi) Optional 900 mm (36") shoe 0.32 kg/cm (4.55 psi) Specifications for DX225LC-3 SP002491 Page 16...
Page 95 4,445 mm (14' 7") Transport Trailer Capacity 22 tons (24 short tons), minimum load capacity Transport Loading Ramp 15° angle Allowable Slope When NOTE: Refer to Operation and Maintenance Manual for Recommended Transporting Transportation Instructions. Specifications for DX225LC-3 SP002491 Page 17...
Page 96: Engine Performance Curves (Per Ks-R1004 Standard)
ENGINE PERFORMANCE CURVES (PER KS-R1004 STANDARD) 1000 1500 2000 Revolution (rpm) FG022719 Figure 6 Specifications for DX225LC-3 SP002491 Page 18...
Page 97 Performance Standard KS-R1004 169 ps @ 1,800 rpm Power (167 hp @ 1,800 rpm) 77 kg•m @ 1,400 rpm Max. Torque (557 ft lb @ 1,400 rpm) 155 g/ps•h Fuel Consumption (Rated) (5.55 oz/hp•h) Specifications for DX225LC-3 SP002491 Page 19...
Page 98: Approximate Weight Of Workload Materials
Dolomite, crushed (2,565 lb/yd 1,202 kg/m Earth, loamy, DRY, loose (2,025 lb/yd 1,522 kg/m Earth, DRY, packed (2,565 lb/yd 1,762 kg/m Earth, WET, muddy (2,970 lb/yd Gypsum, calcined, (heated, 961 kg/m powder) (1,620 lb/yd Specifications for DX225LC-3 SP002491 Page 20...
Page 99 (1,566 lb/yd 529 kg/m Snow, light density (891 lb/yd 1,522 kg/m Sand, DRY, loose (2,565 lb/yd 1,922 kg/m Sand, WET, packed (3,240 lb/yd 1,362 kg/m Shale, broken (2,295 lb/yd 529 kg/m Sulfur, broken (891 lb/yd Specifications for DX225LC-3 SP002491 Page 21...
Page 100: Performance Tests
24.0 ± 1.5 Travel Speed 20 m (66 ft) High 14.5 ± 1.0 13.0 ± 1.0 High mm (in) 150 (6) 150 (6) Travel Deviation 20 m (66 ft) mm (in) 150 (6) 150 (6) Specifications for DX225LC-3 SP002491 Page 22...
Page 101: Excavator Performance Measurements
Travel Speed and Travel Motor Balance (Steering Deviation) Tests Speed Test Prepare the excavator for travel speed tests by extending all hydraulic cylinders - boom, arm and bucket - to the fully extended position, shown in Figure 7. Specifications for DX225LC-3 SP002491 Page 23...
Page 102 Rotate the upper structure 180°. Both tests should be repeated three times. Average all results to obtain a final value. 3 m - 5 m 3 m - 5 m 20 m (10’ - 15’) (10’ - 15’) (65’ 7-1/2’’) FG018737 Figure 8 Specifications for DX225LC-3 SP002491 Page 24...
Page 103: Swing Speed And Deceleration Force Test
(3) full 360° rotations. The time required for three (3) revolutions should be between 15.5 and 17.5 seconds in Standard Mode, 15.5 and 17.5 seconds in Power Mode. Specifications for DX225LC-3 SP002491 Page 25...
Page 104 Maximum distance should be less than 1200 mm (47-1/4"), in both Power Mode and Standard Mode. Reference Description Number Start Swing FG018738 Figure 10 90° Swing Swing Force Swing Stop Specifications for DX225LC-3 SP002491 Page 26...
Page 105: Cylinder Performance Tests
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 three (3) full rotations, during both high-speed and low speed operation. Specifications for DX225LC-3 SP002491 Page 27...
Page 106 Specifications for DX225LC-3 SP002491 Page 28...
Page 107 General Maintenance...
Page 109 SP002454 GENERAL MAINTENANCE INSTRUCTIONS SP002454 General Maintenance Instructions Edition 2 General Maintenance Instructions SP002454 Page 1...
Page 110 MEMO General Maintenance Instructions SP002454 Page 2...
Page 111 Table of Contents General Maintenance Instructions Safety Instructions ..........5 Applicable Models ..........5 Welding Precautions and Instructions ....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 Service10 Oil Leakage Precautions ..........
Page 112 MEMO General Maintenance Instructions SP002454 Page 4...
Page 113: General Maintenance Instructions
SAFETY INSTRUCTIONS WARNING AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read understand Operation Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments repairs or service.
Page 114: Welding Precautions And Instructions
(that is not always readily visible) could result. Always consult DOOSAN After Sales Service before welding on integral components (loader arm, frames, car body, track frames, upper structure, attachment, etc.) of the machine.
Page 115: Hydraulic System - General Precautions
WARNING AVOID DEATH OR SERIOUS INJURY Observe the following safety instructions: Use adequate safety shielding and keep away from fuel and oil tanks, batteries, hydraulic piping lines or other fire hazards when welding. Never weld when the engine is running. Battery cables must be disconnected before the welding procedure is started.
Page 116 When starting the engine (particularly after long layoff or storage intervals), make sure that all hydraulic controls and operating circuits are in neutral, or "OFF." That will prevent pumps or other components that may be temporarily oil starved from being run under a load.
Page 117: 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. NOTE: If the unit is being used in an extreme temperature 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 118: 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 hydraulic system - including both the interior and exterior surfaces of assemblies, and every drop of operating fluid - must be protected from contamination.
Page 119: 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 120: Cleaning And Inspection
CLEANING AND INSPECTION General Instructions 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 121: Bearing Inspection
Be careful when installing sealing members, to avoid cutting or scratching. Curling under of any seal lip will seriously impair its efficiency. Apply a thin coat of Loctite #120 to outer diameter of metal casing and on oil seals to assure an oil tight install into retainer.
Page 122 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 123 Replace bearing. Figure 4 Galling Metal smears on roller ends because of overheat, 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 124 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 125 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 126 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 installation, cocking or poor bearing seat.
Page 127 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 128 General Maintenance Instructions SP002454 Page 20...
Page 129 SP002404 STANDARD TORQUESSP002404 Standard Torques Edition 2 Standard Torques SP002404 Page 1...
Page 130 MEMO SP002404 Standard Torques Page 2...
Page 131 Table of Contents Standard Torques Safety Instructions ..........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 ORFS Swivel Nut Recommended Torque ..
Page 132 MEMO SP002404 Standard Torques Page 4...
Page 133: Standard Torques
SAFETY INSTRUCTIONS WARNING AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read understand Operation Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments repairs or service.
Page 134: Torque Values For Standard Metric Fasteners
TORQUE VALUES FOR STANDARD METRIC FASTENERS NOTE: The units for the torque values are kg•m (ft lb). Grade Dia. x Pitch (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 0.48...
Page 135: Torque Values For Standard U.s. Fasteners
TORQUE VALUES FOR STANDARD U.S. FASTENERS 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 136 The following General Torque Values must be used where SPECIAL TORQUE VALUES are not given. NOTE: Torque values listed throughout this manual are lubricated (wet) threads; values should be increased 1/3 for nonlubricated (dry) threads. Heat-treated Material Grade 5 and Grade 8 Grade 5 Grade 8 Thread Size...
Page 137: 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, nuts and thru hardened flat washers (Rockwell "C"...
Page 138: 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 139: 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. NOTE: Over torquing bolts will damage the flanges and/or bolts, which can cause leakage.
Page 140: 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 141: Other Uses For Torque Wrench Extension Tools
NOTE: The formula assumes there is no added deflection or "give" in the joint between the extension and torque wrench. Readings may also be inaccurate: • If the extension itself absorbs some of the tightening force and starts to bend or bow out. •...
Page 142: Tightening Torque Specifications (Metric)
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 approve a specific manufacturer or brand...
Page 143 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 144 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 145 Upper Structure...
Page 147 SP002324 CABIN SP002324 Cabin Edition 3 Cabin SP002324 Page 1...
Page 148 MEMO Cabin SP002324 Page 2...
Page 149 Table of Contents Cabin Safety Instructions ..........5 Applicable Models ..........5 Cabin Identification ..........6 Rollover Protective Structure (ROPS) ......6 Removal ............... 8 Installation ............12 Cabin SP002324 Page 3...
Page 150 MEMO Cabin SP002324 Page 4...
Page 151: Safety Instructions
MODEL SERIAL NUMBER RANGE DX140LC-3 1001 and Up, 50001 and Up DX180LC-3 1001 and Up, 50001 and Up DX225LC-3 1001 and Up, 50001 and Up DX255LC-3 1001 and Up, 50001 and Up DX300LC-3 1001 and Up, 50001 and Up DX340LC-3...
Page 152: Cabin Identification
Never modify the operator's cabin by welding, grinding, drilling holes or adding attachments unless instructed by DOOSAN. Changes to the cabin can cause loss of operator protection from rollover and falling objects, and operator may suffer death or serious injury.
Page 153 Never modify the operator cabin by welding, grinding, drilling holes or adding attachments unless instructed in writing by DOOSAN. Changes to the cabin can cause loss of operator protection from rollover and falling objects, and can result in death or serious injury.
Page 154: Removal
REMOVAL Park on firm and level ground. Lower bucket or work tool to ground. Stop engine. Move safety lever to "RELEASED" (UNLOCK) position. Turn starter switch to "I" (ON) position. WARNING when performing inspection WARNING 190-00695A FG018470 AVOID DEATH OR SERIOUS INJURY Figure 1 engine must...
Page 155 12. Remove mats from steps and floor. 13. Remove safety lever cover (1, Figure 2). 14. Remove two screws (2, Figure 2) in safety lever to remove lever. FG018676 Figure 2 15. Remove duct covers (1 and 2, Figure 3). FG018677 Figure 3 16.
Page 156 23. Remove air ducts (4 thru 6, Figure 6). Remove atmospheric air duct (7). FG015888 Figure 6 24. Remove all bolts fastening brackets (8 thru 10, Figure 7) to separate brackets from body of operator's cabin. 25. Disconnect connectors on interior lights, speakers and antenna.
Page 157 30. Remove bolt which is attaching the plate to prevent loosening of ROPS bolt (1, Figure 9). FG018678 Figure 9 31. Remove ROPS bolt (2, Figure 10). FG021955 Figure 10 32. Using a suitable lifting device, attach slings to four (4) lift points on top of cabin (Figure 11, Figure 12).
Page 158: Installation
INSTALLATION Using a suitable lifting device, attach slings to four (4) lift points on top of cabin (Figure 13, Figure 14). NOTE: Cabin weighs approximately 485 kg (1,069 lb). Lower cabin into position on cabin floor. FG015892 Figure 13 FG021964 Figure 14 Install four mounting nuts in four corners of cabin floor (2, Figure 15).
Page 159 11. Install the bolt which is fixing the plate to prevent loosening of ROPS bolt (1, Figure 16). FG018678 Figure 16 12. Install ROPS bolt (2, Figure 17). NOTE: Mounting nut torque 13 kg•m (94 ft lb) FG021955 Figure 17 13.
Page 160 15. Install two bolts (2, Figure 20) and center bolts in center, and three bolts on top to install dashboard cover. Install cap (3, Figure 20) on top of dashboard cover. 16. Install glove box pad (1, Figure 20). 17. Connect washer hose at floor plate bottom. FG015896 Figure 20 18.
Page 161 SP002492 COUNTERWEIGHT SP002492 Counterweight Edition 1 Counterweight SP002492 Page 1...
Page 162 MEMO Counterweight SP002492 Page 2...
Page 163 Table of Contents Counterweight Safety Instructions ..........5 Applicable Models ..........5 General ..............6 Warning for Counterweight and Front Attachment Removal ................6 Removal ............... 8 Installation ............9 Counterweight SP002492 Page 3...
Page 164 MEMO Counterweight SP002492 Page 4...
Page 165: Counterweight
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX225LC-3 1001 and Up, 50001 and Up Counterweight SP002492 Page 5...
Page 166: General
Lifting slings, shackles and all other hardware must be rigged safely. An assist crane that is rated above weight capacity is required. Model Weight of Counterweight 4,300 kg (9,480 lb) DX225LC-3 5,300 kg (11,700 lb) (Optional) Counterweight SP002492 Page 6...
Page 167 Responsibility should be assigned to one person to be in charge of the lifting crew, and to verify that required safe lifting precautions have been taken before each part of this procedure has been started. All members of the working crew should know and understand the signals that will be used between the lifting leader, the assist crane operator and the remainder of the work crew.
Page 168: Removal
REMOVAL WARNING AVOID DEATH OR SERIOUS INJURY Death or serious injury can occur from a counterweight falling during removal or installation. Do not allow WARNING personnel under or around the counterweight during removal or installation. when performing inspection 190-00695A Use certified cables and shackles of adequate load rating. FG018470 Improper lifting can allow the load to shift and cause death Figure 4...
Page 169: Installation
Model Bolt Torque FG020092 Figure 6 DX225LC-3 150 kg•m (1,085 ft lb) Remove lifting device from counterweight lifting holes (5, Figure 6) Make sure all electrical and other items are connected. Turn battery disconnect switch to "ON" position.
Page 170 Counterweight SP002492 Page 10...
Page 171 SP002493 FUEL TANK SP002493 Fuel Tank Edition 1 Fuel Tank SP002493 Page 1...
Page 172 MEMO Fuel Tank SP002493 Page 2...
Page 173 Table of Contents Fuel Tank Safety Instructions ..........5 Applicable Models ..........5 General Description ..........6 Parts List ................. 6 Specifications ..............7 Removal ............... 8 Installation ............12 Start-up Procedures ........... 15 Fuel Tank SP002493 Page 3...
Page 174 MEMO Fuel Tank SP002493 Page 4...
Page 175: Fuel Tank
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX225LC-3 1001 and Up, 50001 and Up Fuel Tank SP002493 Page 5...
Page 176: General Description
GENERAL DESCRIPTION WARNING AVOID DEATH OR SERIOUS INJURY Diesel fuel is highly flammable and can be potentially explosive. To prevent fires or explosion, keep arcs, sparks or other ignition sources away from diesel fuel or fuel containers. Parts List FG022488 Figure 1 Fuel Tank SP002493...
Page 177: Specifications
Reference Reference Description Description Number Number Fuel Tank Fuel Strainer O-ring Fuel Tank Cover Level Gauge Bolt Spacer Washer Fuel Sensor Drain Valve Bolt Bolt Spring Washer Shim Fuel Float Switch Shim Specifications Fuel tank capacity is 400 liters (106 U.S. gal). Fuel Tank SP002493 Page 7...
Page 178: Removal
REMOVAL Look at fuel level display (Figure 2) on instrument panel in operator's cabin to see what it displays. The display is divided into ten separated segments, each representing 10 percent of total fuel supply. Also, look at level gauge on side of tank to estimate volume of fuel left in tank.
Page 179 12. Clean area around fuel tank fill cap (11, Figure 5). Open fuel cap. FG022489 Figure 5 13. Open drain valve (Figure 6) right side door and drain. NOTE: Fuel tank capacity is 400 liters (106 U.S. gal). FG020064 Figure 6 14.
Page 180 15. Remove ten bolts (25 and 26, Figure 8) and handrail (27) from fuel tank and frame. Remove four bolts (28 and 29) and fuel tank cover (30) from fuel tank. Remove two bolts (31) and bracket (32) from tank. Remove four bolts (33) and storage box (34) from frame.
Page 181 19. If equipped, remove components from fuel filler pump port (22, Figure 11) on side of fuel tank (1). FG022493 Figure 11 20. Tag and disconnect wires leading to fuel sensor (14) and fuel float switch (17, Figure 12) on side of fuel tank (1). FG022494 Figure 12 21.
Page 182: Installation
INSTALLATION Install two 12 mm eyebolts in threaded holes (38 and 39, Figure 14). Using a suitable lifting device, sling eyebolts. Set fuel tank (1, Figure 14) into position. Install six bolts (7) and spacers (13) finger tight, to secure tank to frame. NOTE: The clear level gauge on the side of the tank is easily damaged.
Page 183 Connect as tagged, fuel supply line (21, Figure 17) and fuel return line (19) to fuel tank (1). Install clamp (20, Figure 17) to hold fuel return line (19) to tank (1). FG022492 Figure 17 Install four bolts (35 and 36, Figure 18) and cover (37) on fuel tank and support.
Page 184 11. Make sure fuel tank drain valve (Figure 20) right side door is closed. 12. Fill fuel tank and check for signs of leaks. Correct any problems found. 13. Turn disconnect switch to "ON" position. FG020064 Figure 20 14. Install five bolts (23, Figure 21) and cover (24) on fuel tank. FG022490 Figure 21 Fuel Tank...
Page 185: Start-Up Procedures
START-UP PROCEDURES If engine does not start, the fuel system may need priming. Prime the fuel system using the following procedure: Turn key to "OFF" position. Open right side door to access fuel filter. FG022496 Figure 22 Loosen plug (1, Figure 23) on top of fuel filter head. Pump hand-operated primer pump (2, Figure 23) by the fuel injection pump.
Page 186 Fuel Tank SP002493 Page 16...
Page 187 SP002534 FUEL TRANSFER PUMP (OPTION)SP002534 Fuel Transfer Pump (Option) Edition 1 Fuel Transfer Pump (Option) SP002534 Page 1...
Page 188 MEMO Fuel Transfer Pump (Option) SP002534 Page 2...
Page 189 Table of Contents Fuel Transfer Pump (Option) Safety Instructions ..........5 Applicable Models ..........5 General Description ..........6 Theory of Operation ............6 Troubleshooting ............ 8 Replacement of Rotor and Vane ......8 Replacement of Rear Cover ......... 9 Replacement of Armature........
Page 190 MEMO Fuel Transfer Pump (Option) SP002534 Page 4...
Page 191: Fuel Transfer Pump (Option)
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX225LC-3 1001 and Up, 50001 and Up Fuel Transfer Pump (Option) SP002534 Page 5...
Page 192: General Description
GENERAL DESCRIPTION Theory of Operation Fuel Fuel Tank DONG JIN FG003881 Figure 1 Reference Reference Description Description Number Number Motor Inlet Hose Pump Outlet Hose Pump Cover Check Valve Rotor and Vane Strainer Cap Fuel Transfer Pump (Option) SP002534 Page 6...
Page 193 The fuel pump consists of a motor, pump, switch, and hose assembly. Hose Pump FG024596 Figure 2 SENSOR POWER PUMP CONTROL UNIT FOR FUEL FILLER PUMP START STOP FG024597 Figure 3 Fuel Transfer Pump (Option) SP002534 Page 7...
Page 194: Troubleshooting
TROUBLESHOOTING On some pumps the ON-OFF switch is installed separately at a Switch Cover remote location. Connector "B" A thermal limiter, built into the motor, will automatically shut off power if motor is overheating to protect it from being damaged. NOTE: OPEN TEMP: 150 ±...
Page 195: Replacement Of Rear Cover
Insert vane, with the circled edge of vane facing in the counterclockwise direction. (Detail A) Insert a new O-ring during reassembly of pump cover. FG003883 Figure 7 REPLACEMENT OF REAR COVER Brush assembly and a thermal limiter are installed in the rear cover.
Page 196 Fuel Transfer Pump (Option) SP002534 Page 10...
Page 197 SP002329 SWING BEARING SP002329 Swing Bearing Edition 2 Swing Bearing SP002329 Page 1...
Page 198 MEMO Swing Bearing SP002329 Page 2...
Page 199 Table of Contents Swing Bearing Safety Instructions ..........5 Applicable Models ..........5 Swing Bearing Maintenance ......... 6 Operating Recommendation ........... 6 Measuring Swing Bearing Axial Play....... 6 Measuring Bearing Lateral Play ........6 Swing Bearing Basic Operation........7 Disassembly ..............7 Assembly.................
Page 200 MEMO Swing Bearing SP002329 Page 4...
Page 201: Swing Bearing
MODEL SERIAL NUMBER RANGE DX140LC-3 1001 and Up, 50001 and Up DX180LC-3 1001 and Up, 50001 and Up DX225LC-3 1001 and Up, 50001 and Up DX255LC-3 1001 and Up, 50001 and Up DX300LC-3 1001 and Up, 50001 and Up DX340LC-3...
Page 202: Swing Bearing Maintenance
SWING BEARING MAINTENANCE Operating Recommendation The service life of the swing bearing may be extended if a daily effort is made to equalize usage over both ends of the excavator. If the excavator is used in the same operating configuration day in and day out (for example, with the travel motors always under the counterweight, or with the attachment over one side of the machine more than the other), the bearing's service life could be reduced.
Page 203: Swing Bearing Basic Operation
Swing Bearing Basic Operation The swing bearing, which connects the upper structure with the lower structure, consists of a inner ring, outer ring and ball bearings. During swing movement, power from the swing motor is transferred to the pinion by planetary gears connected to gears on the inner ring, which is fixed in the undercarriage.
Page 204 Lift outer ring and check that inner ring can move freely. See Figure 5, if not, replace seal (7, Figure 6). Figure 5 Turn inner ring and use magnet bar (C, Figure 6) to remove steel balls (5). Figure 6 Turn inner ring and use wire (D, Figure 7) to remove retainers (6).
Page 205 Assembly Clean (degrease) the seal groove for the outer and inner seals (7). Apply instant glue to seal (7). Install both seals respectively into position. Figure 8 Hoist the outer race by crane horizontally and match it with the inner race coaxially. Rotating the outer race, insert balls (5), support (6) into the plug (4) hole one by one with a round bar.
Page 206 Swing Bearing SP002329 Page 10...
Page 207 Lower Structure and Chassis...
Page 209: Assembly
SP002494 TRACK ASSEMBLY SP002494 Track Assembly Edition 1 Track Assembly SP002494 Page 1...
Page 210 MEMO Track Assembly SP002494 Page 2...
Page 211 Table of Contents Track Assembly Safety Instructions ..........5 Applicable Models ..........5 General Description ..........6 Track Tension ............7 Cleaning and Inspection (Wear Limits and Tolerances)............9 Track Shoe ..............10 Lower Roller ..............12 Upper Roller ..............13 Front Idler ..............
Page 212 MEMO Track Assembly SP002494 Page 4...
Page 213: Safety Instructions
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX225LC-3 1001 and Up, 50001 and Up Track Assembly SP002494 Page 5...
Page 214: General Description
GENERAL DESCRIPTION The track assembly is composed of the following major components: Track Front Idler Roller Upper Roller Lower Roller Track Spring and Track Adjustment Cylinder Track Assembly SP002494 Page 6...
Page 215: Track Tension
TRACK TENSION WARNING AVOID DEATH OR SERIOUS INJURY Measuring track tension requires two people. One person must be in the operator's seat, operating the controls while the other person makes dimensional checks. Block frame to make sure the machine won't move or shift position during service.
Page 216 The increased clearance recommended for muddy, sandy or snowy ground conditions is between distance "C" on below table. Recommended Terrain Type Distance "A" 290 - 310 mm Normal "B" (11.40 - 12.20 in) 310 - 340 mm Muddy, Sandy or Snowy "C" (12.20 - 13.40 in) WARNING AVOID DEATH OR SERIOUS INJURY...
Page 217: Cleaning And Inspection
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) CAUTION AVOID INJURY Refer to the "Welding Precautions and Guidelines" information in "General Maintenance Procedures" section general recommendations specific safety precautions, before starting any lower travel frame component rebuilding procedure. The tables that follow provide factory specified dimensional limits (as new condition, recommended service and replacement limit) for lower travel frame components.
Page 218: Track Shoe
Track Shoe 2, 7 2, 7 FG023178 Figure 4 Track Assembly SP002494 Page 10...
Page 219 Limit for Use Recommended Limit Check Item Standard Dimension (Repair - P or for Maintenance Replace - R) 190 mm 193 mm 194.5 mm [R] Link Pitch (7.48") (7.598") (3.72") Bushing Outside 59 mm 57 mm 54.0 mm [R] Diameter (2.323") (2.244") (2.126")
Page 220: Lower Roller
Lower Roller FG022504 Figure 5 Limit for Use Recommended Limit for Check Item Standard Dimension (Repair - P or Maintenance Replace - R) Outside Diameter 185 mm of Flange (7.283") Outside Diameter 154 mm 150 mm 166 mm (P) of Tread (6.063") (5.906") (6.535")
Page 221: Upper Roller
Upper Roller FG022505 Figure 6 Limit for Use Recommended Limit for Check Item Standard Dimension (Repair - P or Maintenance Replace - R) Outside Diameter of 169 mm 165 mm Flange (6.654") (6.496") Outside Diameter of 142 mm 136 mm 130 mm (P) Tread (5.591")
Page 222: Front Idler
Front Idler FG022506 Figure 7 Limit for Use Recommended Limit for Check Item Standard Dimension (Repair - P or Maintenance Replace - R) Outside Diameter of 541.6 mm Flange (21.322") Outside Diameter of 500 mm 488 mm Tread (19.685") (19.213") 85 mm 75 mm 65 mm...
Page 223: Track Shoes And Links
TRACK SHOES AND LINKS Track Removal Position machine on a smooth level surface with adequate room for forward and reverse travel. FG019247 Figure 8 Release track tension. Refer to “Track Tension” on page -7 in this section for procedure. Move machine until master link (4, Figure 9) is positioned at approximately 4 o'clock from top position on front idle roller.
Page 224: Track Installation
Move unit forward until entire track is laying on ground. NOTE: Do not drive unit off track. FG003911 Figure 11 Rotate upper structure to 90° from track. Use bucket and boom to raise track frame off track. 10. Position blocking under frame. FG018383 Figure 12 Track Installation...
Page 225: Front Idler Roller
FRONT IDLER ROLLER Parts List FG022507 Figure 15 Reference Reference Description Description Number Number Idler Assembly Idler Floating Seal Bearing O-ring Shaft Plug Bushing Track Assembly SP002494 Page 17...
Page 226: Front Idler Roller Disassembly
Front Idler Roller Disassembly Remove plug (9, Figure 16) from idler assembly (1), and drain oil into a suitable container. FG022246 Figure 16 Separate the pin (6, Figure 17) from the bearing (3). FG022247 Figure 17 Use a press to remove bearing from the axle (4). Separate the O-ring (8, Figure 18) from the axle.
Page 227 Use a press to separate the axle (4, Figure 20), O-ring (8) and bearing (3). FG022509 Figure 20 Remove bushing (5, Figure 21) with the press and special tool (10, ST-1909). FG022510 Figure 21 Track Assembly SP002494 Page 19...
Page 228: Front Idler Roller Reassembly
Front Idler Roller Reassembly Degrease, clean and dry all parts before reassembly. Insert bushing (5, Figure 21) into the idler (2). Grease O-ring (8, Figure 22) and insert it into the axle. Align the bearing (3, Figure 22) and axle (4) holes and pin (6) them together.
Page 229 Track Assembly SP002494 Page 21...
Page 230: Lower Roller
LOWER ROLLER Parts List FG022255 Figure 25 Reference Reference Description Description Number Number Roller Floating Seal Collar O-ring Shaft Plug Bushing Bolt Track Assembly SP002494 Page 22...
Page 231: Lower Roller Removal
Lower Roller Removal Relieve track tension. Refer to "Track Tension" in this section for procedure. Swing upper structure at 90° to frame. Using bucket raise track off ground and place blocking under frame. Remove four bolts and lower roller assembly from track frame.
Page 232: Lower Roller Reassembly
Detach O-rings (7, Figure 29) from the axle. Separate floating seals (6, Figure 29) from the collar and roller (1). Detach collar (2, Figure 29) and O-rings (7) from the axle, using press. FG022515 Figure 29 Lower Roller Reassembly Degrease, clean and dry all parts before reassembly. Insert bushing (4, Figure 30) into roller.
Page 233: Lower Roller Installation
Insert floating seals (6, Figure 32) into the roller (1) and collar (2). NOTE: Apply clean gear oil (ISO VG 220EP) to the joint side of the floating seal. Apply grease to the floating seal O-ring. Slide the axle inside the roller. FG022515 Figure 32 Install the collar (2, Figure 33), O-ring (7), and pin (5) on...
Page 234: Upper Roller
UPPER ROLLER Parts List Track Frame FG022519 Figure 35 Track Assembly SP002494 Page 26...
Page 235: Upper Roller Removal
Reference Reference Description Description Number Number Roller Plug Shaft Cover Thrust Ring Washer Bushing Bolt Bushing Blot Floating Seal Spring Washer O-ring Spring Washer Upper Roller Removal Relieve track tension. This will allow track to be raised so links clear top of roller. Position a bottle jack on top of track frame and apply pressure to track shoe.
Page 236 Remove bolts (12, Figure 38) and cover (9). Detach bolts (11) and washer (10). FG022268 Figure 38 Separate the roller (1, Figure 39) from the axle (2). FG022522 Figure 39 Separate the floating seal (6, Figure 40) from the roller. Separate the thrust ring (3) from the axle.
Page 237: Upper Roller Reassembly
Upper Roller Reassembly Degrease, clean and dry all parts before reassembly. Insert bushing (4 and 5, Figure 42) into the roller (1). FG022271 Figure 42 Insert floating seal (6, Figure 43) into the roller (1) and bushing. NOTE: Apply clean engine oil to the joint side of the floating seal.
Page 238: Track Spring And Track Adjusting Cylinder
TRACK SPRING AND TRACK ADJUSTING CYLINDER Parts List Idler FG022524 Figure 45 Track Assembly SP002494 Page 30...
Page 239 Reference Reference Description Description Number Number Cylinder Body Bolt Piston Rod Spring Pin Bracket Washer Spacer U Packing Shaft Plate Spring Dust Seal Piston Ring Plate Retaining Ring Track Assembly SP002494 Page 31...
Page 240 Track Assembly SP002494 Page 32...
Page 241 Engine and Drivetrain...
Page 243 SP002328 ENGINE COOLANT HEATER (OPTION) SP002328 Engine Coolant Heater (Option) Edition 2 Engine Coolant Heater (Option) SP002328 Page 1...
Page 244 MEMO Engine Coolant Heater (Option) SP002328 Page 2...
Page 245 Table of Contents Engine Coolant Heater (Option) Safety Instructions ..........5 Applicable Models ..........5 Disassembly and Assembly........6 Changing the Circulating Pump........6 Changing the Temperature Limiter........8 Changing the Temperature Sensor ......... 9 Changing the Combustion Air Fan ........ 11 Changing the Burner, Flame Monitor and Glow Plug..
Page 246 MEMO Engine Coolant Heater (Option) SP002328 Page 4...
Page 247: Engine Coolant Heater (Option)
MODEL SERIAL NUMBER RANGE DX140LC-3 1001 and Up, 50001 and Up DX180LC-3 1001 and Up, 50001 and Up DX225LC-3 1001 and Up, 50001 and Up DX255LC-3 1001 and Up, 50001 and Up DX300LC-3 1001 and Up, 50001 and Up DX340LC-3...
Page 248: Disassembly And Assembly
DISASSEMBLY AND ASSEMBLY Changing the Circulating Pump Removal Remove heater. Disconnect the electrical connections. Remove screws (4, Figure 1). Remove clip (3, Figure 1) and circulating pump (2, Figure Complete the work on stripped-down components. Installation Apply acid-free grease to the sealing ring (1, Figure 1). Place the circulating pump (2, Figure 1) in the assembly position and attach with the clip (3, Figure 1) and screws (4, Figure 1).
Page 249 FG018670 Figure 1 Changing the Circulating Pump Reference Reference Description Description Number Number Sealing Ring Clip Circulating Pump Screw (2) NOTE: A Thermo 90 ST heater is shown. In the Thermo 90 S heater, the control unit can also be arranged on the combustion air fan without having any effect on changing the circulating pump.
Page 250: Changing The Temperature Limiter
Changing the Temperature Limiter Removal NOTE: The temperature limiter only has to be removed if it is being replaced with a new one. The function must be checked in the installed condition. Remove heater. Disconnect the electrical connections. Remove clip (2, Figure 2) and pull off the protective cap (1, Figure 2).
Page 251: Changing The Temperature Sensor
Changing the Temperature Sensor Removal Remove heater. Disconnect the electrical connections. WARNING AVOID DEATH OR SERIOUS INJURY Leaking hot coolant can cause burns. Unscrew and remove temperature sensor (6, Figure 2) and remove it with the round sealing ring (5, Figure 2). Complete the work on stripped-down components.
Page 252 FG018671 Figure 2 Changing the Temperature Limiter and Temperature Sensor Reference Reference Description Description Number Number Protective Cap Heat Exchanger Clip Round Sealing Ring Temperature Limiter Temperature Sensor NOTE: A Thermo 90 ST heater is shown. In the Thermo 90 S heater, the control unit can also be arranged on the combustion air fan without having any effect on changing the temperature sensor.
Page 253: Changing The Combustion Air Fan
Changing the Combustion Air Fan Removal Remove heater. Disconnect the electrical connections. Remove screws (2, Figure 3). Pull the combustion air fan (1, Figure 3) off the burner head (4, Figure 3) and remove with the shaped sealing ring (3, Figure 3).
Page 254 Thermo 90 S Control Unit FG018672 Figure 3 Changing the Combustion Air Fan Reference Reference Description Description Number Number Combustion Air Fan Burner Head Screw (2) Control Unit Shaped Sealing Ring NOTE: A Thermo 90 ST heater is shown. Engine Coolant Heater (Option) SP002328 Page 12...
Page 255: Changing The Burner, Flame Monitor And Glow Plug
Changing the Burner, Flame Monitor and Glow Plug Removal Remove heater. Remove combustion air fan. Remove screw (5, Figure 5) and washer (4, Figure 5). Remove nuts (10, Figure 5) and pull off the bar (8, Figure 5). Pull the grommets (11 and 12, Figure 5) out of the slots in the housing of the combustion pipe (3, Figure 5).
Page 256 FG018674 Figure 5 Changing the Burner, Flame Monitor and Glow Plug Reference Reference Description Description Number Number Burner Swirl Orifice Insulation Burner Head Nut (2) Washer Grommet Screw Grommet Glow Plug Grommet Flame Monitor NOTE: A Thermo 90 ST heater is shown. The figure can also be used for the Thermo 90 S heater.
Page 257: Changing The Burner Head
Changing the Burner Head Removal Remove heater. Remove combustion air fan. Remove burner, flame monitor and glow plug. Remove mounting screw of the V-clamping collar (2, Figure 6) and pull off the clamping collar. Pull out and remove burner head (1, Figure 6) from the heat exchanger (3, Figure 6).
Page 258 FG018675 Figure 6 Changing the Burner Head Reference Reference Description Description Number Number Burner Head Heat Exchanger V-clamping Collar NOTE: A Thermo 90 ST heater is shown. The figure can also be used for the Thermo 90 S heater. Engine Coolant Heater (Option) SP002328 Page 16...
Page 259: Changing The Heat Exchanger
Changing the Heat Exchanger Removal Remove heater. Remove circulating pump. Remove temperature limiter. Remove temperature sensor. Remove combustion air fan. Remove burner, flame monitor and glow plug. Remove burner head. Remove plug and connector housing. Complete the work on stripped-down components. Installation Clip the connector housing onto the heat exchanger and insert the plug into the connector housing.
Page 260 Engine Coolant Heater (Option) SP002328 Page 18...
Page 261 SP002495 DRIVE COUPLING (MAIN PUMP)SP002495 Drive Coupling (Main Pump) Edition 1 Drive Coupling (Main Pump) SP002495 Page 1...
Page 262 MEMO Drive Coupling (Main Pump) SP002495 Page 2...
Page 263 Table of Contents Drive Coupling (Main Pump) Safety Instructions ..........5 Applicable Models ..........5 Drive Coupling ............6 Special Tools ............7 Installation of Drive Coupling ........ 8 Installation Procedure............ 10 Drive Coupling (Main Pump) SP002495 Page 3...
Page 264 MEMO Drive Coupling (Main Pump) SP002495 Page 4...
Page 265: Safety Instructions
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX225LC-3 1001 and Up, 50001 and Up Drive Coupling (Main Pump) SP002495 Page 5...
Page 266: Drive Coupling
DRIVE COUPLING It is very important to set specified clearance between the end of the pump driveshaft (the "Dimension H" described below) and the coupling hub surface when installing the main pump in the engine. The Figure 1 shows installation of a typical drive coupling. FG019390 Figure 1 Drive Coupling (Main Pump)
Page 267: Special Tools
HAAA8020 Figure 2 Relief Relief KNURL HAAA8360 Figure 3 Model 10.5 ± 5.0 ± Radius, Radius, Radius, 1.0 mm DX225LC-3 20.0mm 7.0 mm 0.1mm 0.1mm 12.0 mm 14.0 mm 25.0 mm X 45° Drive Coupling (Main Pump) SP002495 Page 7...
Page 268: Installation Of Drive Coupling
INSTALLATION OF DRIVE COUPLING Follow the installation dimensions and procedures whenever installing the drive coupling in the main pump. HAAA8040 Figure 4 Installation of Drive Coupling Drive Coupling (Main Pump) SP002495 Page 8...
Page 269 Coupling Part MODEL Measure H Torque of Ta Torque of Tb Reference DX225LC-3 2414-9041 10.0 - 11.0 mm 21 - 23 kg 10 - 12 kg • • Drive Coupling (Main Pump)
Page 270: Installation Procedure
Installation Procedure NOTE: Refer to Figure 5 for the installation procedure. Install spring pin (1) and then insert (2) with bolt (3) into engine flywhee (4). NOTE: Tighten the bolt using the torque Ta value specified in the table. Install two spring pins (5) and then insert (6) bolt (8) in hub (7).
Page 271 Hydraulics...
Page 273 SP002535 HYDRAULIC SYSTEM TROUBLESHOOTING, TESTING AND ADJUSTMENTSP002535 Hydraulic System Troubleshooting, Testing and Adjustment Edition 1 Hydraulic System Troubleshooting, Testing and Adjustment SP002535 Page 1...
Page 274 MEMO SP002535 Hydraulic System Troubleshooting, Testing and Adjustment Page 2...
Page 275 Table of Contents Hydraulic System Troubleshooting, Testing and Adjustment Safety Instructions ..........5 Applicable Models ..........5 Hydraulic System - General Notes ....... 6 Hydraulic Schematic ..........7 General Notes ..............7 Operation of Working Components ...... 9 Boom Operating Circuit ........... 9 Boom Up Circuit ..............
Page 276 Checks and Adjustments..........18 Pump Input Power Control ......... 20 Pump Regulator Adjustment ......... 20 Flow Meter and Flow Meter Kit Installation and Testing ..............23 Swing System Troubleshooting ......25 Precautions/Initial Checks ..........25 Swing Relief Valve Checking and Adjustment ....26 Troubleshooting –...
Page 277: Hydraulic System Troubleshooting, Testing And Adjustment
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX225LC-3 1001 and Up, 50001 and Up SP002535 Hydraulic System Troubleshooting, Testing and Adjustment Page 5...
Page 278: Hydraulic System - General Notes
HYDRAULIC SYSTEM - GENERAL NOTES Center Joint Travel Motor FG019034 Travel Motor Figure 1 hydraulic system several improvements over conventional hydraulic systems - including cross sensing total horsepower control - to maximize output efficiency. The system features an electronically controlled output optimization system, which allows the operator to choose between two, distinctly different power modes: high output/rapid cycling maximum speed power mode, and a standard power...
Page 279: Hydraulic Schematic
HYDRAULIC SCHEMATIC The hydraulic schematic(s) is available in the "Hydraulic and Electrical Schematic Shop Manual." This manual is a collection of diagrams and schematics for several models. General Notes When referring to the schematic, refer to the following items: • As shown in the schematic, the main pump assembly is driven by the engine.
Page 280 • The hydraulic reservoir return line has 10 micron and the pilot circuit line has 30 micron full flow filters. The disposable elements in these two canister type filters trap and remove impurities from the oil in the system. An 80 mesh, 177 micron reservoir intake strainer also helps maintain system cleanliness and should be cleaned each time hydraulic fluid is drained and replaced.
Page 281: Operation Of Working Components
OPERATION OF WORKING COMPONENTS Boom Operating Circuit The boom operating circuit includes the right and left main hydraulic pumps (both halves of the main pump assembly), both sides of the control valve and the boom cylinder. The circuit operates in boom down mode through the first shift position and through the second shift position in boom up mode.
Page 282: Arm Operating Circuit
Arm Operating Circuit The arm operating circuit includes both the right and left hydraulic main pumps, the right and left halves of the control valve, a slow return orifice, and the arm cylinder. The circuit can be operated in the two-stage speed control mode which works through both halves of the control valve and doubles the volume of oil flowing to the cylinder.
Page 283: Bucket Operating Circuit
Bucket Operating Circuit The bucket operating circuit includes the left main pump, the left half of the control valve and the bucket cylinder. 370 kg/cm (5,265 psi) overload relief valves at BKT and BKTD 1 ports of the control valve protect the circuit and its components from being damaged.
Page 284: Right Swing Operating Circuit
Right Swing Operating Circuit When the swing control lever is pushed to the right swing position, pilot pressure from the left side pilot valve is directed to CONTROL the right side pump regulator and right half of the control valve. VALVE(L) Output flow from the right pump is then directed through the PR and SWR ports of the control valve to the swing motor.
Page 285: Forward Travel Circuit
Forward Travel Circuit When the right and left travel control levers are pushed forward, TRAVEL TRAVEL MOTOR(L) MOTOR(R) output from both of the main pumps is directed through the PR, PL, TRRF, and TRLF ports on the control valve, through the CENTER JOINT upper works center joint, to the travel motors on each side of the machine.
Page 286: Procedural Troubleshooting Baseline Recommendations
PROCEDURAL TROUBLESHOOTING BASELINE RECOMMENDATIONS Initial Checks and Tests to Establish Operating Condition of the Excavator Troubleshooting Recommendations An excavator that fails to deliver designed performance should be checked for the following: • First hydraulic flow. • Then hydraulic pressure in a specified order of priority through different points of the system.
Page 287 System specification performance tests of NOTE: individual activator function are determined by flow rate through the component or circuit, not the control pressure or system pressure available to the actuator. Poor flow through the individual circuit may indicate that component is worn beyond tolerance limits, while all other hydraulic functions are adequate.
Page 288: Pilot Pressure
PILOT PRESSURE Adjustment and Testing WARNING AVOID DEATH OR SERIOUS INJURY This procedure should be done with two people. To reduce the chance of accidental movement of the excavator, one person should be properly seated at the operator's controls while checks and adjustments are made. Vent hydraulic pressure from the reservoir before breaking the seal on fittings to install two in-line "T-style"...
Page 289: Power Mode Valve
The jumper harness (which is available through DOOSAN After Sales Service, or could be spliced together from commonly available, purchased parts) has extra leads so a VOM meter can be connected to the circuit. To set up the testing equipment, stop engine and disconnect the single electrical lead from the power mode valve.
Page 290: Pressure Up Valve
PRESSURE UP VALVE Checks and Adjustments WARNING AVOID DEATH OR SERIOUS INJURY This procedure should be done with two people. To reduce the chance of accidental movement of the excavator, one person should be properly seated at the operator's controls while checks and adjustments are made.
Page 291 Main Pressure and Pilot Pressure and Power Mode Operation Tolerance Tolerance 20 - 40 kg/cm 40 ± 10 kg/cm Power Mode Neutral, No Operation (285 - 570 psi) (569 ± 142 psi) 330 ± 5 kg/cm 40 ± 10 kg/cm Power Mode Cylinder Stall (4,693 ±...
Page 292: Pump Input Power Control
PUMP INPUT POWER CONTROL Pump Regulator Adjustment WARNING AVOID DEATH OR SERIOUS INJURY This procedure should be done with two people. To reduce the chance of accidental movement of the excavator, one person should be properly seated at the operator's controls while checks and adjustments are made.
Page 293 adjustment, the pump which supplies output to the track frame toward which the excavator is veering is weak. FG000654 Figure 12 Refer to the illustration of the pump regulator control valve (Figure 12) for the location of adjustment screws (1, 2 and 3). There are two different adjustments, with the Negacon, negative control, adjustment screw (3, directly below 1 and 2).
Page 294 or adjusting one of them, the remaining unit should also be checked. Start the engine and turn the engine speed dial to maximum. When normal operating temperature is reached, loosen the largest diameter locknut around the adjustment screw (2) for the outer regulator spring.
Page 295: Flow Meter And Flow Meter Kit Installation And Testing
The After Sales Service department of the nearest local DOOSAN dealer can assist you with these tests or, if you prefer performing your own testing, they should be able to help in putting together a hose and fitting kit (or the required dimensions and specifications for hoses and fittings) to allow you to install a flow meter downstream from the main pump assembly.
Page 296 • Unloaded maximum engine speed baseline test (all controls in neutral). • Front pump test – operate "travel right" lever. Record values at all specified pressures. • Rear pump test – operate "travel left" lever. Record values at all specified pressures. Record the values for each of the three tests (neutral, travel right and travel left) at the following pump pressure levels, with travel speed control set at "high-speed."...
Page 297: Swing System Troubleshooting
SWING SYSTEM TROUBLESHOOTING Precautions/Initial Checks Stop work. Release all weight or any load safely before proceeding. Avoid risking injury or adding to damage. Stop engine and disengage control functions until initial tests are ready to be made. WARNING AVOID DEATH OR SERIOUS INJURY Stop operation and park excavator whenever these problems are noticed: Equipment breakdown.
Page 298: Swing Relief Valve Checking And Adjustment
Swing Relief Valve Checking and Adjustment Make a check of operating pressures through the swing relief valve if: • The swing motor fails to turn. • Swings in one direction only. • Swings but continues to coast. • There is drifting on a slope. Check operation by connecting: Two 500 kg/cm (7,112 psi) pressure gauges to the...
Page 299 fails to release, the brake piston or friction plate may be frozen, requiring disassembly of the motor and parts repair/ replacement. If pressure tested at the motor makeup valve drops below recommended minimum level, and consequent problems with cavitation, stalling and surging are observed, check the restriction valve.
Page 300: Troubleshooting - Swing Gearbox
TROUBLESHOOTING – SWING GEARBOX Problem Possible Cause Remedy Swing motor fails to operate and: Three pressure tests at Swing relief valve defective. Adjust pressure to recommended range motor, brake or makeup Brake release valve defective. in affected valve. valve show low reading (s). Motor makeup valve defective.
Page 301: Troubleshooting - Hydraulic Problems
Problem Possible Cause Remedy Pressure at swing motor Swing motor driveshaft damage. Replace swing motor. inlet shows no increase, Internal damage to gearbox Repair/Replace broken or faulty and the swing motor is drivetrain. assemblies. making irregular noises. Pressure at swing motor Hydraulic pump or valve problem.
Page 302 Problem Possible Cause Remedy Oil temperature abnormally Oil cooler clogged or air circulation Clean. high. to cooler blocked. Cooling fan belt tension too loose. Readjust belt tension. Relief valve set too low. Readjust valve. Relief valve in constant use. Reduce or slow workload or cycling rate. Hydraulic oil severely neglected or Replace oil.
Page 303: Troubleshooting - Control Valve
TROUBLESHOOTING – CONTROL VALVE Check control valve problems only after other hydraulic circuit operational tests have been made. Refer "Troubleshooting Baseline Recommendations" procedure. Pump flow, pilot pressure, Negacon pressure, main relief pressure, and port relief pressure should all be checked before starting to work on the control valve.
Page 304: Troubleshooting - Travel Control Valve
Problem Possible Cause Remedy Irregular or uneven Poppet seat damaged or pilot Clean/replace. pressure. piston sticking to main poppet. Loose locknut and adjusting screw. Readjust. Components worn out, past wear Replace. limits. TROUBLESHOOTING – TRAVEL CONTROL VALVE Problem Possible Cause Remedy Secondary pressure does Low primary pressure.
Page 305: Troubleshooting - Joystick Control Valve
TROUBLESHOOTING – JOYSTICK CONTROL VALVE Problem Possible Cause Remedy Secondary pressure does Low primary pressure. Check primary pressure. not increase. Broken spring. Replace spring. Spool sticking. Clean, repair or replace. Excess spool to casing clearance. Replace spool casing. Worn or loose handle subassembly. Repair or replace handle subassembly.
Page 306 Hydraulic System Troubleshooting, Testing and Adjustment SP002535 Page 34...
Page 307 SP002455 ACCUMULATOR SP002455 Accumulator Edition 1 Accumulator SP002455 Page 1...
Page 308 MEMO Accumulator SP002455 Page 2...
Page 309 Table of Contents Accumulator Safety Instructions ..........5 Applicable Models ..........5 General Description ..........6 Specifications ..............8 Accumulator SP002455 Page 3...
Page 310 MEMO Accumulator SP002455 Page 4...
Page 311: Safety Instructions
MODEL SERIAL NUMBER RANGE DX140LC-3 1001 and Up, 50001 and Up DX180LC-3 1001 and Up, 50001 and Up DX225LC-3 1001 and Up, 50001 and Up DX255LC-3 1001 and Up, 50001 and Up DX300LC-3 1001 and Up, 50001 and Up DX340LC-3...
Page 312: General Description
GENERAL DESCRIPTION The accumulator is a gas-charged storage device designed to hold a reserve quantity of hydraulic fluid under pressure. Accumulators are used in hydraulic circuits in much the same way that condensers (or capacitors) are used to collect, store and maintain electrical charge in a circuit.
Page 313 When hydraulic fluid is pushed out the lower valve opening by the pressure of the gas charge on the other side of the diaphragm - and there is no counterpressure from system oil - the valve button on the bottom of the diaphragm eventually seals off the lower oil passage.
Page 314: Specifications
10 kg/cm DX180LC-3 Pilot S/N 50001 and Up (140 psi) (19.53 in S/N 1001 and Up 320 cc 10 kg/cm DX225LC-3 Pilot S/N 50001 and Up (140 psi) (19.53 in 320 cc S/N 1001 and Up 10 kg/cm DX255LC-3 Pilot...
Page 315 SP002456 CENTER JOINT (SWIVEL)SP002456 Center Joint (Swivel) Edition 2 Center Joint (Swivel) SP002456 Page 1...
Page 316 MEMO Center Joint (Swivel) SP002456 Page 2...
Page 317 Table of Contents Center Joint (Swivel) Safety Instructions ..........5 Applicable Models ..........5 General Description ..........7 Parts List ................. 8 Troubleshooting, Testing and Adjustment .... 9 Inspection ................ 9 Testing................9 Disassembly ............10 Reassembly ............13 Center Joint (Swivel) SP002456 Page 3...
Page 318 MEMO Center Joint (Swivel) SP002456 Page 4...
Page 319: Center Joint (Swivel)
MODEL SERIAL NUMBER RANGE DX140LC-3 1001 and Up, 50001 and Up DX180LC-3 1001 and Up, 50001 and Up DX225LC-3 1001 and Up, 50001 and Up DX255LC-3 1001 and Up, 50001 and Up DX300LC-3 1001 and Up, 50001 and Up Center Joint (Swivel)
Page 320 Center Joint (Swivel) SP002456 Page 6...
Page 321: General Description
GENERAL DESCRIPTION The center joint (swivel) is designed to allow hydraulic oil from the upper structure to flow to components in the lower structure. It is capable of allowing continuous 360° rotation of the upper structure in relationship to the lower structure. Center Joint (Swivel) SP002456 Page 7...
Page 322: Parts List
Parts List Figure 1 Reference Reference Description Description Number Number O-ring (1AP105) Shaft O-ring (1BP90) Cover Retaining Ring Spacer PT-Plug (PT1/4) Shim Bolt (M12) Shim Spring Washer Wear Ring O-ring (1AG100) Slipper Seal Center Joint (Swivel) SP002456 Page 8...
Page 323: Troubleshooting, Testing And Adjustment
TROUBLESHOOTING, TESTING AND ADJUSTMENT Inspection The center joint should be checked for evidence of external oil leakage every 2,000 operating hours. Leaking or defective O-rings are an indication that dirt and other contaminants could be getting inside the assembly, which will promote accelerated, abnormal wear and can cause early failure of the assembly.
Page 324: Disassembly
DISASSEMBLY IMPORTANT Do not unbolt the center joint from the lower frame until an adequate number of piping block off plates are available, for disconnected piping lines. Be sure that system pressure has been relieved - including the hydraulic accumulator and tank reserve pressure - before disassembly is started.
Page 325 IMPORTANT Care should be taken not to make a scratch or damage the surface of the shaft when disassembling the Hub of the Shaft assembly. Disassemble the hub from the shaft assembly. It can be disassembled easily by fixing the shaft assembly, tightening at least 2-10 mm eyebolts on the Hub, and lifting it with a hoist slowly.
Page 326 Remove PT plugs sealing the shaft * PT 1/4: 6 mm wrench FG013237 Figure 7 10. Remove foreign substance on pieces disassembled and wash them out. 11. Replace disassembled O-rings and slipper seals with new ones, for they cannot be reused. 12.
Page 327: Reassembly
REASSEMBLY IMPORTANT Apply a very light film of white grease or petroleum jelly to the lower rim of the stem and inner surface of the center swivel body. Apply slow, evenhanded pressure, using both hands, to slowly push the stem into the body. Seals may be damaged if the stem is pushed in too quickly.
Page 328 IMPORTANT For any slipper seal which is protruded, press it with finger to seat it in its position. Care should be taken when using a driver or a metal tool, which can cause damage the seal. IMPORTANT Applying oil to the surface of the shaft will help prevent damage to the slipper seal.
Page 329 SP002497 CYLINDERS SP002497 Cylinders Edition 1 Cylinders SP002497 Page 1...
Page 330 MEMO SP002497 Cylinders Page 2...
Page 331 Table of Contents Cylinders Safety Instructions ..........5 Applicable Models ..........5 General Description ..........6 Theory of Operation ............6 Parts List ................. 8 Special Tools and Materials ....... 14 Piston Nut..............14 Piston Jig............... 16 Steel Bushing Jig............19 Dust Wiper Jig ...............
Page 332 MEMO SP002497 Cylinders Page 4...
Page 333: Safety Instructions
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX225LC-3 1001 and Up, 50001 and Up SP002497 Cylinders Page 5...
Page 334: General Description
GENERAL DESCRIPTION Two essentially similar types of hydraulic cylinders are used on the excavator. The cylinder that is used to operate the excavator boom or bucket is equipped with a rod stopper, which acts as a cushion only when the cylinder rod is fully retracted (and the bucket is pulled close to the arm).
Page 335 Because the volume of oil needed to lengthen the cylinder rod (Q1) is greater than the volume of oil required to retract the cylinder rod, it takes more time to extend a cylinder than it does to retract it. π(D = S x π(D = S x...
Page 336: Parts List
Parts List The following parts list is a partial listing only; for complete parts list information, refer to the Hydraulic Equipment Component Parts List. Cross-section in Figure 4 shows an arm cylinder. Cross-section in Figure 5 shows a boom cylinder (LH). Cross-section in Figure 6 shows a boom cylinder (RH).
Page 337 Reference Reference Description Description Number Number Tube Ass’y Piston Nut Bush Steel Ball Cylinder Rod Set Screw Bush Cushion Plunger Rod Cover Stop Ring DD-Bushing Socket Bolt Retaining Ring Check Valve Buffer Seal Spring U-packing Spring Support Backup Ring O-ring Dust Wiper Plug Pipe Band Ass’y: B...
Page 338 FG024695 Figure 5 Cylinders SP002497 Page 10...
Page 339 Reference Reference Description Description Number Number Cylinder Tube O-ring Bush Backup Ring Cylinder Rod Ass’y Piston Nut Bush Set Screw Rod Cover Socket Bolt DD-bush Pipe Band Ass’y Retaining Ring Pipe Band Buffer Seal Spring Washer U-packing Bolt Backup Ring H Pipe Ass’y (L.H) Dust Wiper O-ring...
Page 340 FG024696 Figure 6 Cylinders SP002497 Page 12...
Page 341 Reference Reference Description Description Number Number Cylinder Tube O-ring Bush Backup Ring Cylinder Rod Ass’y Piston Nut Bush Set Screw Rod Cover Socket Bolt DD-bush Pipe Band Ass’y Retaining Ring Pipe Band Buffer Seal Spring Washer U-packing Bolt Backup Ring H Pipe Ass’y (R.H) Dust Wiper O-ring...
Page 342: Special Tools And Materials
SPECIAL TOOLS AND MATERIALS Piston Nut FG018703 Figure 7 Material SM45C (AISI 1045) Rockwell Hardened from 22 - 27 Oil Quench Cylinders SP002497 Page 14...
Page 343 Hex 90 Boom Hex 80 Hex 90 DX180LC-3/ DX190W-3 Bucket Hex 80 Arti Hex 100 Boom Hex 80 Hex 110 DX225LC-3 Bucket Hex 80 Arti Hex 110 Boom Hex 90 Hex 110 DX255LC-3 Bucket Hex 90 Arti Hex 110 Boom...
Page 344: Piston Jig
Piston Jig 2-∅"B" ∅ Through Hole R(R15~20) ARS4740L Figure 8 Material SM45C (AISI 1045) Rockwell Hardened from 22 - 27 Oil Quench Cylinders SP002497 Page 16...
Page 345 (2.95 in) (4.92 in) 110.0 mm 13.0 mm 85.0 mm 140.0 mm (4.33 in) (0.51 in) (3.35 in) (5.51 in) DX225LC-3 90.0 mm 13.0 mm 67.0 mm 120.0 mm Bucket (3.54 in) (0.51 in) (2.64 in) (4.72 in) 120.0 mm 13.0 mm...
Page 346 ø ø ø Model Cylinder A (±0.1) Model (Cylinder) 130.0 mm 13.0 mm 100.0 mm 160.0 mm Boom (5.12 in) (0.51 in) (3.94 in) (6.30 in) 135.0 mm 13.0 mm 105.0 mm 170.0 mm DX380LC-3 (5.31 in) (0.51 in) (4.13 in) (6.70 in) 120.0 mm 13.0 mm...
Page 347: Steel Bushing Jig
Steel Bushing Jig (∅20) ARS4750L Figure 9 Material: SM45C which is done thermal refining <QT> HRC 22 - 28 Undefined Chamfer C/R = 0.5 Max. Place: Finally work to used DNMG Tip <Nose R0.4> SP002497 Cylinders Page 19...
Page 348 (1.57 in) (0.26 in) 80.0 mm 95.0 mm 40.0 mm 6.5 mm (3.15 in) (3.74 in) (1.57 in) (0.26 in) DX225LC-3 80.0 mm 95.0 mm 40.0 mm 6.5 mm Bucket (3.15 in) (3.74 in) (1.57 in) (0.26 in) 100.0 mm 115.0 mm...
Page 349 ø -0.05 ø +0.05 Model Cylinder B (±0.1) Part Model (Cylinder) -0.15 105.0 mm 120.0 mm 45.0 mm 7.5 mm HEAD SIDE (4.13 in) (4.72 in) (1.77 in) (0.30 in) Boom 100.0 mm 115.0 mm 45.0 mm 7.5 mm ROD SIDE DX340LC-3/ (3.94 in) (4.53 in)
Page 350: Dust Wiper Jig
Dust Wiper Jig ARS4760L Figure 10 Material: SM45C which is done thermal refining <QT> HRC 22 - 28 Undefined Chamfer C/R = 0.5 Max. Place: Finally work to used DNMG Tip <Nose R0.4> Cylinders SP002497 Page 22...
Page 351 (0.24 in) (0.28 in) 100.0 mm 114.0 mm 6.0 mm 7.0 mm (3.94 in) (4.49 in) (0.24 in) (0.28 in) DX225LC-3 80.0 mm 94.0 mm 6.0 mm 7.0 mm Bucket (3.15 in) (3.70 in) (0.24 in) (0.28 in) 100.0 mm 114.0 mm...
Page 352 -0.2 -0.2 Model Cylinder ø ø Model (Cylinder) -0.3 -0.3 -0.1 100.0 mm 114.0 mm 6.0 mm 7.0 mm Boom (3.94 in) (4.49 in) (0.24 in) (2.28 in) DX340LC-3/ 120.0 mm 136.0 mm 6.0 mm 7.0 mm DX350LC-3 (4.72 in) (5.35 in) (0.24 in) (2.28 in)
Page 353: Slipper Seal Jig
Slipper Seal Jig (B+40) ARS4770L Figure 11 SP002497 Cylinders Page 25...
Page 354 (6.30 in) (1.36 in) 125.0 mm 28.5 mm Boom (4.92 in) (1.12 in) 140.0 mm 28.5 mm (5.51 in) (1.12 in) DX225LC-3 120.0 mm 28.5 mm Bucket (4.72 in) (1.12 in) 150.0 mm 28.5 mm Arti (5.91 in) (1.12 in) 130.0 mm...
Page 355 +0.2 +0.2 ø Model Cylinder Model (Cylinder) +0.1 +0.1 160.0 mm 34.5 mm Boom (6.30 in) (1.36 in) 170.0 mm 41.5 mm DX380LC-3 (6.69 in) (1.63 in) 150.0 mm 34.5 mm Bucket (5.91 in) (1.36 in) 170.0 mm 34.5 mm Boom (6.69 in) (1.36 in)
Page 356: Slipper Seal Straightening Jig
Slipper Seal Straightening Jig ∅ ARS4780L Figure 12 Cylinders SP002497 Page 28...
Page 357 DX180LC-3 110.0 mm Bucket (4.33 in) 160.0 mm Arti (6.30 in) 125.0 mm Boom (4.92 in) 140.0 mm (5.51 in) DX225LC-3 120.0 mm Bucket (4.72 in) 150.0 mm Arti (5.91 in) 110.0 mm Boom (4.33 in) 115.0 mm (4.53 in) DX140W-3 95.0 mm...
Page 358 +0.2 ø Model Cylinder Model (Cylinder) +0.1 160.0 mm Boom (6.30 in) 170.0 mm DX380LC-3 (6.69 in) 150.0 mm Bucket (5.91 in) 170.0 mm Boom (6.69 in) 180.0 mm DX420LC-3 (7.09 in) 160.0 mm Bucket (6.30 in) 170.0 mm Boom (6.69 in) DX490LC-3/ 190.0 mm...
Page 359: Disassembly
DISASSEMBLY IMPORTANT Vent air from the hydraulic system before disconnecting cylinder piping connections. Use the lever on the reservoir, while the engine is running. Discharge the hydraulic accumulator and vent residual tank pressure after the engine is shut off. Pour clean replacement hydraulic fluid into the system if excessive fluid is lost.
Page 360 Tap two bolts into cover of cylinder head, 180° apart. Tighten them in a staggered, even sequence, to back off piston rod end cover from edge of cylinder wall. Look for adequate clearance between cover and end of cylinder wall before using a plastic or other soft faced hammer for final disassembly.
Page 361 Figure 20 Fabricate or purchase a piston nut removal wrench. (Dimensions are called off at beginning of this procedure. This tool may also be ordered through your local DOOSAN Parts distributor). Remove nut from end of piston. Figure 21 10. Use second piston tool described at beginning of this procedure to separate piston.
Page 362 12. Use a dull, rounded tip tool to pry off O-ring (13) and backup ring (14). HAOF37OL Figure 24 13. Find a screwdriver with an appropriate width tip to facilitate removal of slipper seal (18), wear ring (19) and slide ring (20) from piston (17).
Page 363 16. Disassemble retaining ring (12) and dust wiper (11). Separate retaining ring (7) and rod bushing (6). Figure 28 17. Force out pin bushing (2), (4) from body of cylinder. Figure 29 SP002497 Cylinders Page 35...
Page 364: Reassembly
REASSEMBLY IMPORTANT Before reassembly: • Inspect and replace damaged or excessively worn parts. • Clean parts and lubricate with clean hydraulic oil. • Make sure work area is clean. Replace any part that shows evidence of damage or excessive wear. Replacement of all O-rings and flexible seals is strongly recommended.
Page 365 Following reassembly of rod cover components, install the dust wiper (11) and rod bushing (6) to the rod cover (5). Insert retaining rings (7 and 12). Figure 31 Prelubricate O-rings and seals before reassembly (Figure 32). Figure 32 Before starting to rebuild piston assembly, heat slipper seal for 5 minutes in an oil bath warmed to 150°...
Page 366 Immobilize piston rod on solid support blocks. Assemble O-ring (21) and backup ring (22). Prepare to attach rod cover assembly to piston rod. Push rod cover by tightening piston nut (23). Figure 34 Assemble cushion ring (16) and attach piston assembly to piston rod.
Page 367 Immobilize body of cylinder before reassembly. Figure 38 Pre-apply fastener locking compound (Loctite #242 or #243 or an alternate manufacturer's equivalent product) to all end cover retaining bolts. Wrap a protective cushion around end of rod while tightening fasteners, to prevent possible damage to polished surface of rod, should a wrench slip during retightening.
Page 368 Cylinders SP002497 Page 40...
Page 369 SP002498 SWING DEVICE SP002498 Swing Device Edition 1 Swing Device SP002498 Page 1...
Page 370 MEMO SP002498 Swing Device Page 2...
Page 371 Table of Contents Swing Device Safety Instructions ..........5 Applicable Models ..........5 Indication of Type ..........6 Specifications ............7 Structure and Principle of Operation ....8 Structure................8 Principles of Operation ..........13 Valve Casing ..............14 Brake Part ..............17 Cautions for Operation ........
Page 372: Swing Device
MEMO SP002498 Swing Device Page 4...
Page 373: Safety Instructions
The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX180LC-3 1001 and Up, 50001 and Up DX190W-3 1001 and Up DX225LC-3 1001 and Up, 50001 and Up SP002498 Swing Device Page 5...
Page 374: Indication Of Type
INDICATION OF TYPE – 1600 – Design code Max. theoretical output torque Reduction gear type If or not there is an auxiliary device. B: Mechanical brake installed Type of valve cover Capacity 72: 72.0 cc/rev 86: 86.0 cc/rev 128: 127.9 cc/rev 132: 131.8 cc/rev Type of motor Swing Device...
Page 375: Specifications
SPECIFICATIONS DX180LC-3 DX190W-3 DX225LC-3 Model TSM128CHB-RG1600 Displacement (cc/rev) Set Pressure of Relief Valve (kg/cm Nomal 1,250 (min Maximum 1,700 (min Motor Theoretical Output Torque 56.0 56.0 55.0 • Brake Torque • Brake Release Pressure (kg/cm Weight (kgf) No.1 Sun Gear Module: 3, No.
Page 376: Structure And Principle Of Operation
STRUCTURE AND PRINCIPLE OF OPERATION Structure Structural Diagram (Motor) FG022304 Figure 1 Motor Structure Swing Device SP002498 Page 8...
Page 377 Reference Reference Description Description Number Number Casing Valve Roller Plug Washer Spring Spring Plunger Ring Snap Swing Reactionless Valve Assembly Valve Plate Relief Valve Casing S1 Ball Bearing Oil Seal Socket Bolt Roller Bearing VP Plug Separation Plate O-ring Friction Plate Pin Spring O-ring Driveshaft...
Page 378 Structural Diagram (Reduction Gear) FG022340 Figure 2 Reduction Gear Structure Swing Device SP002498 Page 10...
Page 379 Reference Reference Description Description Number Number Casing Inner Ring Pinion Shaft Needle Bearing Spherical Roller Bearing No.1 Thrust Washer Spherical Roller Bearing Thrust Plate Oil Seal Flat Head Screw Cover No.2 Carrier Flat Head Screw No.2 Sun Gear No.3 Thrust Washer No.2 PL Gear Hex Bolt No.2 Pin...
Page 380 Structural Diagram (Swing Device) FG022341 Figure 3 Swing Device Structure Reference Reference Description Description Number Number Level Gauge Socket Bolt Swing Device SP002498 Page 12...
Page 381: Principles Of Operation
Principles of Operation Hydraulic Motor High-pressure oil from the control valve is routed through valve casing and valve plate to pistons. When the oil enters the cylinder bores through port, it forces the pistons against the fixed and inclined swash plate (F1, F2). The force (F2) causes the piston shoes to slide on the swash plate forcing the rotating group to turn, thereby rotating the output shaft.
Page 382: Valve Casing
Valve Casing Anticavitation check valve The motor can be rotated faster than supplied oil flow because there is no counterbalancing valve to prevent over speed : in order to prevent cavitation of the motor, oil compensation insufficient flow is drawn through the anticavitation check valve.
Page 383 Spring Piston (321) (302) P. Port HYD. Area A1 Plunger HYD. Area A2 Adjust Plug (301) (Pressure : Pg) (401) Pressure: Ps FG018897 Figure 6 Relief Valve: Operation Diagram of KRD22EK10C SP002498 Swing Device Page 15...
Page 384 Reactionless valve By the spool's shift in the main control valve, oil is supplied to Hydraulic motor's A port (or B port), and the poppet of reactionless valve moves, then it blocks the bypass. As a result, swing device is operated. (1, Figure 7) If the spool is returned to neutral position, it blocks the two ports of Hydraulic motor but the swing device tends to swing by inertia-force.
Page 385: Brake Part
Brake Part The cylinder block (205) consists of the driving shaft (201) and the spline. The separation plate (305) is kept from the revolution in the cylindrical direction by the arc opening processed at the casing. A friction force occurs among the friction plate (306) in the tooth combination at the circumference of the cylinder block and the casing (301), the separation plate (305), and the brake piston (309) when the friction plate is pressed against the casing...
Page 386: Cautions For Operation
CAUTIONS FOR OPERATION Inspection Prior to installation of a new motor, inspect the following items. Inspect whether or not there is any damage during transit, or if any parts are lost missing. Inspect each tightened part to see if it is loosened or not. Check whether or not covers for flange surface and drain port are perfect, and if the inside of the motor is dirty with intruded dust.
Page 387: External Load At The End Of Shaft
External Load at the End of Shaft In principle, the end of the motor shaft should be free of any external radial or thrust load. Hydraulic Oil and Temperature Range Oil type Generally used mineral hydraulic active recommended, but with additives of extreme pressure, foaming preventive prevention, oxidization prevention, and dampproofing as well as high coefficient of viscosity.
Page 388: Filter
Active Oil Other than Mineral Oil If you are going to use phosphoric acid-, water-glycol, or fatty acid-based active oil, please contact a Doosan distributor for more information. in advance. Filter If fine particles of dirt and metal are mixed with oil, they enter into sliding surfaces and accelerate wear in each part, and in the worst case sticking will be likely to occur.
Page 389: Oil Filling And Air Breather
Oil Filling and Air Breather Fill in the casing with oil by using the drain port before the operating. In the motor, there are many kinds of high-speed sliding surface like bearing, piston, shoe, spherical bushing, and etc. So If there isn't enough oil, it can make some problem like sticking or damage.
Page 390: Troubleshooting
TROUBLESHOOTING General Pre-caustions Pre-cautions to be taken when troubles have happened while the motor is in operation are described as below: As for general precaution. Consider a cause of the trouble before repairing. Before setting to work, think whether the same thing has happened before or not.
Page 391: Troubleshooting
Troubleshooting Motor does not rotate Symptom Possible Cause Corrective Action The pressure of the circuit is not Setting pressure of relief Reset the pressure to increasing. valve is incorrect. correct value. Relief valve malfunction. Plunger sticks. Revise or exchange of stick face. Plunger orifice clogged.
Page 392 Rotating speed fails to reach setting value Symptom Possible Cause Corrective Action Rotating speed fails to reach The volume incoming flow Check discharge volume of setting value. is not sufficient. pump and circuit up to the motor. The temperature is too high Reduce the oil temperature.
Page 393 Oil leak Oil leak at the oil seal Symptom Possible Cause Corrective Action Oil leak from the oil seal The lip is dirty or damaged. Replace the oil seal. The shaft may be damaged Replace the driving shaft or or worn out. defective centering of the driving shaft.
Page 394: Disassembly And Reassembly
DISASSEMBLY AND REASSEMBLY Tightening Torque of Bolts Table 1 shows tightening torque of bolts used in motor. Observe the specified torque when tightening the bolts. Table 1 Bolt Size Type Tightening Torque (kg•cm) Part No. Hexagon Bolt 120 ± 20 Hexagon Socket Bolt 4,400 ±...
Page 395 2 x o9 (effectiveness screw length: 20) o169 o240 FG022440 Figure 13 Tools for Break Piston Disassembly SP002498 Swing Device Page 27...
Page 396: Disassemble Swing Motor
Disassemble Swing Motor Please use the following procedures for the inspection and repair of the motor. Numerals given in parentheses following the parts names indicate the parts number shown by the drawing in the instruction and maintenance manual. Wind the wire rope around motor, Lift up the motor with a crane and clean the motor with cleaning oil.
Page 397 Remove RO plug (102) and take out spring (103) and plunger (104) from valve casing (101). FG022405 Figure 17 Remove swing reactionless valve assembly (105) from valve casing (101). FG022406 Figure 18 Remove hex socket bolts (109, 110) and disassemble valve casing (101) from casing (301).
Page 398 10. Disassemble brake piston (309) from casing (301) by using the special tool for removing the brake piston. Lift it up straight by using the bolt hole in the brake piston. FG022409 Figure 21 11. After placing the motor horizontally, take out cylinder block (205) from casing (301).
Page 399 14. Remove driveshaft from casing (301). Be careful not to damage the roller bearing and oil seal contact surface. If you beat a driveshaft (201) end with plastic hammer, it is easy to be disassembled. FG022413 Figure 25 15. Do next step only if required. Remove roller bearing (303) from casing (301).
Page 400: Reassemble Swing Motor
Take out ball bearing (108) from the valve casing (101). Do not reuse the disassembling ball bearing (108). Disassembling is finished, check each component throughly. FG022417 Figure 29 Reassemble Swing Motor Use care with the following instructions. After disassembly, make sure to repair damaged parts and prepare the parts to be replaced.
Page 401 Insert roller bearing (303) at the casing (301) with a tool. FG022414 Figure 32 Insert the driveshaft (201) into casing (301). Coat the lip of the oil seal with grease and tape the shaft spline for the protection of spline. Tap evenly.
Page 402 Place collar (208), thrust ball (206) to the cylinder block (205). FG022421 Figure 36 Assemble the retainer (207) with the piston sub assembly 203,204 (203, 204) unit to the cylinder block (205). FG022422 Figure 37 Insert cylinder block to driveshaft (201) by aligning with the spline.
Page 403 11. Mount O-ring (307, 308) to casing (301). (Apply grease thinly on the O-rings to prevent being cut during assembling the brake piston.) FG022424 Figure 40 12. Assemble brake piston (309) to casing (301). If the piston is difficult to assemble because of the restriction of the O- ring;...
Page 404 15. Assemble valve plate (213) to valve casing (101) and install O-ring (113). Be careful to note the direction of the valve plate. Mount the valve plate with its round part toward the opposite side of the flange. Coat lightly with grease. FG022425 Figure 44 16.
Page 405: Disassemble The Reduction Gear
19. Assemble relief valve (107) with O-ring to valve casing (101). FG022404 Figure 48 20. Assemble brake valve (400) to casing (301) and tightening the hex bolts to specified torque. The assembly is completed. FG022428 Figure 49 Disassemble the Reduction Gear Please use the following procedures for the inspection and repair of the reduction gear 2009.
Page 406 Remove No. 1 sun gear (602) from No. 1 carrier subassembly. No. 1 Carrier FG022430 Figure 51 Remove No. 1 carrier subassembly. No. 1 Carrier sub-assembly FG022431 Figure 52 Remove No. 2 sun gear (702) from No. 2 carrier subassembly. FG022441 Figure 53 Remove bolt (509) in No.
Page 407 Remove No.2 carrier subassembly from ring gear. No. 2 Carrier No. 2 Carrier Sub-assembly FG022452 Figure 55 Remove bolt (314) in ring gear. FG022453 Figure 56 Remove ring gear (801) from casing (501). FG022454 Figure 57 10. Remove pins (512) from casing (501). FG022455 Figure 58 SP002498...
Page 408 11. Remove bolt (507) from casing (501). FG022456 Figure 59 12. Use a rollover machine to turn case over and place a jig on driveshaft. Use a press to remove pinion shaft from case (501). FG022457 Figure 60 13. Remove bearing (504) from case (501). FG022458 Figure 61 14.
Page 409: Reassemble The Reduction Gear
15. Remove oil seal (505). IMPORTANT Do not reuse oil seal! Disassembling is finished, check each component throughly. FG022460 Figure 63 Reassemble the Reduction Gear Assembly should be done in the reverse order of disassembly described above, taking into consideration the following points: Parts damaged during disassembly should be repaired without fail and spare parts should be prepared in advance.
Page 410 Install the pinion shaft (502) and other associated parts. IMPORTANT Prior to assembling the pinion shaft,etc. Apply grease slightly on the lip surface to prevent any scratch when installing. FG022462 Figure 65 Tighten screws (507) to assemble cover (506). FG022463 Figure 66 Mount a casing (501) on a suitable work table or jig.
Page 411 Install the taper roller bearing (504) with a using of tool. FG022466 Figure 69 Assemble pins (512) with casing (501). FG022455 Figure 70 Apply sealant evenly to ring gear assembly of casing. FG022467 Figure 71 Lift ring gear (801) with hoist, wipe its mating surface clean with cloth, Match and align holes and attach to casing.
Page 412 10. Tightening special bolts (314) with no Loctite applied. FG022453 Figure 73 11. Assemble bushing (705) and the washer (606) onto planet gear No.2 (703) and arrange it on the pinhole of the carrier No.2. FG022469 Figure 74 12. Turn over gear assembly (703, 705, 606) and insert it and thrust washer (508) into No.
Page 413 14. After tightening the bolt (509), to attach carrier assembly 2 and use a torque wrench to tighten it up to the standard torque. After checking the torque, bend the longer part of the tongued washer until it sticks to the head of the hexagon bolt (509).
Page 414 18. Install the carrier No.1 subassembly. Lift the carrier No.1 subassembly and turn it clockwise or counterclockwise No. 1 Carrier gently for it to engage with the spline of the No.2 sun gear sub-assembly (702) and the ring gear (801). FG022431 Figure 81 19.
Page 415 22. Put the motor on the reduction gear carefully as shown in the figure. The level gauge port and hole in the ring gear should be alligned. Level Assemble motor turning clockwise Gauge counterclockwise gently so that splines of the shaft shall be Port engaged with the No.1 sun gear.
Page 416 25. Install the level gauge pipe sealed with teflon tape with a pipe wrench. Level Gauge Pipe FG022500 Figure 88 26. Fill with the correct hydraulic oil and check the oil level with stick level gauge. Assembly is done. FG022501 Figure 89 Swing Device SP002498...
Page 417: Maintenance Instructions
Maintenance Instructions Replacement Standard of Worn Parts When a part is worn exceeding the criteria below, adjust or replace the part. However, the criteria for parts with distinct damage are not defined. Standard Size Replacement Item Corrective Action (mm) Criteria (mm) Clearance between the piston and Replace the piston or 0.025...
Page 418 Swing Device SP002498 Page 50...
Page 419 SP002499 TRAVEL DEVICE SP002499 Travel Device Edition 1 Travel Device SP002499 Page 1...
Page 420 MEMO Travel Device SP002499 Page 2...
Page 421 Table of Contents Travel Device Safety Instructions ..........5 Applicable Models ..........5 TM40VD Operation Manual ........6 Specifications ............6 Indication of Type ..........7 Basic Structure and Diagram .......... 8 Operation Principles ............9 Cautions for Operation ..........16 External Specifications Diagrams........
Page 422 MEMO Travel Device SP002499 Page 4...
Page 423: Travel Device
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX225LC-3 1001 and Up, 50001 and Up Travel Device SP002499 Page 5...
Page 424: Tm40Vd Operation Manual
TM40VD OPERATION MANUAL This Manual contains information needed for the use of TM40VD. Read it carefully before using the product. TM40VD, a reduction gear attached hydraulic motor, is characterized by: Traveling motor for excavator consisting of planetary differential reduction gear, axle piston motor, and brake valve.
Page 425: Indication Of Type
INDICATION OF TYPE VD - 92 / 169 Design number Discharge capacity (cc/rev) (2-speed/1-speed) Reduction ratio of reducer Classification of motor Size number Type (hydraulic motor with reducer) Travel Device SP002499 Page 7...
Page 426: Basic Structure And Diagram
Basic Structure and Diagram Basic Structure of TM Motor Figure 1 Travel Device SP002499 Page 8...
Page 427 Operation Principles Reducer Function reducer consists planetary automatic combination including the planetary gear and the differential gear, maintaining the high-speed rotation of the hydraulic motor, changing it to torque, and creating the hub (case) rotation. Operation (Principle) The rotation of the sun gear (S) at the input side rotates the Planetary planetary gear (P) on its on axis to be engaged and revolve Gear...
Page 428 The rotation of the sun gear (S) will create planetary Planetary Differential movement between gears (S, P1, and R) that revolution of Combination gear (P1) rotates carrier (K). Its rotation starts automatic movements among gears (R, P1, P2, and D) and rotates ring gear (D).
Page 429 Description and Principles of Operation Hydraulic Motor Figure 5 Pressure oil from the hydraulic pump flows into the rear flange of TM motor (101) and through timing plate (109) in the brake valve into the cylinder block (104). This pressure oil is designed to dictate the top and bottom dead centers and to be induced only to the lateral side of (Y1) - (Y2).
Page 430 Brake Valve Consider that the P port is pressurized by the tank pressure. (When Traveling) - Brake Released - Oil from port (A) opens valve (227) to flow into port c at the suction side of the motor to enable the rotation of the hydraulic motor.
Page 431 Parking Brake (When Traveling) Oil is supplied to the brake valve to run the spool in the brake valve of the hydraulic motor and open the line to the parking brake and oil flows into cylinder chamber a consisting of spindle and piston (112) of the reducer.
Page 432 High and Low 2-Speed Shifting (At Low Speed) - Pilot Pressure is Below 10 kg/cm Without pilot pressure from port (A) (pressure is below 10 kg/cm ), valve (263) moves to the left side by the force of spring (266) to stop hydraulic fluid of supply port (B) but to release hydraulic fluid of chamber (C) into the motor case.
Page 433 (At High-Speed) - Pilot Pressure is Above 10 kg/cm Without pilot pressure from port (A) (pressure is above 10 kg/cm ), pilot pressure overcomes the force of spring (266) to move valve (263) to the right side and pressure oil of supply port (B) flows into chamber (C) through valve (263).
Page 434: Cautions For Operation
Cautions for Operation Installation Method (Refer to the External Specifications Diagrams.) Frame Fitting Part Sprocket Fitting Part FG007065 Figure 12 Tightening Torques of Mounting Bolts Categories Q'ty Bolt Sizes Tightening Torques Body Fitting Bolt M16 (P2.0) 25.7 ± 4.0 kg •...
Page 435 TM motor. Use hydraulic oil equal to ISO VG32-VG56 (SAE 10W-20). Hydraulic oil should be of wear resistance. Contact a DOOSAN distributor when selecting other hydraulic oil than those in the table below. Viscosity (40°C) 32 CST 46 CST...
Page 436 Lubricating Oil Products are shipped with lubricating oil (gear oil) for reducer filled, but check it before operation. Selection of Gear Oil Use gear oil equal to SAE #90 containing an extreme pressure additive (above the 4th GL grade, API classification).
Page 437 Maintenance Make sure to check the following lists before operating the TM motor. If there is any leakage (hydraulic or gear oil). If bolts are loosen. If there is any noise If temperature in the case increases abnormally. (External standard temperature of the case during continuous operation = Max.
Page 438 Troubleshooting Pressure Relief pressure is set low Set the correct pressure available Check if there are any moving Pump is damaged parts when engine stops. Repair, Operation if necessary Direction switch valve Check if spool is normal and damaged repair, if necessary No pressure Replace burned spool or valve Brake valve is damaged...
Page 439 Siding Bad volumetric efficiency of motor Replace the hydraulic motor slope Replace the brake valve (rear Increased internal leakage of brake valve flange) No operation of parking brake Damaged spring Replace the spring Replace the friction plate and Worn friction plate mating plate High temperature of the surface of...
Page 440: External Specifications Diagrams
External Specifications Diagrams Figure 14 Travel Device SP002499 Page 22...
Page 441: Basic Structure And Diagrams
Basic Structure and Diagrams Assembly Cross-Section Figure 15 Travel Device SP002499 Page 23...
Page 442 Reference Reference Description Description Number Number Rear Flange Sun Gear Main Spool Retaining Ring Plug (for Main) Planetary Gear (R) Plug (for Check) Needle Bearing Valve Check Drive Gear Spring (for Main) Pin Spring Spring (for Check) Cover Stopper A Socket Bolt Stopper B A/Ball Bearing...
Page 443 Reference Reference Description Description Number Number Ball Bearing Plunger Ball Bearing (HR6206HL1B) Piston Seal Spring (2-speed) Body Piston (2-speed) Back up Ring Shoe (2-speed) O-ring Pivot O-ring O-ring Spring Retainer Hydraulic Motor Assembly Spring Cylinder Block and Piston Kit Piston Piston Assembly Adjust Plug Piston (2-speed) Kit...
Page 444: Tm40Vd Maintenance Instructions
TM40VD MAINTENANCE INSTRUCTIONS CAUTION AVOID INJURY Please read these instructions carefully before the disassembly and reassembly. Precautions The overhaul of this machine should be performed in accordance with instructions stated in this manual. Use tools stated in these instructions for the disassembly and reassembly of the machine.
Page 445: Tools List For Disassembly And Reassembly
Tools List for Disassembly and Reassembly Standard Tools Tools Description / Sizes Q'ty Hexagon Wrench 6 (M8) (PF1/4), 8 (M10) (JIS B 4648) 10 (M12) (PF1/2) 14 (M16), 4 (M6) Socket Wrench Nominal 280N dial type Torque Wrench Nominal 850N dial type Socket 22, 30, 32,41, 40 EA 1 Adapter for Torque Wrench...
Page 446 Machined Tools Names and Typical Sizes Q'ty Names and Typical Sizes Q'ty Main Bearing Press Fitting Tool Coupling Gear Hanger FG007070 FG007071 Aluminum Rod Pressing Tool (1) FG007072 FG007073 Thrust Plate (R) Adjustment Tool Gap Measuring Tool FG007074 FG007075 Hanger (1) Sun Gear Positioning Tool FG007076 FG007077...
Page 447 Names and Typical Sizes Q'ty Names and Typical Sizes Q'ty Steel Rod Cocking Tool FG007080 FG007081 Shaft Insertion Guiding Tool Insert Tool FG007083 FG007082 Travel Device SP002499 Page 29...
Page 448 Disassembly Instructions General Cautions Spread s rubber or vinyl cover on the workbench. When disassembling the traveling motor, provide a match mark on the mating face or each part. Arrange the detached parts to prevent them from being damaged or lost. The disassembled seals must be replaced with new ones as a rule even if they are free from damage.
Page 449 Remove drive gear (121). Figure 17 Remove carrier no.1 assembly. NOTE: Carrier no. 1 assembly consists of planetary gear (117), needle bearing (118), shaft bearing (107), carrier (134) thrust washer (131), spring pin (122). Figure 18 Dissembling the carrier no. 1 assembly. Drive spring pins (122) into shaft bearing (R) (107).
Page 450 Remove sun gear (114). NOTE: Snap ring (115) is assembled in sun gear (114). Do not remove it if not necessary. Figure 21 Remove carrier no.2 assembly. NOTE: Remove it using a crane after M10 eyebolts are installed. Figure 22 Drive spring pins (110) into shaft bearing (F) (113).
Page 451 10. Remove the thrust washer (F) (109), planetary gears (F) (108), needle bearings (111), floating bushing (112) from carrier no. 2 (103). NOTE: Each part consists of the 1 st. Figure 25 11. Take off lock shim plate (136) by hammering on chisel or on similar tool placed at parting surface.
Page 452 14. Remove the floating seal (101) from the hub (105) and the spindle (101). NOTE: θ User can remove easily if using " "driver. Figure 29 15. The seal (129), the angular bearing (125) (2 ea), the O-ring (130) are assembled on the hub (105) with the floating seal (102).
Page 453 Remove the parallel pin (42) from the spindle (101). Figure 33 Remove the O-ring (126) from the spindle (101). Do not reuse the O-ring (126). NOTE: Do not reuse the O-ring (126). Figure 34 Disassembling the rear flange (1) part Remove the timing plate (9) from the rear flange (1).
Page 454 Remove the ball bearing (250) from the rear flange (1). Figure 37 Disassembling the spool Remove two plugs (24) from the rear flange (1). NOTE: Users can work easily if sub-disassembly was done on the reversal table. Hexagon socket 41/Torque wrench. Take out two springs (28), two stopper (c-3) from the rear flange (1).
Page 455 Remove the spring (30) (2 ea), valve (27) (2 ea) from rear flange (1). Figure 41 10. Disassembling the two speed valve Remove the plug (63) from the rear flange (1). NOTE: Users can work easily if sub-disassembly was done on the reversal table. Hexagon wrench 10.
Page 456 Remove the O-rings (235) (239), backup ring (247) (248) from the piston (212). NOTE: Do not reuse O-rings (235) (239), backup ring (247) (248) after removal. Figure 45 12. Disassembling the hydraulic motor part Lay the TM motor body on the side. Drain out the oil from the TM motor.
Page 457 13. Disassembling the cylinder block kit Remove the piston assembly (piston (205), shoe (206)) from the removed cylinder block (204). Figure 48 Remove piston (205), shoe (206) from the removed retainer plate (207). Figure 49 Remove thrust ball (208) from the removed cylinder block (204).
Page 458 14. Remove swash plate (203) from the shaft (202). 15. Remove shaft (202) from the spindle (101). Figure 52 NOTE: When separating the swash plate, separate and turn it by using hands to free from intervention of the stopper. 16. Remove speed selector piston assembly (piston (261) and shoe (262)) form the spindle (101) by feeding compressed air from the access hole in spindle (101).
Page 459 Reassembly General Precautions Reassemble in a work area that is clean and free from dust and dirt. Handle parts with bare hands to keep them free of linty contaminants. Repair or replace the damaged parts. Each parts must be free of burrs on corners. Do not reuse O-rings, oil seal and floating seal that were removed in disassembly.
Page 460 Install parallel pin (242) (2 ea) and two speed piston assembly (261) (262) into the spindle (101). Figure 57 Install shaft (202) into the spindle (101). NOTE: Assemble after applying grease on oil seal lip (232). Figure 58 Install pivot (267) (2 ea) into the spindle (101). Figure 59 Install swash plate (303) to the spindle (101).
Page 461 Reassemble the cylinder block kit Install spring (214) (9 ea) to the cylinder block (204). Figure 61 Install thrust ball (208) to the cylinder block (204). Insert piston assembly (piston (205), shoe (206)) into retainer plate (207). NOTE: After mounting, immerse the entire them in a working fluid.
Page 462 Reassemble the parking brake Install mating plate (216) first and then a friction plate (215), one by one, into the grooves of the outer surface of the cylinder block (204). NOTE: Immerse the friction plates (215) in a working fluid before fitting them into the grooves.
Page 463 Reassemble the Rear Flange Part (1) Reassemble the check valve Install O-ring (37) (2 ea) on the plug (26) (2 ea). NOTE: Apply grease to the O-ring (37). Install spring (30) and a valve (27) into the plug (26). NOTE: Install a spring (30) and a valve (27) into the plug (26), and then grease the spring (30) and the valve (30) and hand-lock the...
Page 464 Tighten the plug (24) to the required torque. Figure 71 Reassemble the two speed valve Install O-rings (46) on plugs (63). NOTE: Apply grease to the O-ring (46). Apply hydraulic oil to the spool (65), while the spool (65) is installed into the rear flange (1). Insert a spool (65) and spring (66) into the rear flange (1).
Page 465 Assembling of the rear flange’s inner parts After installing the O-ring (74) on the plug (52), install the steel ball (68), the plug (52) into the rear flange (1). NOTE: Apply grease to the O-ring (74). Do not disassemble and assemble if not necessary.
Page 466 Figure 78 Reassemble the rear flange (1) and spindle (101). Mount the rear flange (1) on the spindle (101). NOTE: When the rear flange (1) is mounted on the spindle (101), fix the spring (13) with applied grease so it does not drop. Figure 79 Tighten the socket bolt (43) into the spindle (101) to the required torque.
Page 467 The Reduction Gear Assembly Rotate the TM motor through 180 degrees to make the spindle side face upward. Install floating seal (102) on the spindle (101). Figure 82 NOTE: Apply grease to the floating seal (102). Floating Seal Spindle Floating Seal FG018821 Figure 83 Hub Assembly...
Page 468 Insert the O-ring (130), the sealing (129) in the hub (105). NOTE: Apply a thin layer of grease to the O-ring (130) Figure 85 Install floating seal (102) on the hub (102). Figure 86 NOTE: Apply grease to the floating seal (105). Figure 87 Install distance piece (106) into the spindle.
Page 469 Install the hub assembly into the spindle. Use a press, and press inner lace of bearing (125) into its full depth. Figure 89 While pressing flange spindle (101), install Shimplate[136] into groove. Figure 90 Assemble thrust washer (F) (109) planetary gears (F) (108), needle bearings (111), floating bushing (112) into carrier no.2 (103).
Page 470 10. Install spring pin (110) into the carrier no.2 (103). Figure 93 11. Place carrier no.2 assembly into hub (105). Figure 94 12. Attach the retaining ring (115) on the sun gear (114). NOTE: Snap ring pliers (Snap ring C-75 (S)) Figure 95 13.
Page 471 14. Assemble thrust washer (R) (131), planetary gears (R) (117), needle bearings (118), shaft bearing (R) (107) into carrier no.1 (134). Figure 97 15. Install the spring pin (122) into the carrier no.1 (134). Figure 98 16. Place carrier no.1 assembly into hub (105). Figure 99 17.
Page 472 18. Install thrust plate (133) in the cover (123). NOTE: Apply grease to the thrust plate (133). Figure 101 19. Install thrust washer (M) (132) in the cover (123). Figure 102 20. Apply sealant to the cover (123) after intalling with the hub (107).
Page 473 22. Tighten the socket bolt (124) (16 ea) to the specified torque. • Tightening torque : 5.9 ± 1.kg • • #8 adapter/torquer wrench for hexagon wrench NOTE: Apply Loctite to the socket bolt (124) and then install it. 23. Install O-ring (38) on the plug (128). Figure 105 24.
Page 474: Testing
Testing The motor case must be filled up with a working fluid before starting performance verification tests. After completion of TM motor maintenance, the performance verification tests listed below must be performed. When a testing apparatus is available If internal parts have been replaced, carry out running in operation, followed by performance tests.
Page 475 Second-speed volume efficiency verification tests During the no-load tests under the running-in operating conditions for (C) and (D) above, make sure that motor will change from the low speed over to the high-speed when fluid pressures of 20 kg/cm or more are applied from the second-speed selector pilot port (D-port).
Page 476: List Of Seals
List of Seals Ref. Nos Parts Description Sizes Q'ty Remarks O-ring 1BP8 O-ring 1AG230 Floating Seal 90626501 O-ring 1BP18 46, 38 Oil Seal TCN48 x 70 x 12 O-ring 1BP180 O-ring 1BP210 Backup Ring 1BP180 Backup Ring 1BP210 O-ring 1BP16 Backup Ring T2-P16 O-ring...
Page 477 SP002502 MAIN PUMP SP002502 Main Pump Edition 1 Main Pump SP002502 Page 1...
Page 478 MEMO Main Pump SP002502 Page 2...
Page 479 Table of Contents Main Pump Safety Instructions ..........5 Applicable Models ..........5 Pump Maintenance..........6 Component Locations ............. 6 Parts List ................. 8 Tools................10 Tightening Torque ............11 Disassembly ............12 Reassembly ............15 Pump Body Maintenance Standards ....18 Change Standards of Worn Parts .........
Page 480 MEMO Main Pump SP002502 Page 4...
Page 481: Main Pump
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX225LC-3 1001 and Up, 50001 and Up Main Pump SP002502 Page 5...
Page 482: Pump Maintenance
PUMP MAINTENANCE Component Locations 532 214 531 724 792 534 151 152 717 985 VIEW "A" 490 401 211 153 313 468 725 710 212, 214 = 30 541, 544, 545 = 42 13, 14 FG001841 Figure 1 Main Pump SP002502 Page 6...
Page 483 Reference Reference Description Description Number Number Piston and Shoe Assembly Plug Cylinder Block and Valve (R) Expander Cylinder Block and Valve (L) Tilted Pin Assembly Swash Plate Assembly Piston Check 1 Assembly Stopper Check 2 Assembly Stopper Professional Valve O-ring Driveshaft O-ring Driveshaft...
Page 484: Parts List
Parts List FG001842 Figure 2 Main Pump SP002502 Page 8...
Page 485 Reference Reference Description Description Number Number Piston and Shoe Assembly Plug Cylinder Assembly(R) Tilting Pin Assembly Cylinder Assembly(L) Piston Swash Plate Assembly Stopper (L) Check 1 Assembly Stopper (S) Check 2 Assembly O-ring Proportional Valve O-ring Driving Shaft (F) O-ring Driving Shaft (R) O-ring Gear...
Page 486 Tools The following table contains tools required for the disassembly and reassembly of the T5V pump. Each type of pump uses different bolts and plugs. Necessary tools marked 0 Tools and Sizes Parts Pump Types PT Plugs Socket Adjustment Tools (NPTF PF Plugs Bolts...
Page 487: Tightening Torque
Tightening Torque Tools Tightening Torque Parts Sizes (kgf•m) Size(mm) Names Socket Bolts (Quality: SCL435) Hex Wrench PT 1/16 PT Plugs PT 1/8 1.05 (Quality: S45C). PT 1/4 1.75 Hex Wrench Wrap thread tape 1.5~2 times. PT 3/8 PT 1/2 PF 1/4 PF 1/2 PF 3/4 PF Plugs...
Page 488 DISASSEMBLY Read the disassembly instructions throughly before starting to disassemble the pump, and follow the procedures below. Numbers in the parenthesis following the parts indicate the reference numbers in the next pump figures. Select a place to disassemble the pump. IMPORTANT The place should be clean.
Page 489 Put the pump flat on the working die with its regulator connection part facing downward and remove pump casing (271) and valve block (312). IMPORTANT Always put a rubber sheet or similar protection on the working die to prevent any damage to the regulator connection part facing downward.
Page 490 Remove shoe plate (211) and swash plate (212) from pump casing (271). Figure 8 Remove driveshaft from the swash plate support by gently knocking the end of driveshafts (111, 113) with plastic hammer. Figure 9 Remove valve block (312) from valve plates (313, 314). IMPORTANT Sometimes this procedure may not be necessary.
Page 491 REASSEMBLY Reassembly shall be done in the reverse order of disassembly, but with cautions for: • Repair any parts damaged during disassembly and have spare parts at hand. • Wash each part sufficiently with lubricating oil and dry them with compressed air before their reassembly. •...
Page 492 Install driveshaft (111) containing bearing (123), bearing spacer (127), and stop ring (824) in swash plate support (251). IMPORTANT Do not strike driveshaft with hammer or a hard object. Use a plastic hammer to gently knock the rim of bearing to insert it and use a steel rod to insert it Figure 13 up to the end firmly.
Page 493 Install valve block (312) in pump casing (271) and tighten socket bolts (401). IMPORTANT Start to reassemble from the rear pump, which facilitates the reassembly. Take care not to set valve block in the wrong direction (the ball regulator should be at the top and the suction flange at the right side when Figure 17 observed from the front side).
Page 494: Pump Body Maintenance Standards
PUMP BODY MAINTENANCE STANDARDS Change Standards of Worn Parts Change or readjust parts which are worn more than references below. Always change, however, any parts which have clearly visible damage. Standard References/Change References Parts and Checks Pump Types Remarks T5V80 T5V112 0.028 0.039...
Page 495: Fix Standards Of Cylinder Block, Valve Plate, And Swash Plate (Shoe Plate)
Fig. 1 Gap between Piston and Cylinder Bore Fig. 3 Free Field of Cylinder Spring : L Fig. 2 Gap between Piston and Shoe Pressing Part : Fig. 4 Height of Push Plate and Thickness of Shoe : T Spherical Bushing Assembly : H-h FG007123 Figure 19 Fix Standards of Cylinder Block, Valve...
Page 496 Main Pump SP002502 Page 20...
Page 497 SP002503 PTO SERVER SP002503 PTO Server Edition 1 PTO Server SP002503 Page 1...
Page 498 MEMO PTO Server SP002503 Page 2...
Page 499 Table of Contents PTO Server Safety Instructions ..........5 Applicable Models ..........5 Pump Maintenance..........6 Disassembly ............7 Reassembly ............9 Maintenance Standards of Pump Body ....10 PTO Server SP002503 Page 3...
Page 500 MEMO PTO Server SP002503 Page 4...
Page 501: Safety Instructions
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX225LC-3 1001 and Up, 50001 and Up PTO Server SP002503 Page 5...
Page 502: Pump Maintenance
PUMP MAINTENANCE Tools The following tools are needed for the disassembly and reassembly of the PTO server: Tools Parts List Hex Bolt (M10) Hex Wrench Flange Socket Bolt (10) Flyer Retaining Ring RR-20 TRR150 Retaining Ring RR-72 TRR200 Tightening Torque Torque Values Parts Size...
Page 503: Disassembly
DISASSEMBLY Read this Disassembly instructions throughly before starting to disassemble the PTO server, and follow the procedures below. Numbers in the parentheses following the parts indicate the reference numbers in the next pump figures. Select a place to disassemble the pump. NOTE: The place should be clean.
Page 504 Remove retaining ring (825) and disassemble the gear 3 (118) and the ball bearing. NOTE: Do not remove ball bearing (125) from the gear 3 (118). Figure 3 PTO Server SP002503 Page 8...
Page 505: Reassembly
REASSEMBLY Reassembly is the reverse order of the disassemble with cautions for: Repair damaged parts during the disassembly and have spare parts prepared by hand. Wash each part sufficiently with lubricating oil and dry them with compressed air before their reassembly. Always apply clean lubricating oil to sliding parts and bearing before their reassembly.
Page 506: Maintenance Standards Of Pump Body
MAINTENANCE STANDARDS OF PUMP BODY Standards to Replace Worn Parts Replace gears 2 (117) and 3 (118) whose teeth have pitting (the size of 1 ft is the same and below 1 mm or is more than 5% of the area). Any parts whose appearance is severly damaged should be replaced also.
Page 507 GEAR PUMP GEAR PUMP FG007126 Figure 5 Reference Parts Reference Parts Socket Bolt Retaining Ring Gear Case Retaining Ring Bearing Spacer Retaining Ring Roller Bearing O-ring Ball Bearing O-ring Gear 3 O-ring Gear 2 VP Plug Idle Shaft PTO Server SP002503 Page 11...
Page 508 PTO Server SP002503 Page 12...
Page 509 SP002500 GEAR PUMP SP002500 Gear Pump Edition 1 Gear Pump SP002500 Page 1...
Page 510 MEMO Gear Pump SP002500 Page 2...
Page 511 Table of Contents Gear Pump Safety Instructions ..........5 Applicable Models ..........5 Single Gear Pump ..........6 Disassembly ..............6 Reassembly..............8 Gear Pump SP002500 Page 3...
Page 512 MEMO Gear Pump SP002500 Page 4...
Page 513: Gear Pump
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX225LC-3 1001 and Up, 50001 and Up Gear Pump SP002500 Page 5...
Page 514: Single Gear Pump
SINGLE GEAR PUMP Disassembly Clean exterior of pump. FG001072 Figure 1 Remove clamp bolts. FG001074 Figure 2 Cover sharp edges of driveshaft with adhesive tape and coat shaft end extension with clean grease, to avoid any damage to lip of shaft seal when removing mounting flange.
Page 515 Remove mounting flange taking care to keep flange as straight as possible during removal. If mounting flange is stuck, tap around edge with rubber mallet in order to break it away from body. NOTE: Make sure that while removing mounting flange, shaft and other components remain in position.
Page 516: Reassembly
Remove driving gear and driven gear, keeping gears as straight as possible. FG001077 Figure 8 Remove rear plate and end cover. FG001078 Figure 9 Reassembly Clean all components with care. FG001078 Figure 10 Using a suitable driver, install shaft seal in mounting flange.
Page 517 Install retaining ring in groove. FG000840 Figure 12 Install O-ring on both sides of rear section of body. NOTE: Coat O-rings with grease to hold O-rings in body. FG001079 Figure 13 Install rear section body on rear cover. FG001080 Figure 14 Install seals in pressure plate(s) groove.
Page 518 Insert pressure plate assembly into body while keeping it straight. NOTE: Seal side should face to rear cover, opposite side of gears. NOTE: Pay attention to installation direction of seal. FG001081 Figure 16 Install drive gear and driven gear. FG001082 Figure 17 Insert pressure plate into body in proper direction.
Page 519 11. Tighten bolts with washer in a crisscross pattern to a torque value of 45 Nm. FG001085 Figure 20 12. Check that pump rotates freely when driveshaft is turned by hand. If not a pressure plate seal may be pinched. FG000851 Figure 21 Gear Pump...
Page 520 Gear Pump SP002500 Page 12...
Page 521 SP002403 MAIN CONTROL VALVESP002403 Main Control Valve Edition 1 Main Control Valve SP002403 Page 1...
Page 522 MEMO Main Control Valve SP002403 Page 2...
Page 523 Table of Contents Main Control Valve Safety Instructions ..........5 Applicable Models ..........5 General Description ..........6 Theory of Operation ............6 Parts List ............... 38 Specifications ..............43 Troubleshooting, Testing and Adjustment ..44 Troubleshooting............. 44 Adjustment of Valves............. 45 Removal .............
Page 524 MEMO Main Control Valve SP002403 Page 4...
Page 525: Main Control Valve
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX225LC-3 1001 and Up, 50001 and Up DX255LC-3 1001 and Up, 50001 and Up DX300LC-3 1001 and Up, 50001 and Up...
Page 526: General Description
GENERAL DESCRIPTION Theory of Operation When All Spools are in Neutral Neutral Passage The oil supplied from the port (P1) enters into the tank passage (Ta) through the orifice (Lc 1) of negative relief from the neutral passage (L1) and returns to ports (T1, T2 and T3). The oil supplied from the port (P2) passes the tank passage (Ta) through orifice (Rc 1) of negative relief from the neutral passage (R1) and returns to port (T1, T2 and T3).
Page 527 Negative Control Negative Control Relief Valve (L) Relief Valve (R) ARM 1 ARM 2 [Section 5] [Section 9] BOOM 2 BOOM 1 [Section 4] [Section 8] SWING BUCKET [Section 3] [Section 7] TRAVEL OPTION [Section 6] [Section 2] STRAIGHT TRAVEL TRAVEL [Section 1] [Section ST]...
Page 528 ARM 1 [Section 5] BOOM 2 [Section 4] SWING [Section 3] OPTION [Section 2] TRAVEL [Section 1] SECTION "L-L" FG001296 "Z" Detail Figure 2 Main Control Valve SP002403 Page 8...
Page 529 ARM 2 [Section 9] BOOM 1 [Section 8] BUCKET [Section 7] TRAVEL [Section 6] STRAIGHT TRAVEL [Section ST] SECTION "R-R" FG001297 Figure 3 Main Control Valve SP002403 Page 9...
Page 530 Signal Passage Oil supplied to port (PP) flows through orifice (Lc3) to port (PT) and simultaneously flows through land (Lc4), passage (5), and land (Rc3) into tank passage (Ta). The same oil supplied to port (PP), then flows through orifice (Lc5) into port (PA), and it also flows through passages (L4, 7 and R4) to bucket spool land (Rc4) and then flows into drain passage (DR).
Page 531 Main Control Valve SP002403 Page 11...
Page 532 Single Operation Travel Spool Shift When shifting travel spool by increasing pressure of travel (Section 1) pilot port (Pb1 (Pa1)), oil supplied to port (P1) flows through neutral passage (L1) to spool and flows to port (B1 (A1)). Return oil flows through port (A1 (B1)), to spool and returns to tank passage (Ta).
Page 533 Switched Position OPTION [Section 2] Neutral Position Switched Position TRAVEL [Section 6] Neutral Position TRAVEL [Section 1] Switched Position STRAIGHT TRAVEL [Section ST] FG001299 Figure 5 Main Control Valve SP002403 Page 13...
Page 534 Swing Spool Shift When shifting swing spool by increasing pressure of swing (Section 3) pilot port (Pb3 (Pa3)), neutral port (L1) is closed. Oil supplied to port (P1) flows through parallel passage (L3), load check valve (S3-2), passage (S3-1) and spool, it then flows to port (B3 (A3)).
Page 535 Switched Position SWING [Section 3] Neutral Position BUCKET [Section 7] FG001300 Figure 6 Main Control Valve SP002403 Page 15...
Page 536 Regeneration When bucket spool is shifted by increasing pressure of bucket (Section 7) pilot port (Pb7), neutral passage (R1) is closed. Oil supplied to port (P2) flows through parallel passage (R3), load check valve (S7-2), passage (S7-1), spool and into port (A7). Oil flows through port (B7) and one portion of the oil returns through spool to tank passage (Ta), and the other portion of oil flows through inside of spool, and pushes up...
Page 537 Boom Spool Shift Neutral This valve also works with antidrift valves that are installed on the bottom side of each boom cylinder. When in neutral, poppet (AD1) is closed by port (A8) pressure that is sent through passage (AD2), spool (AD3) to spring chamber (AD4).
Page 538 Boom up (2-pump confluence) When boom 1 spool is shifted by increasing pressure of boom 1 (Section 8) pilot port (Pa8), neutral passage (R1) is closed. Oil supplied to port (P2) flows through parallel passage (R3) and load check valve (S8-2) to spool and flows into port (A8).
Page 539 (Boom down (regeneration) When boom 1 (Section 8) spool is shifted by increasing pressure of boom 1 pilot port (Pb8), neutral passage (R1) is closed. Oil supplied to port (P2) flows through parallel passage (R3) and load check valve (S8-2) to spool and flows into port (B8).
Page 540 Arm Spool Shift Neutral This valve also works with an antidrift valve that is installed on rod side of the arm cylinder. When in neutral, poppet (AD1) is closed by port (A5) pressure that is sent through passage (AD2), spool (AD3) and to spring chamber (AD4).
Page 541 Arm in 2-pump confluence When arm 1 spool is shifted by increasing pressure of arm 1 (Section 5) pilot port (Pb5), oil supplied to port (P1) flows through neutral passage (L1), load check valve (S5-2), passage (S5-1) and spool into port (B5). When arm 2 spool is shifted by increasing pressure of arm 2 (Section 9) pilot port (pb9), oil supplied to port (P2) flows through neutral passage (R1), load check...
Page 542 Variable regeneration When crowding arm, after return oil from port (A5) flows through notch (a), one portion of the oil returns through fixed orifice (d), passage (e) and variable orifice (f) and to tank passage (Ta). The other portion of the oil flows through fixed orifice (b), regeneration check (c), and fixed orifice (i) in arm 1 spool, and joins in bridge passage (S5-1).
Page 543 Arm out (2-pump confluence) When arm 1 spool is shifted by increasing pressure of arm 1 (Section 5) pilot port (Pa5), oil supplied to port (P1) flows through neutral passage (L1), load check valve (S5-2), passage (S5-1) and spool and into port (A5). Oil supplied to port (P2) flows through neutral passage (R1), load check valve (S9-2), passage (S9-1), spool and passage (8) and joins at port (A5).
Page 544 Parallel Orifice for Arm The orifice, that is installed in parallel passage for arm 1, controls arm speed when operating in a combined operation. Oil supplied from parallel passage (L3) of arm 1 (Section 5) pushes open poppet (S5-3). It then flows through orifice (Lc8) of variable orifice spool, and then is connected to passage (L5).
Page 545 Relief Valve Main relief valve Oil supplied to port (P1) flows through poppet (LP). Oil supplied to port (P2) flows through poppet (RP) and passage (3). They join at the main relief valve. The highest pressure of pump (P1 and P2) is controlled by reaction of main relief valve.
Page 546 Compound Operation Travel Compound Operation In the event of operating another function when the traveling left or right (when advancing, backing, or pivot turning) or operating for travel operation during the operation other than traveling, the oil supplied from the port (PP) is cut off from the tank passage (Ta) in the signal land part of the section other than the travel shifted from the land (Lc4), (Lc7), (Rc3), and (Rc5), and the pressure of the signal passage is increased to the relief set...
Page 547 TRAVEL [Section 1] TRAVEL [Section 1] STRAIGHT TRAVEL [Section ST] FG001310 Figure 17 Main Control Valve SP002403 Page 27...
Page 548 Bucket Compound Operation A priority control valve is installed in bucket (Section 7). This valve controls oil flow entering bucket when operating during a combined operation with travel, boom 1, and arm 2 sections, on P2 side. If pressure at port (Pi) is increased when operating bucket, piston (S7-6), piston (S7-5) and plug (S7-4) are pressed, and poppet assembly (S7-2) is seated on valve housing.
Page 549 Switched Position SWING [Section 3] Neutral Position BUCKET [Section 7] FG001311 Figure 18 Main Control Valve SP002403 Page 29...
Page 550 Swing Compound Operation The valve's swing Section (Section 3) is equipped with the control valve that adjusts the flux that flows into the swing when combined operating with the Section (travel, boom 2, arm 1) of If port (Pi) is pressurized when operating swing function, piston (S3-6) is pushed to have the poppet assembly (S3-2) to be pressed under the seat part of the valve housing through the piston (S3-5) and plug (S3-4).
Page 551 Switched Position SWING [Section 3] Neutral Position BUCKET [Section 7] FG001312 Figure 19 Main Control Valve SP002403 Page 31...
Page 552 Antidrift Valve The antidrift valve is installed on the cylinder port on the arm load (boom bore) for the natural antidrift of the arm (boom) cylinder. (For typical example, arm (A5) is shown.) Neutral condition (maintaining port (A5)) The holding pressure of port (A5) is sent through passages (a, b, and c), and into spring chamber (d) of poppet (1).
Page 553 Main Relief Valve The main relief valve is between neutral oil passage (HP, "LP" Figure 23) and low-pressure oil passage (LP). Pressurized oil flows into neutral oil passage (HP) through orifice in the main poppet (C) to fill internal cavity (D). Due to the difference in areas between (A and B), on which hydraulic "HP"...
Page 554 Overload Relief Valve "LP" Operation The overload relief valve is between cylinder port (HP) and low-pressure oil passage (LP). Pressurized oil at cylinder "HP" port (HP), flows through an orifice in piston (C), to fill internal cavity (G). Due to the difference in area between (A and B) on which the hydraulic pressure acts, main poppet (D) seats on sleeve (K).
Page 555 Absorption Operation "LP" An anticavitation unit is installed in cylinder port (HP) to prevent the development of cavitation. If pressure at cylinder port (HP) becomes lower than that of oil passage (LP), sleeve (K) moves so oil is supplied from the low-pressure oil passage (LP) to cylinder port (HP) to "HP"...
Page 556 Low-pressure Relief Valve Signal pressure Poppet Oil supplied from pump port (P1 (P2)) flows through neutral passage (L1 (R1)), low-pressure relief valve passage (L2 (R2)), and orifice (Lc1 (Rc1)) to tank passage (Ta). Lc1 [Rc1] Now, pressure generated at passage (L2 (R2)) by orifice (Lc1 (Rc1)) moves to low-pressure relief signal port (Ps1 (Ps2)).
Page 557 Main Control Valve SP002403 Page 37...
Page 558: Parts List
Parts List VIEW A Figure 34 FG003962 Main Control Valve SP002403 Page 38...
Page 559 Reference Reference Description Description Number Number Poppet Plug Assembly Spring Socket Bolt (M10 x 40L) Spacer Socket Bolt (M16 x 130L) Plug Assembly Washer Plug O-ring O-ring Main Relief Valve Plug Assembly Overload Relief Valve Plug Assembly Plug Assembly Main Control Valve SP002403 Page 39...
Page 560 ARM 1 BOOM 2 SWING OPTION TRAVEL ARM 2 BOOM 1 BUCKET TRAVEL STRAIGHT TRAVEL VIEW A SECTION B FG003963 Figure 35 Main Control Valve SP002403 Page 40...
Page 561 Reference Reference Description Description Number Number Housing Valve Swing Spool Assembly Arm Spool Assembly 2 Option Spool Assembly Boom Spool Assembly 1 Plug Bucket Spool Assembly O-ring Travel Spool Assembly Orifice Plug T/S Spool Assembly O-ring O-ring O-ring Foot Relief Valve Plug Assembly Housing Valve Socket Bolt (M10 x 28L)
Page 562 VIEW A Figure 36 FG003964 Main Control Valve SP002403 Page 42...
Page 563: Specifications
Reference Reference Description Description Number Number O-ring SP Valve Spring Spool Poppet Spring Seat Poppet Spring Flange End Spool Spacer O-ring O-ring Arm Regeneration Assembly Backup-ring Plug Antidrift Valve Assembly O-ring Socket Bolt (M10 x 55L) Spring Socket Bolt (M10 x 40L) Spool Socket Bolt (M10 x 70L) O-ring...
Page 564: Troubleshooting, Testing And Adjustment
TROUBLESHOOTING, TESTING AND ADJUSTMENT Troubleshooting Overall Control Valve Problem Possible Cause Remedy Spool does not move. Oil temperature is abnormally Remove part with resistance of oil increased. leakage within pipeline. Pollution of operation oil. Replace operation oil and wash circuit at same time.
Page 565: Adjustment Of Valves
Relief Valve Problem Possible Cause Remedy Pressure does not increase. Main poppet, sleeve or pilot poppet Replace relief valve. are stuck open and valve seat part has dust. Unstable relief pressure. The seat part of pilot poppet has groove. Piston or main poppet gets stuck. Abnormal relief pressure.
Page 566 Loosen locknut (4) and turn adjusting plug (6) clockwise to raise relief pressure of preceding step. Turn adjusting plug (6) counterclockwise to lower relief pressure. One turn varies pressure by approximately 28.4 MPa (9,290 kg/cm (4,120 psi)). Tighten locknut (4) after pressure has been adjusted. Low-pressure adjustment (second stage) Loosen locknut (7) and turn adjusting plug (8) counterclockwise to lower relief pressure at state of...
Page 567: Removal
REMOVAL WARNING AVOID DEATH OR SERIOUS INJURY Release any pressure in the hydraulic oil tank before doing any work. Remove all hoses and connectors from control valve (1, Figure 37). Cap the hoses and control valve (1, Figure 37). Attach identification tags to the removed hoses for reassembling.
Page 568: Disassembly
DISASSEMBLY Caution in Disassembly Stop engine when pressure of actuator is not indicated. It is dangerous to disassemble control valve while it is under pressure. High-pressure oil can squirt out or components can spring out. When partially disassembling control valve that is on machine, be careful to follow the following caution.
Page 569 Disassembly of Main Spool Part Remove socket head bolt (74, two places on each section, width across flats: 8 mm) and cap (8, ten places). Remove plug assembly (72, width across flats: 8 mm) and plug (91, width across flats: 22 mm) according to necessity.
Page 570 Disassembly of Arm 1 Para-turn Spool Part Remove socket head bolt (78, width across flats: 5 mm) and cap (18). Remove O-ring (23) from cap (18). Remove spool (19) from valve housing under subassembly conditions. Disassembly of spool. IMPORTANT Work with spool gripped in vise with wood (see Figure 38), so as not to scratch outside diameter of spool.
Page 571 Disassembly of Load Check Valve Part WARNING AVOID DEATH OR SERIOUS INJURY Always relieve hydraulic pressure and fully lower bucket (or attachment) to the ground, before disassembly. Failure to follow instructions can cause sudden release of component parts or boom dropping, resulting in death or serious injury.
Page 572 18. Grip body (96) in vise. Remove plug (94), piston (95) and O-ring (102). Disassembly of Antidrift Valve Part NOTE: The part including the assembly is shown (assembly number-part number). WARNING AVOID DEATH OR SERIOUS INJURY Always relieve hydraulic pressure and fully lower bucket (or attachment) to the ground, before disassembly.
Page 573 NOTE: Do not remove steel ball (67-14) because it is pressed in body. Disassembly of Relief Valve WARNING AVOID DEATH OR SERIOUS INJURY Always relieve hydraulic pressure and fully lower bucket (or attachment) to the ground, before disassembly. Failure to follow instructions can cause sudden release of component parts or boom dropping, resulting in death or serious injury.
Page 574 Disassembly of Valve Housing Bolt IMPORTANT Do not disassemble combined bolt (77). If it is necessary to disassemble it, place it horizontally on a workbench. Prepare spare O-ring (65 and 66). Remove socket head bolt (77, eight places, width across flats: 14 mm) and washer (81, eight places).
Page 575 Disassembly of Overload Relief Valve Poppet Spring "O-ring" P/N: 95113-01000 "O-ring" P/N: 21001-00098 Width across flat 31.75 Width across flat 17 Width across flat 6 (Cap) (Lock Nut) (Adjuster) FG001318 Figure 40 This relief valve should be replaced as an assembly. When replacing it, remove cap (1, width across flats: 32 mm) and O-ring (2).
Page 576 Instruction of Disassembly and Assembly of Low-pressure Relief Valve "O-ring" P/N: 95113-02100 "O-ring" P/N: 21001-00213 FG001321 Figure 41 This unit has press fit portion (D) and it should be replaced as a complete assembly. Main Control Valve SP002403 Page 56...
Page 577: Cleaning And Inspection (Wear Limits And Tolerances)
CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures" section. Cleaning Clean all parts thoroughly using a suitable cleaning fluid and dry them with moisture free compressed air. Put them on a clean paper or a vinyl for inspection.
Page 578: Reassembly
REASSEMBLY Caution on Assembly Caution on Handling O-ring Do not use O-ring which has any defect or scratches from handling. Apply grease or hydraulic oil to installation portion of O-ring grooves and O-ring to ease installation. Do not stretch O-ring beyond permanent set. When installing O-ring, be careful not to twist it.
Page 579: Sequence Of Subassembly
Loctite application Lightly apply Loctite #274 or equivalent to two or three threads of spool female inlet. Now, be careful not to touch coated part to spring seat. Sequence of Subassembly IMPORTANT Check number of each part, installation position and tools needed before reassembling.
Page 580 Antidrift Valve Assembly Install O-ring (67-9 and 67-10) and backup ring (67-11 and 67-12) in groove of sleeve (67-6). IMPORTANT Be careful of installation position of O-ring and backup ring. If they are reversed, the O-ring will be damaged and drift speed of actuator can be increased.
Page 581 Assembly of Relief Valve Install main relief valve (68). Tightening torque: Tightening torque: 7.95 - 8.97 kg•m (58 - 65 ft lb). Install overload relief valve (69, six places) in each section. Tightening torque: 7.95 - 8.97 kg•m (58 - 65 ft lb). Install spring seat (67-16) on small diameter of poppet.
Page 582 Insert backup ring (103), O-ring (104), spring (98) and poppet assembly (100) in sleeve (99), and install in body (96). Install O-ring (36) in valve housing and fasten body using socket head bolt (101). Tightening torque: 5.91 - 6.53 kg•m (43 - 47 ft lb) Insert poppet (32) and spring (33) in arm 1 para turn part (Section C-C).
Page 583 Assembly of Arm 1 Para-turn Spool Install spool subassembly (19) into valve housing. IMPORTANT After inserting spool, check to see if it slides easily. Install O-ring (23) on cap (18) and fasten it in place with socket head bolt (78). Tightening torque: 0.90 - 1.10 kg•m (6.49 - 7.97 ft lb).
Page 584 Assembly of Other Plugs Install O-ring on plug assembly (60) and install. Tightening torque: 11 - 12 kg•m (76 - 83 ft lb) Install O-ring (62) on plug assembly (61) and install. Tightening torque: 4 - 4.5 kg•m (29 - 32 ft lb) Tighten orifice plug (63).
Page 585: Maintenance Of Relief Valves
Maintenance of Relief Valves Reassembly of Main Relief Valve "O-ring" P/N: 95111-01100 Width across flat 27 Width across flat 30 (Plug) (Hex. Nut) Width across "O-ring" P/N: 95111-01400 Width across flat 36 flat 27 (Hex. Nut) (Plug) JIS O-ring Type Piston Width across flat 32 "O-ring"...
Page 586 Reassembly of Overload Relief Valve (69, Total of 6 Places) Poppet Spring "O-ring" P/N: 95113-01000 "O-ring" P/N: 21001-00098 Width across flat 31.75 Width across flat 17 Width across flat 6 (Cap) (Lock Nut) (Adjuster) FG001318 Figure 43 Check if there is dirt and paint chips around cap (1). Replace O-ring with new one.
Page 587 Reassembly of Low-pressure Relief Valve (70, Total of 2 Places) "O-ring" P/N: 95113-02100 "O-ring" P/N: 21001-00213 FG001321 Figure 44 Check if there is dirt and paint chips around plug (1). Replace O-ring (3) with new one. Install new O-ring (4) on sleeve (2).
Page 588: Installation
INSTALLATION Install eyebolts (M10 x 1.5) (2 used) to control valve (1, Eyebolt Figure 45). Mouting Position • Control Valve weight: 193 kg (M10 x 1.5) Hoist and align control valve (1, Figure 45) with the mounting position in bracket. Install control valve (1, Figure 45) to the bracket with bolts (2, Figure 45) (4 used) and spacers (4 used).
Page 589: Start-Up Procedures
START-UP PROCEDURES Before operating machine, make sure that oil passages and hydraulic oil are clean. Hydraulic oil of which annealing point is 82° - 113°C (180° - 235°F) should be used in the hydraulic system. Relief valve pressure should not be raised above specified pressure setting.
Page 590 Main Control Valve SP002403 Page 70...
Page 591 SP002395 REMOTE CONTROL VALVE (WORK LEVER / JOYSTICK) SP002395 Remote Control Valve (Work Lever / Joystick) Edition 2 Remote Control Valve (Work Lever / Joystick) SP002395 Page 1...
Page 592 MEMO Remote Control Valve (Work Lever / Joystick) SP002395 Page 2...
Page 593 Table of Contents Remote Control Valve (Work Lever / Joystick) Safety Instructions ..........5 Applicable Models ..........5 General Description ..........7 Theory of Operation ............7 Parts List ................. 8 Specifications ..............10 Torques ................. 10 Tools and Materials ..........10 Disassembly ............
Page 594 MEMO Remote Control Valve (Work Lever / Joystick) SP002395 Page 4...
Page 595: Remote Control Valve (Work Lever / Joystick)
DX170W-3 1001 and Up DX180LC-3 1001 and Up, 50001 and Up DX190W-3 1001 and Up DX225LC-3 1001 and Up, 50001 and Up DX255LC-3 1001 and Up, 50001 and Up DX300LC-3 1001 and Up, 50001 and Up Remote Control Valve (Work Lever / Joystick)
Page 596 Remote Control Valve (Work Lever / Joystick) SP002395 Page 6...
Page 597: General Description
GENERAL DESCRIPTION Theory of Operation Structure The remote control valve contains four push rods, spring holders, spools and return springs, which are in the valve casing. The valve works as a pressure reduction valve. The housing has six ports, which include input port P, tank port T, and four secondary pressure ports.
Page 598: Parts List
Parts List (L.H) (R.H) : 24 ~ 28 FG019389 Figure 1 Remote Control Valve (Work Lever / Joystick) SP002395 Page 8...
Page 599 Reference Reference Description Description Number Number Case Plate Plug Boot Bushing Joint Assembly Spool Swash Plate Shim Spring Spring Seat Joystick (LH) Stopper Joystick (RH) Spring Handle Bar Stopper Bellows Spring Bushing Push Rod Spring Pin Spring Spool Kit 1, 3 Spring Seat Spool Kit 2, 4 Stopper...
Page 600: Specifications
Specifications Performance (2, 4) (1, 3) 28 1.5 28 1.5 (20.5) (20) (19) (17.5) Operating Torque 17 3 Operating Torque 16.6 3 6.5 1 6.5 1 5.5 2 5.5 2 Secondary Pressure Secondary Pressure 6.5 7 (6.2) 7.5 8 Push Rod Strike (mm) Push Rod Stroke (mm) FG019380 Figure 2...
Page 601: Disassembly
DISASSEMBLY Prepare the necessary tools. (+Type screwdriver, long-nose pliers (M), 13 mm hex socket and ratchet, hex wrench set) FG019384 Figure 3 Remove armrest. (M8 bolt 3 each) Remove armrest cover. (M5 screw 1 each) FG019385 Figure 4 Remove rubber pad then unscrew M6 screws and disassemble S/W cover.
Page 602 Remove bracket. (M5 screw 2 each) Disassemble joystick. (Socket bolt 4 each) FG019388 Figure 7 Remove lead wire from bushing (29). FG013494 Figure 8 Remove lever assembly from case (1). FG013495 Figure 9 Remove hex nut (23) and swash plate (22) from case (1). FG013496 Figure 10 Remote Control Valve (Work Lever / Joystick)
Page 603 Remove joint assembly (21) from case (1). FG013497 Figure 11 10. Install lead wire terminal into connector terminal pressing them together. FG013118 Figure 12 11. Assemble connector assembly, and connect it to lead wire terminal, and properly route wiring. FG013519 Figure 13 Remote Control Valve (Work Lever / Joystick) SP002395...
Page 604: Reassembly
FG013520 Figure 14 REASSEMBLY Install four plugs (2) into case (1). FG013504 Figure 15 FG013507 Figure 16 Remote Control Valve (Work Lever / Joystick) SP002395 Page 14...
Page 605 Install bushing (3) into case (1) using jig. FG013506 Figure 17 FG013508 Figure 18 Take care when assembling spool kit assemblies (1 and 3, 2 and 4). (They should be assembled in same way). The assembly order is; spool (4), shim (5), spring (6), spring seat (7), and stopper (8).
Page 606 Install spring (9) into case (1). FG013499 Figure 21 Install spool kit assembly into case (1). (The same way is used for four parts.) FG013502 Figure 22 Assemble plug kit insert rod seal (18), O-ring (17), and push rod (12) into plug (16) in proper order. FG013511 Figure 23 FG013512...
Page 607 Assemble four springs (11) and stoppers and insert assembled set in case (1) to form a plug kit assembly. NOTE: Pay attention to measurement specifications of stoppers (1 and 3, 2 and 4). FG013499 Figure 25 FG013501 Figure 26 Install plate (19) into case (1). FG013498 Figure 27 Install joint assembly (21) into case (1).
Page 608 10. Install boot and swash plate (22) and hex nut (23) into case (1). FG013513 Figure 29 FG013514 Figure 30 11. Insert bar and tighten it with a wrench to check balance of joint assembly. FG013515 Figure 31 12. Install bushing (29) into case (1). FG013516 Figure 32 Remote Control Valve (Work Lever / Joystick)
Page 609 13. Install lever assembly into case (1). FG013495 Figure 33 14. Put lead wire in bushing (29), tie it, and arrange boot. FG013494 Figure 34 15. Install lead wire terminal into connector terminal pressing them together. FG013118 Figure 35 Remote Control Valve (Work Lever / Joystick) SP002395 Page 19...
Page 610 16. Assemble connector assembly (30), and connect it to lead wire terminal, and properly route wiring. FG013519 Figure 36 FG013520 Figure 37 17. Assemble joystick. (Socket bolt 4 each) Assemble bracket. (M5 screw 2 each) FG019388 Figure 38 18. Assemble upper cover. Then add socket bolt (1 each) and M6 screws.
Page 611 19. Assemble S/W cover then add M6 screws. And add the rubber pad. FG019386 Figure 40 20. Assemble armrest. (M8 bolt 3 each) Assemble armrest cover. (M5 screw 1 each) FG019385 Figure 41 FG019384 Figure 42 Remote Control Valve (Work Lever / Joystick) SP002395 Page 21...
Page 612: Start-Up Procedures
START-UP PROCEDURES Start engine and set throttle at "LOW IDLE." Set safety lever to "UNLOCK" position. FG019382 Figure 43 Slowly cycle boom, arm, bucket cylinders and swing motor about five times without a load to vent air from pilot lines. Do this for five minutes.
Page 613 SP002381 TRAVEL CONTROL VALVE (WITH DAMPER) SP002381 Travel Control Valve (with Damper) Edition 2 Travel Control Valve (with Damper) SP002381 Page 1...
Page 614 MEMO Travel Control Valve (with Damper) SP002381 Page 2...
Page 615 Table of Contents Travel Control Valve (with Damper) Safety Instructions ..........5 Applicable Models ..........5 General Description ..........6 Theory of Operation ............6 Pressure Reducing Valve..........7 Operating Theory of Damper Mechanism ....... 8 Causes of Faults and Measures ......9 Parts List ...............
Page 616 MEMO Travel Control Valve (with Damper) SP002381 Page 4...
Page 617: Travel Control Valve (With Damper)
MODEL SERIAL NUMBER RANGE DX140LC-3 1001 and Up, 50001 and Up DX180LC-3 1001 and Up, 50001 and Up DX225LC-3 1001 and Up, 50001 and Up DX255LC-3 1001 and Up, 50001 and Up DX300LC-3 1001 and Up, 50001 and Up DX340LC-3...
Page 618: General Description
GENERAL DESCRIPTION Theory of Operation The damper valve is divided into two areas of operation. The pressure reducing valve (a) and the damper mechanism (b). The following hydraulic circuit is an example of a remotely located control valve. ARS1810L Figure 1 Reference Reference Description...
Page 619: Pressure Reducing Valve
Pressure Reducing Valve Neutral Condition If pedal is in neutral, the spool is pushed up by return spring and spring seat. Port (P) is blocked by bottom part of spool and four operating ports (left forward and backward, right forward and backward) are connected to port (T) through inner hole of spool.
Page 620: Operating Theory Of Damper Mechanism
Operating Theory of Damper Mechanism Operation When Operating Lever When pushing the pedal, the force against the push rod and spool presses the cylinder, return spring and the hydraulic oil in cylinder is compressed. The piston coming down compresses the oil in the vibration prevention chamber which flows through the orifice to the low- pressure upper chamber.
Page 621: Causes Of Faults And Measures
CAUSES OF FAULTS AND MEASURES At times it may be difficult to pinpoint the source of the problem. The following table lists some of the possible problems, possible causes and remedies. Refer to this table for possible causes and remedies to assist in correcting the sometimes difficult problems.
Page 622: Parts List
Parts List Figure 3 Travel Control Valve (with Damper) SP002381 Page 10...
Page 623 Reference Reference Description Description Number Number Body (1) O-ring Body (2) Rod Seal Plug Dust Seal Plug Cover Spring Seat Hex Socket Head Bolt Spring Shim Bushing Spool Camshaft Stopper Set Screw Spring Set Screw Spring Pin Hex Nut O-ring Bellows Push Rod Piston...
Page 624: Specification
Specification 112.6 25 1.5 Operating Torque 91.8 46.4 7.5 1 Secondary Pressure 1 0.5 4.3 0.5 5 Rush Rod Stroke (mm) FG024460 Figure 4 Travel Control Valve Specification Type Pilot Control (With Damper) 25 kg/cm @ 4.3 mm Stroke Pressure / Stroke (356 psi @ 0.1692 in Stroke) Weight 7.8 kg (17 lb)
Page 625: Removal
REMOVAL Park on firm and level ground. Lower bucket (or work tool) to ground. Stop engine. Set safety lever to "RELEASED" position. Turn starter switch to "I" (ON) position. WARNING when performing inspection WARNING 190-00695A FG018470 AVOID DEATH OR SERIOUS INJURY Figure 5 engine must...
Page 626 13. Remove hex bolts (1) and washer. Remove cover (2) from frame (3). • : 19 mm FG020150 Figure 7 14. Remove hoses (1) from travel control valve (2). Attach identification tags to the removed hoses for reassembling. • : 17 mm, 22 mm FG020145 Figure 8 15.
Page 627 17. Remove bolts (1) and washer (2). Remove travel pedal (3) from travel pedal bracket (4). • : 17 mm 1, 2 FG020146 Figure 11 Remove socket bolts (1) and washer (2). Remove travel pedal bracket (3) from travel control valve (4).
Page 628: Disassembly
DISASSEMBLY Remove bellows (32). FG013535 Figure 14 Remove set screw (29) from cam (26). FG013536 Figure 15 Remove camshaft (28) from cam (26). FG013537 Figure 16 Remove hex nut (31) and set screw (30) from cam (27). FG013538 Figure 17 Travel Control Valve (with Damper) SP002381 Page 16...
Page 629 Remove hex socket head bolt (25) and cover (24) from each body (1 and 2). FG013539 Figure 18 FG013540 Figure 19 Remove push rod assembly from body (2). FG013541 Figure 20 Remove body (2) from body (1). FG013542 Figure 21 Travel Control Valve (with Damper) SP002381 Page 17...
Page 630: Cleaning And Inspection (Wear Limits And Tolerances)
Remove damper spool assembly and spring (10) from body (1). FG013543 Figure 22 FG013544 Figure 23 Remove plug (3 and 4) and O-rings (12 and 34). FG013545 Figure 24 CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) For general cleaning and inspection procedures, refer to "General Maintenance Procedures"...
Page 631: Reassembly
REASSEMBLY Insert spring (10) into body (1). FG013544 Figure 25 Assemble in proper order, damper spool (8), shim (7), spring (6), spring seat (5) and stopper (9). FG013546 Figure 26 Install damper spool assembly into body (1). FG013547 Figure 27 Assemble body (2) onto body (1).
Page 632 Assemble rod seal (22), dust seal (23) and O-ring (21) into plug (20). FG013548 Figure 29 FG013549 Figure 30 Assemble seal (15), piston (33), steel ball (16), plate (18), spring (17) and retaining ring (19) into push rod (13). FG013550 Figure 31 Assemble push rod and plug.
Page 633 Install push rod assembly into body (2). FG013552 Figure 33 Install bushing (27) in cover (24) using jig. FG013553 Figure 34 10. Assemble cover (24) onto each body (1 and 2) and install hex socket head bolt (25) using torque wrench. FG013554 Figure 35 Travel Control Valve (with Damper)
Page 634 11. Install set screws (30) and hex nut (31) into cam (26) and tighten it. FG013555 Figure 36 FG013556 Figure 37 12. Position cam (26) on cover (24) and insert camshaft (29) using hammer. FG013557 Figure 38 13. Install set screw (29) in cam (26) and tighten it using torque wrench.
Page 635 14. Check cam balance. FG013559 Figure 40 15. Install bellows. FG013560 Figure 41 FG013561 Figure 42 Travel Control Valve (with Damper) SP002381 Page 23...
Page 636: Installation
INSTALLATION Position pedal valve (1, Figure 43) on cabin floor plate and install four bolts and washers (2). FG003016 Figure 43 Install pedal brackets (3, Figure 44) on pedal valve and install four bolts and washers (2). Install plastic pedals (1). FG019381 Figure 44 Connect hoses as tagged during removal to pedal valve (1,...
Page 637 Move travel control valve (3) to floor plate (4). Install travel control valve (3) to floor plate (4). Install socket bolts (1) and washer (2). 1, 2 • : 8 mm FG020149 Figure 46 Install travel pedal bracket (3) to travel control valve (4). Install socket bolts (1) and washer (2).
Page 638 Install floor mat (1) to the cabin. FG020151 Figure 50 10. Detach identification tags from the removed hoses for reassembling. Install hoses (1) to travel control valve (2). • : 17 mm, 22 mm FG020145 Figure 51 11. Install cover (2) to frame (3). Install hex bolts (1) and washer.
Page 639: Start-Up Procedures
START-UP PROCEDURES Start engine and set throttle at "LOW IDLE." Set safety lever to "UNLOCK" position. FG019382 Figure 53 Slowly push and pull both travel levers about five times without a load to vent air from pilot lines. HAOB903L Figure 54 Travel Control Valve (with Damper) SP002381 Page 27...
Page 640 Travel Control Valve (with Damper) SP002381 Page 28...
Page 641 SP002406 SOLENOID VALVE ASSEMBLYSP002406 Solenoid Valve Assembly Edition 2 Solenoid Valve Assembly SP002406 Page 1...
Page 642 MEMO SP002406 Solenoid Valve Assembly Page 2...
Page 643 Table of Contents Solenoid Valve Assembly Safety Instructions ..........5 Applicable Models ..........5 5-Solenoid Valve ..........6 Parts List ................. 6 Functions of 5-Solenoid Valve Assembly ......7 Assembly Diagram and Tools Required ......8 Cautions During Disassembly and Reassembly ..... 9 Solenoid Valve Diagram..........
Page 644 MEMO SP002406 Solenoid Valve Assembly Page 4...
Page 645: Solenoid Valve Assembly
MODEL SERIAL NUMBER RANGE DX140LC-3 1001 and Up, 50001 and Up DX180LC-3 1001 and Up, 50001 and Up DX225LC-3 1001 and Up, 50001 and Up DX255LC-3 1001 and Up, 50001 and Up DX300LC-3 1001 and Up, 50001 and Up DX340LC-3...
Page 646: 5-Solenoid Valve
5-SOLENOID VALVE Parts List Figure 1, shows components used in the 5-solenoid valve. FG020607 Figure 1 Reference Description Sizes Quantity Remarks Number Block Body 78 x 82 x 263 FB-EXDS01657 Solenoid Valve SQ-S3A-00 C1 - C5 Coil (Deutsch Type) VDD24VDC C1 - C5 Check Valve FD-DCP-0-A...
Page 647: Functions Of 5-Solenoid Valve Assembly
Functions of 5-Solenoid Valve Assembly The solenoid valve assembly controls the following functions. Pilot Cutoff Breaker Pressure Supply High/Low Travel Speed Main Pressure (Power Boost) Increase Two-Pump Mode Selection Functions and Operations of Solenoid Valves Reference Function Operations Remarks Number Provides pressurized oil coming from the pilot pump for Pilot Cut-off the pilot pressure supply solenoid valve to operate...
Page 648: Assembly Diagram And Tools Required
Assembly Diagram and Tools Required Figure shows assembly torques recommended components in the solenoid valve. Designated tools and torques should be used. FG020608 Figure 2 Reference Torques Description Sizes Tools Number (kg•cm) Solenoid Valve UNF7/8 - 14" 350 ± 25 Torque Wrench/1,"...
Page 649: Cautions During Disassembly And Reassembly
Cautions During Disassembly and Reassembly Choose a work area for disassembly. Choose a clean work area. NOTE: Use a rubber mat or other protective covering on the workbench area to prevent damage or scratching of any precision machined components. For disassembly and reassembly, use torques and tools listed in tables.
Page 650: Solenoid Valve Diagram
Solenoid Valve Diagram Reference Description Number Coil Locknut Coil Connector Tube and Retainer Case FG020609 Figure 3 Solenoid Valve Assembly SP002406 Page 10...
Page 651: Check Points And Solutions For Problems
Check Points and Solutions for Problems Symptoms Causes How to Check Solutions Foreign sub- Disassemble the solenoid valve and check if Remove contami- stance, dirt and there is any contamination such as a foreign sub- nant, wash, and dust in solenoid stance and sludge between the case and the assemble compo- valve.
Page 652 Solenoid Valve Assembly SP002406 Page 12...
Page 653 SP002458 BREAKER EPPR VALVE (OPTION)SP002458 Breaker EPPR Valve (Option) Edition 2 Breaker EPPR Valve (Option) SP002458 Page 1...
Page 654 MEMO SP002458 Breaker EPPR Valve (Option) Page 2...
Page 655 Table of Contents Breaker EPPR Valve (Option) Safety Instructions ..........5 Applicable Models ..........5 Structure ............... 6 Parts List ................. 6 Functions and Operation ........7 Cautions for Operation ......... 7 Maintenance Instructions........8 Maintenance..............8 Disassembly ..............9 Assembly...............
Page 656: Breaker Eppr Valve (Option)
MEMO SP002458 Breaker EPPR Valve (Option) Page 4...
Page 657: Safety Instructions
MODEL SERIAL NUMBER RANGE DX140LC-3 1001 and Up, 50001 and Up DX180LC-3 1001 and Up, 50001 and Up DX225LC-3 1001 and Up, 50001 and Up DX255LC-3 1001 and Up, 50001 and Up DX300LC-3 1001 and Up, 50001 and Up DX340LC-3...
Page 658: Structure
STRUCTURE Parts List Figure 4 Reference Reference Description Description Number Number Solenoid Valve casing Spring Sleeve O-ring Spool O-ring Breaker EPPR Valve (Option) SP002458 Page 6...
Page 659: Functions And Operation
FUNCTIONS AND OPERATION The proportional reducing valve shall be adjusted so that its reduced pressure is proportional to the current pressure of the solenoid. The proportional solenoid shall be changed with pressure proportional to the electrical input signal. Flow increases corresponding to the force of the solenoid.
Page 660: Maintenance Instructions
MAINTENANCE INSTRUCTIONS Maintenance Bolt Tightening Torque Table 1 shows torques used to tighten bolts of the motor. Make sure that assembly work should be done according to Table 1. Used Torques Bolt Sizes Names (kg•cm) M 35 Hex bolt 450 ± 50 M 10 Hex bolt 200 ±...
Page 661: Disassembly
Disassembly Determine a place for disassembly. • It should be clean. • Lay a rubber board or a cloth on the table and take care not to damage parts. Remove dust and rust of the proportional pressure reducing valve with cleansing oil. Disassemble the solenoid •...
Page 662: Assembly
Assembly Assembly shall be done in the reverse order of disassembly described above, taking into consideration the following points. • Parts damaged during disassembly should be repaired without fail and spare parts should be prepared in advance. • Every part should be cleaned thoroughly with cleaning oil and dried with compressed air before starting assembly.
Page 663 Assemble the spool, the spring, and the pin. FG003695 Figure 10 • Make sure that the spring and the pin do not fall off. FG003696 Figure 11 SP002458 Breaker EPPR Valve (Option) Page 11...
Page 664 Assemble the solenoid correctly. PART No.: 426-00266 SERIAL No.: FG003697 Figure 12 • Take care not to damage O-rings of the solenoid. FG003698 Figure 13 Breaker EPPR Valve (Option) SP002458 Page 12...
Page 665 SP002529 DOZER VALVE SP002529 Dozer Valve Edition 1 Dozer Valve SP002529 Page 1...
Page 666 MEMO SP002529 Dozer Valve Page 2...
Page 667 Table of Contents Dozer Valve Safety Instructions ..........5 Applicable Models ..........5 Structure Diagram ..........6 Performance Specification........7 Hydraulic Pressure Circuit Diagram...... 7 Parts List............... 8 Disassembly and Assembly ToolS ....... 9 Disassembly ............9 Assembly Method ..........11 Dozer Valve SP002529 Page 3...
Page 668 MEMO SP002529 Dozer Valve Page 4...
Page 669: Dozer Valve
The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX140LC-3 1001 and Up, 50001 and Up DX180LC-3 1001 and Up, 50001 and Up DX225LC-3 1001 and Up, 50001 and Up SP002529 Dozer Valve Page 5...
Page 670: Structure Diagram
STRUCTURE DIAGRAM II-13 II-11 II-10 II-12 IV-3 FG023116 Figure 1 Dozer Valve SP002529 Page 6...
Page 671: Performance Specification
PERFORMANCE SPECIFICATION Secondary Pressure 16.6 Operating Torque 2.4 1.5 6.5 0.5 Push-ROD Stroke (mm) FG023115 Figure 2 HYDRAULIC PRESSURE CIRCUIT DIAGRAM Symbol FG011415 Figure 3 SP002529 Dozer Valve Page 7...
Page 672: Parts List
PARTS LIST Part Name Standard Material Q’TY Remark Body JA3H1001 Plug J96H2002 IV-3 O-ring N.B.R PO 08 Spring JAOL6001 Spool Kit JA6J8010 Spring Seat J96H2004 Spool J96H2005 Spring Seat AJV12D103 Spring JAOL6002 Stopper 2 set AJV12D106 Plug Kit JA6J8011 II-10 Plug J96H2007 II-11...
Page 673: Disassembly And Assembly Tools
DISASSEMBLY AND ASSEMBLY TOOLS Part No. Tool Specification Remarks Torque Wrench L35 mm 150 kg/cm L Wrench 10 mm L Wrench 15 mm Wrench 8 mm DISASSEMBLY Separate the boot (22). Figure 4 Remove the pin (17) and separate the lever (20). Figure 5 Loosen the fixated wrench bolt (15) and separate the cover (14).
Page 674 Separate the plug kit (II) from the body (1). Figure 7 Separate the spool kit (I) from the body (1). Figure 8 Separate the spring (4) from the body (1). Figure 9 Separate the plug (2) from the body (1). Figure 10 Dozer Valve SP002529...
Page 675: Assembly Method
ASSEMBLY METHOD Assemble the plug (2) to the body (1). Figure 11 Assemble the spring (4) to the body (1). Figure 12 Assemble the spool kit (I). Assemble spring seat (I-5), spring (I-8), spring seat (I-5) stopper (I-9) to spool (I-6) in this order. Figure 13 Assemble the spool kit (I) to the body (1).
Page 676 Assemble the plug kit (II). Assemble the rod seal (II-11), O-ring (II-12) and push rod (II-13) to the plug (II-10) in this order. Figure 15 Figure 16 Assemble the plug kit (II) to the body (1). Figure 17 Dozer Valve SP002529 Page 12...
Page 677 Assemble the cover (14) to the body (1). Figure 18 Figure 19 After assembling the lever (20) and guide (16), then install it on the body (1) and attach the assembly with the pin (17). Figure 20 Figure 21 SP002529 Dozer Valve Page 13...
Page 678 Adjust the gap between the guide (16) and push rod (II-13). Figure 22 10. Assemble the boot (22). Figure 23 Dozer Valve SP002529 Page 14...
Page 679 SP002507 HYDRAULIC SCHEMATIC (DX225LC-3)SP002507 Hydraulic Schematic (DX225LC-3) Edition 1 Hydraulic Schematic (DX225LC-3) SP002507 Page 1...
Page 680 MEMO Hydraulic Schematic (DX225LC-3) SP002507 Page 2...
Page 681 Table of Contents Hydraulic Schematic (DX225LC-3) Safety Instructions ..........5 Applicable Models ..........5 DX225LC-3 ............7 Hydraulic Schematic (DX225LC-3) SP002507 Page 3...
Page 682 MEMO Hydraulic Schematic (DX225LC-3) SP002507 Page 4...
Page 683 APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX225LC-3 1001 and Up, 50001 and Up Hydraulic Schematic (DX225LC-3) SP002507 Page 5...
Page 684 Hydraulic Schematic (DX225LC-3) SP002507 Page 6...
Page 685 A(#56) P(#52) from PRESS. SWITCH ON #7 300kg/cm 177u ENGINE RH-HI from SELECTION ON DISPLAY MONITOR (OPEN) DL06 from JOYSTICK(R) BOTTON C1 C r1~r4 Hammer Select from JOYSTICK(R) PPC P (#42) Shear Select FG024463 Figure 1 Hydraulic Schematic (DX225LC-3) SP002507...
Page 687 Electrical System...
Page 689 SP002337 ELECTRICAL SYSTEMSP002337 Electrical System Edition 2 Electrical System SP002337 Page 1...
Page 690 MEMO SP002337 Electrical System Page 2...
Page 691 Table of Contents Electrical System Safety Instructions ..........7 Applicable Models ..........7 Introduction ............8 Electrical Supply System ........10 Engine Starting Circuit ........12 Start Operation .............. 12 After Start ..............14 Engine Preheating System ......... 16 Engine Stop ............18 Charging System ..........
Page 692 Control System Schematic ..........92 Power Plus Mode Control ........94 Operation............... 96 Power Mode Control - Circuit Diagram ....98 Engine Control System ........100 Engine Control Dial........... 101 Engine Control Circuit Diagram ......102 Automatic Deceleration Control (Auto Idle Control) Engine Overheat Protection System ....
Page 693 Repair and Replacement Procedure ......141 Refrigerant Recovery ..........143 Vacuuming Refrigerant System........143 Leakage Check ............145 Refrigerant Charging ........... 145 Inspecting System For Leakage........147 Wiper System ........... 148 Wiper Circuit..............148 Wiper operation ............149 Lighting System ..........152 Lighting System Circuit Diagram .........
Page 694 Electrical System SP002337 Page 6...
Page 695: Electrical System
MODEL SERIAL NUMBER RANGE DX140LC-3 1001 and Up, 50001 and Up DX180LC-3 1001 and Up, 50001 and Up DX225LC-3 1001 and Up, 50001 and Up DX255LC-3 1001 and Up, 50001 and Up DX300LC-3 1001 and Up, 50001 and Up SP002337...
Page 696: Introduction
INTRODUCTION MEMO The electrical system for this equipment is DC 24 volts. The rated voltage for all electric components is 24 volts with the exception of the stereo and the air-conditioning control actuator. The system contains two 12 volt batteries connected in series and a three phase AC generator with a rectifier.
Page 697 SP002337 Electrical System Page 9...
Page 698: Electrical Supply System
ELECTRICAL SUPPLY SYSTEM The electric power circuit supplies electric current to each electric component. It consists of a battery, battery relay, starter switch, circuit breaker, fusible link and fuse box. The negative terminal of the battery is grounded to the machine body.
Page 699 0.5G 12V 150AH 12V 150AH R(I) P(R) B(B+) 0.5 uF STARTER SWITCH CONNECTION I(L) REG. TRIO DIODE FIELD START FG018839 Figure 1 Electric Power Circuit Diagram Reference Reference Description Description Number Number Battery Starter Switch Battery Relay Fuse Box Fusible Link Alternator Circuit Breaker Diode...
Page 700: Engine Starting Circuit
ENGINE STARTING CIRCUIT Start Operation When the starter switch is turned to the "START" position, the "S" and "E" terminals of the starter controller (7) are connected. Now the contacts in the starter relay (8) are closed by the current flow from the battery (1) → fusible link (3) → fuse box (6) → "B"...
Page 701 CN2-96 CN1-58 R(I) B(B+) P(R) STARTER SWITCH CONNECTION PREHEAT START FG018841 Figure 3 Starter Circuit (1) - While Starting Reference Reference Description Description Number Number Battery Starter Relay Battery Relay Starter Fusible Link Alternator Circuit Breaker Diode Starter Switch Starter Relay 2 Fuse Box e-EPOS Controller Starter Controller...
Page 702: After Start
After Start Once the engine has been started, the belt driven alternator (10) generates a current. The output generated by the alternator (10) is a square wave pulse voltage through the "P" terminal and the frequency of the pulse voltage is proportional to the rotation of the alternator. The starter controller (7) monitors the frequency of the output current.
Page 703 Operation of the Start Circuit (2) - Immediately After Start CN2-96 CN1-58 R(I) B(B+) P(R) STARTER SWITCH CONNECTION PREHEAT START FG018841 Figure 4 Operation of Start Circuit (2) - Immediately After Start Reference Reference Description Description Number Number Battery Starter Relay Battery Relay Starter Fusible Link...
Page 704: Engine Preheating System
ENGINE PREHEATING SYSTEM An air heater (8) is installed in the intake manifold of the engine. When the starter switch (5) is turned "ON," the current flows from the battery (1) → fusible link (3) → fuse box (6) → "B" terminal of starter switch (5) →...
Page 705 CN6-9,10 CN6-4,5 CN1-77,78,59 CN2-93 200A STARTER SWITCH CONNECTION 1-46,47,10 1-69 1-74 PREHEAT 1-83 START FG018842 Figure 5 Engine Preheat Circuit Reference Reference Description Description Number Number Battery Air Heater Battery Relay Preheat Indicator Light Fusible Link Diode Circuit Breaker e-EPOS Controller Starter Switch Engine Controller Fuse Box...
Page 706: Engine Stop
ENGINE STOP When starter switch (5) is turned "ON" the engine controller (8) is activated. The engine controller monitors and controls the engine including the injector solenoid (9). It controls the fuel deliver rate and the injection timing for each cylinder. There is an individual injector solenoid (9) for each of NOTE: the six cylinders.
Page 707 STARTER SWITCH CONNECTION PREHEAT START 0.5G 1-11 1-69 FG018843 Figure 7 Engine Stop Circuit Reference Reference Description Description Number Number Battery Fuse Box Battery Relay Diode Fusible Link Engine Controller Circuit Breaker Injector Solenoid Starter Switch Emergency Stop Switch SP002337 Electrical System Page 19...
Page 708: Charging System
CHARGING SYSTEM When the starter switch (5) is turned to the "ON" position, an initial excitation current flows to the field coil of the alternator (7) through the battery relay (2) and circuit breaker (4). When the engine is started from this condition the alternator (7) starts charging.
Page 709: Monitoring System
MONITORING SYSTEM FG018845 Figure 9 Reference Reference Description Description Number Number Instrument Panel Pump Discharge Pressure Sensor Battery Hydraulic Oil Temperature Light Switch Sensor Return Filter Switch Fuel Sensor Pilot Filter Switch Air Cleaner Indicator e-EPOS Controller Engine Controller Alternator Jog Switch Control Panel Warning Buzzer The monitoring system displays the various data and warning...
Page 710: Functional Check
Instrument Panel FG018710 Figure 10 Reference Reference Description Description Number Number Fuel Gauge Warning Light Engine Coolant Temperature Function Buttons Gauge Mode Selector Buttons Hydraulic Oil Temperature Selector Function Display Gauge Jog Switch Multifunction Gauge and Graphic Camera Mode Selector/ESC Information Area Button ECO Gauge...
Page 711 SP002337 Electrical System Page 23...
Page 712: Monitoring System Schematic
Monitoring System Schematic 7-18 7-19 1-58 7-17 7-10 7-20 1-19 1-37 1-18 1-36 2-92 6-12 1-77 6-13 1-78 CAN A 1-46 1-59 1-61 1-64 1-62 1-81 1-14 1-32 1-46 1-15 1-47 1-33 1-10 R(I) FG018846 Figure 11 Electrical System SP002337 Page 24...
Page 713 Reference Reference Description Description Number Number Instrument Panel Return Filter Switch Pilot Buzzer Alternator Light Switch e-EPOS Controller Starter Switch Battery Front Pump Pressure Sensor Battery Relay Rear Pump Pressure Sensor Circuit Breaker Hydraulic Oil Temperature Fusible Link Sensor Fuse Box Fuel Sensor Check Connector Pedal Pressure Switch (Optional)
Page 714: Operation
OPERATION Instruments Sensor Specification Function Display Input Terminal Input Specification 104 C 105 C 110 C 98 C Coolant ECU-CAN 85 C Temperature Communication 60 C White 34 C FG018847 White 1/10 LCD (Red Zone) 1/10 CN1-14 Blinking → over 5K ohms Fuel Level Full CN1-32...
Page 715 Sensor Specification Function Display Input Terminal Input Specification N = 146 f / 60 1750 ECU-CAN N = Engine speed (rpm) Tachometer Communication f = Frequency of engine speed sensor (Hz) FG018850 ECO symbol: The instant workload - Green: Normal operation - Amber: Idling operation Green - Red: Heavy loading...
Page 716: Warning And Indicator Lights
WARNING AND INDICATOR LIGHTS Indication of Warning Lights Input Description Symbol Operation Remarks Terminal This symbol appears in case of no charge [voltage of "R (I)" Normally, it lights terminal is below when starting engine Charge CN1-2 12 ±1V] or and is out after engine overcharge [voltage starts.
Page 717 Input Description Symbol Operation Remarks Terminal This symbol appears Work Light CN1-74 when work light turns "ON" (24 V applied). HB4O2003 Green -> DPF This symbol appears Green automatic ECU-CAN in case of DPF Amber regeneration HEST Communic manual regeneration ation or DPF automatic Amber ->...
Page 718: Indication Of Multifunction Gauge
Indication of Multifunction Gauge Input Description Symbol Operation Remarks Terminal When hydraulic oil CN1-15 Hydraulic Oil temperature is above Temperature CN1-33 about 96°C. FG000056 CN1-14 Fuel When fuel is almost Exhausted exhausted. CN1-32 FG000057 When air cleaner is Air Cleaner CN2-92 clogged.
Page 719 Jog Switch This symbol appears Boost when boost is Communic selected. ation FG000554 Jog Switch This symbol appears Breaker when breaker is Communic selected. ation FG001470 Jog Switch This symbol appears Shear when shear is Communic selected. ation FG001471 This symbol appears when the water separator is full.
Page 720: Graphic Information Area Display
GRAPHIC INFORMATION AREA DISPLAY Overview Machine condition is displayed in the letter information display department. The information display department is divided into two menus. One is main menu for the user and the other is a special menu for the specialist. These menus can be changed from normal display mode by the jog switch.
Page 721: User Menu
USER MENU User Menu - Access and Escape Methods Access Method On the normal display screen, click on the jog switch to access the user menu screen. User Menu Vehicle Vehicle State Configuration Entertainment Configuration <Normal Indication Monitor> <Main Menu Monitor> FG018478 Figure 13 Escape Method...
Page 722 Vehicle State This is used to check the current vehicle state, filter/oil Vehicle State information, vehicle information, etc. Monitoring Turn the jog switch and move the cursor to see a reversed Filter/Oil Information display on the desired menu. Then, click on the jog switch to select the menu.
Page 723 – The filter/oil use time shows the hours of Filter/Oil Information operation after initializing the engine. It begins Fuel Filter again with 0 hr after initialization following the TIME: CHANGE: REMAIN: 500h 450h CLEAR replacement of filter/oil. Air Cleaner Reset Operation Hour? TIME: CHANGE: REMAIN:...
Page 724 Symbol Description Filter/ Return ENG Oil Coolant Fuel Filter Air Cleaner Pilot Filter ENG Oil HYD. Oil DPF Filter Oil Name Filter Filter Water Icon FG024693 Figure 21 If the remaining time for filter/oil replacement is less than 10 hours, this pop-up window will be created. Press the ESC button or the jog switch to allow the pop-up window to disappear.
Page 725 Vehicle Information Click the ESC button to return to the previous screen. FG018482 Figure 25 Vehicle Information Vehicle Name Engine DOOSAN Attachment Option Not Available Vehicle Number 000000 FG024557 Figure 26 Vehicle Configuration This is used when selecting the functions such as...
Page 726 Attachment Select (Optional) Attachment Select The attachment select screen is used to select Two Way Breaker attachments among the already set-up available attachments. At the vehicle configuration, if the cursor is placed on the attachment select, click on the jog switch to access the attachment select screen.
Page 727 On the owner's password input screen, press the Enter Password ESC button to return to the previous screen. Owner Password Enter Owner Password FG018474 Figure 33 If you access the attachment setting list screen, the Attachment Select initial screen locates the cursor at breaker/two-way at the top.
Page 728 Attachment Use Breaker 1 Setting The attachment use is designed to determine Attachment Use Button Type whether relevant attachments are used or not. Max E/G Limit Max E/G Limit Max Flow(Pump) Max Flow(Pump) If set up is enabled, the relevant attachment can be 2 Pump Option Currently Used Item! 2 Pump Option...
Page 729 Max Flow (ATT) / Min Flow (ATT) The max flow (ATT) /min flow (ATT) can be set up as the max/min flow rate value of the attachment by the user according to the attachment's specifications. For instance, if the relevant attachment's use capacity is 90 - 120 lpm, the user can set up 120 lpm for the max.
Page 730 The camera setting list screen displays various camera states (ON/OFF, NORMAL/MIRROR). Camera Setting Select a camera and click the jog switch to access the relevant camera setting screen. No 1 Camera - Off / Normal No 2 Camera - On / Normal Press the ESC button to return to the previous screen.
Page 731 If you access the jog shuttle for dial screen, the initial Jog Shuttle for Dial cursor is located at the using jog shuttle for dial. If the using jog shuttle for dial is shown as disable, Using Jog Shuttle the cursor cannot be moved. for Dial Cuffent Engine Speed...
Page 732 Video ↔ MP3 Press the ESC button to return to the previous screen. Entertainment Video FG018507 Figure 48 If the use of entertainment is limited, this pop-up window will be created. Entertainment To lift the use limits, you should change the limit setup in the GP configuration.
Page 733 Video From the entertainment screen, select video to Entertainment access it. Video FG018507 Figure 51 When there is no USB storage system, a pop-up window is displayed for 3 seconds, saying "USB" Storage is not installed." and the video is not played. Entertainment USB Storage is not Video...
Page 734 If the format is not supported, a pop-up window is Title displayed for 3 seconds, saying "This file is not available!" and the video is not played. This file is not available! FG020115 Figure 55 Formats that can be supported are given below. Formats that can be supported File Type AVI (DIVX), MP4, WMV (VERSION 8)
Page 735 Play/Pause Title Locate the cursor on the play/pause symbol and click on the jog switch to execute the video's play/pause functions. With the play being on, click on the jog switch to display the pause symbol at the center of the screen, thus allowing the video to pause.
Page 736 Video Files List Title Locate the cursor at the video files list symbol and click on the jog switch to move to the video file list screen. FG020121 Figure 62 Select and replay a video. Video Hard Disk MOVIE ..(3) Video(1).avi Video(2).avi Video(3).avi...
Page 737 From the entertainment screen, select MP3 to access Entertainment Video FG018524 Figure 66 If there is no USB storage system, a pop-up window is displayed for 3 seconds, saying "USB Storage is Entertainment not installed." and the MP3 player is not run. Video USB Storage is not installed.
Page 738 The screen composition of MP3 player is given Singer - Title below. The top section displays the name of the file being Title played and the current playing time of the total playing time. The screen center shows the album image of the file being played, the album name, the song name and Next the name of the next file to be played.
Page 739 Fast Forward/Rewinding Singer - Title Locate the cursor at the video progress bar and click on the jog switch to convert into the fast forward/ Title rewinding mode. On the fast forward/rewinding mode, operate the jog switch clockwise/counterclockwise to conduct fast forward/rewinding.
Page 740 BackGround MP3 Play Singer - Title Position the cursor on the Home button and pressing the jog switch, MP3 is played by the initial screen. Title Next FG020130 Figure 77 FG018118 Figure 78 GP Configuration This menu is used to set up password, brightness, default User Menu screen and time, and to input service phone number.
Page 741 Owner Password Setting Selection Password Setting The owner password can be set that manages Owner Password Setting equipment functions and user's equipment use rights. To set the owner password, press the jog switch (or "ENTER" on the keypad) when the cursor is on "Owner Password Setting"...
Page 742 Password Change Enter Password To change the owner password, select Owner Password "Password Change" and change the password using the jog switch (or keypad). Reenter Password FG020171 Figure 84 owner password changed Password Setting successfully, the "Password Set!" popup message will appear. Password Change Owner Engine Startup Lock has not been set!
Page 743 Attachment Setting The password input function can be set for attachment setting. Entertainment Use Setting The password input function can be set for entertainment (video/MP3) use setting. Engine Start-up Setting Password Setting When the "Engine Start-up" in "Item Setting" is selected, the password re-input Password Change time can be set when starting up the Owner...
Page 744 User Password Setting Selection Password Setting If the owner selects the "Use" checkbox besides Owner Password Setting "User Password" in the "Owner Password User Password Setting Setting" window, the "User Password Setting" item will appear on the "Password Setting" window that allows user password setting. (See “User Password Setting”...
Page 745 user password changed Password Setting successfully, the "Password Set!" popup message will appear. Password Change Engine Startup Lock has not been set! User Password Set! Item Setting FG020179 Figure 92 Item Setting Item Setting "Item Setting" enables the user to select Item the use of Engine Start-up, Attachment Engine Startup...
Page 746 Engine Start-up Setting Password Setting When the "Engine Start-up" in "Item Setting" is selected, the password re-input Password Change time can be set when starting up the Always 1min 5min User engine. (See “Engine Start-up” Item Setting page -57.) Always Password input is required whenever the engine is started.
Page 747 Turn the jog switch and adjust the brightness of 0 - Screen Brightness Setting 100% at an interval of 10%. The screen brightness when manufactured is set as 60%. Press the ESC button to return to the previous screen. FG018532 Figure 97 If you want to change the camera screen brightness, select the camera brightness setting to display the...
Page 748 Default Screen Setting On the GP configuration screen, when the cursor is GP Configuration placed on the default screen setting, click on the jog Password Setting switch to access the default screen setting. Brightness Setting On the default screen setting, turn the jog switch and Default Screen Setting locate the cursor at a desired style.
Page 749 Default Power Mode Setting On the GP configuration screen, when the cursor is GP Configuration placed on the default power mode setting, click on Password Setting the jog switch to access the default power mode Brightness Setting setting. Default Screen Setting Fuel Saving Mode is Enable Default Power Mode Setting Time Setting...
Page 750 Service Phone Number Setting On the GP configuration screen, when the cursor is GP Configuration placed on the service phone number setting, click on Brightness Setting the jog switch to access the service phone number Default Screen Setting setting. Default Power Mode Setting Time Setting Service Phone Number Setting FG022145...
Page 751 On the unit setting screen, change the units of Unit Setting temperature, pressure, flow rate, and speed. These figures at the machine release time are set as below: Temperature Temperature: °C Pressure Pressure: bar Flux Flow rate: lpm Speed Speed: km/h FG018546 Figure 111 Language Setting...
Page 752 Depending on the notification setting screen details, Notification Setting pop-ups are created or not created on the main screen when warning/alarm is issued, when the switch operated, when supplies Enable Warning Alarm Pop up replacement period expires. Enable Status Change Notification Pop up On the notification setting screen, turn the jog switch and move the cursor to a desired location.
Page 753: Special Menu
SPECIAL MENU In this menu, many types of operating conditions and functions can be accessed and displayed, including the e-EPOS controller. This menu is mainly used for machine testing and fault diagnostics. The special menu offers three submenus: Monitoring. Graph. Failure Information.
Page 754: Special Menu Selections
Special Menu Screen Displayed language on the special menu screen NOTE: Service Menu consists of Korean and English. Monitoring. If any language except for Korean is selected during Graph language selection mode of main menu, only English Failure Information will be displayed on special menu screen. Operationg Hour Information Vehicle Configuration FG018858...
Page 755 Vehicle Analog Description Analog Items Display Remark Front Pump Pressure Front pump pressure Rear Pump Pressure Rear pump pressure Boom Cylinder Pressure Boom cylinder head pressure Px Pressure Px pressure Py Pressure Py pressure Alternator Voltage Indicating alternator voltage. Battery Voltage Indicating battery voltage.
Page 756 Vehicle Digital Descriptions Digital Items Mark Remark Lights up when output at alternator "R (I)" terminal is Alternator above 12 ±1 V. Lights up when the boost button is "ON" with the Power Max Switch work mode selected to "BOOST." Lights up when the boost button is "ON"...
Page 757 Submenu Selections FG018866 Figure 124 SP002337 Electrical System Page 69...
Page 758 Engine Signal Description Analog Items Display Remark Engine Speed Engine Speed Throttle Position Throttle Position % Load at Current Speed Current load ratio of equipment Fuel Rate Fuel Rate Boost Pressure Pump pressure for boost Engine Oil Pressure Engine Oil Pressure Fuel Temperature °C Fuel Temperature...
Page 759 User Menu Monitor Data Setting User Menu Monitor Data Setting User can be monitor data setting. Front Pump Pressure The maximum limit of the monitor data setting is 6. Rear Pump Pressure Boom Cylinder Pressure Px Pressure Py Pressure Alternator Voltage Battery Voltage FG018862 Figure 126...
Page 760 Graph Entering Submenus: When a cursor is located in "Failure Graph Info" of special menu screen press enter jog switch (1 on Figure 118) and "Failure Info" screen is displayed. Graph Data Monitoring Graph Data Setting Exiting Submenus: If escape button (ESC, 4 on Figure 118) is pressed for more than 1 second, this information screen will be returned to previous screen.
Page 761 Graph Data Setting Graph Data Setting User can be graph data setting. Engine Dial Voltage The maximum limit of the graph data setting is 6. Flow Con Flow Con You can select up to 6 Fuel Level items! Hydraulic Power Shift Flow Control P/V FG018872 Figure 134...
Page 762 Refer to the failure information code for unique codes and FMI numbers. This example shows one of two fault. Past failure information Failure Log Information Memorized record of past failure is displayed (Failure Code FMI Count Occurrence Time code, fault contents). When several fault are produced, failure information can be checked using the jog switch (1, Figure 118).
Page 763 Failure Code at Machine Correct Value Measuring Display GP Display Description Remarks Point Active Passive Code CN6-4, It is a composite R = 60 ±5 Ω V000201 Gauge Panel Error CN6-5 resistance of CAN line. This value has to be measured by CN1-72, V000202 E-ECU Error...
Page 764 Correct Value Measuring Display GP Display Description Remarks Point Active Passive Code CN1-1, V000229 Forward S/V (G) V = V_volt CN2-108 CN1-1, V000230 Reverse S/V (H) V = V_volt CN2-107 CN1-1, V000231 2 Pump Select S/V (I) V = V_volt CN1-8 CN1-1, V000232 Bypass Cut Off S/V (J)
Page 765 Correct Value Measuring Display GP Display Description Remarks Point Active Passive Code CN4-6, V000252 Att (Option) Press. Sensor V = 1 V CN4-12 R = 2.45 ±0.25 Ω (25°C CN1-15, V000253 Oil Temp. Sensor (77°F)) CN1-33 R = 320 ±32 Ω (80°C (176°F)) CN1-20, V000254 Accelerator Pedal Sensor...
Page 766 Failure Code at Engine Correct Value Measuring Display GP Display Description Remarks Point Active Passive Code Position angle: Intake throttle opening degree: 0° = 4.5 V ± 1% unknown. Position angle: E000051 Throttle Valve Position Sensor 2.15, 2.40 * Default value = 0 % 90°...
Page 767 Correct Value Measuring Display GP Display Description Remarks Point Active Passive Code 20°C: R = 2.5 kΩ ± 5% Air Intake Manifold Default value of intake air E000105 2.37, 2.90 Temperature 100°C: temperature: -10°C R = 0.186 kΩ ± 2% 25°C: R = 220.1Ω...
Page 768 Correct Value Measuring Display GP Display Description Remarks Point Active Passive Code Time Out Error of CAN E001482 CAN signal Torque limit = 1 Only loader Receive Frame TCU E001639 Auto Fan Clutch Speed 1.65, 1.64 No torque limit 25°C: * Inhibit the HC dosing R = 220.1Ω...
Page 769 Correct Value Measuring Display GP Display Description Remarks Point Active Passive Code E520203 Monitoring of PRV 2.36, 2.60 Torque limit level = 2 Time Out Error of CAN E520206 CAN signal No Torque limit Module A Engine Temperature Sensor E520336 No Torque limit Plausibility Hydraulic Oil Temperature...
Page 770 Correct Value Measuring Display GP Display Description Remarks Point Active Passive Code Detection of Failed Engine Internal E520625 No torque limit Start fault Refer to E520626 Injection Bank injector No torque limit connector R = 15.95 Ω ± 5% (at MU Hydrocarbon Dosing E520628 1.22, 1.24...
Page 771 Correct Value Measuring Display GP Display Description Remarks Point Active Passive Code Monitoring for Maximum Ash Internal E520651 No torque limit Mass in DPF fault Monitoring of the Engine E520648 Torque limit level = 2 Protection Monitoring of Incomplete E520649 No torque limit Regeneration E520650 Regeneration Locked...
Page 772 Information of Machine Operation Accumulated operation hour of each mode and status is displayed. Operating Hour Information Entering Submenus: When a cursor is located in Service Menu "Operating Hrs" of special menu screen (Figure 139) press Monitoring. jog switch (1 on Figure 118) and "Operating Hrs" screen Graph will be displayed (Figure 140).
Page 773 Information contents of operation hour Item Information Contents Detection Method Power Plus Mode Operation hours used Power Plus Power Plus Mode status (Instrument Mode are displayed. panel) and Alternator signal (CN1-2) is "HI" Power Mode Operation hours used Power Mode Power Mode status (Instrument panel) are displayed.
Page 774 Example of Machine Operation Info Screen Operationg Hour Operationg Hour Operationg Hour FG018879 Figure 141 Electrical System SP002337 Page 86...
Page 775 Vehicle Configuration Vehicle Configuration Entering Submenus: When a cursor is located in Service Menu "Vehicle Configuration" of special menu screen Monitoring. (Figure 142) press jog switch (1 on Figure 118) and Graph "Vehicle Configuration" screen will be displayed Failure Information (Figure 143).
Page 776 Option Setting • Attachment Option Vehicle Configuration When a cursor is located in check box of breaker or Option Setting two-way, press jog switch (1 on Figure 118) and then, Program Update the check box light turns "ON." Vehicle Serial Number •...
Page 777 Vehicle Serial Number Entering Submenus: When a cursor is located in "Vehicle Vehicle Configuration Serial Number" of special menu screen (Figure 149) press Option Setting jog switch (1 on Figure 118) and "Vehicle Serial Number Program Update Screen" will be displayed (Figure 150). Vehicle Serial Number Vehicle serial number can be input by turning the jog Vehicle Information Delete...
Page 778 Version Information Entering Submenus: When a cursor is located in "Version Vehicle Configuration Information" of special menu screen (Figure 153) press jog Option Setting switch (1 on Figure 118) and "Version Information Screen" Program Update will be displayed (Figure 154). Vehicle Serial Number Vehicle Information Delete Vehicle Information...
Page 779 SP002337 Electrical System Page 91...
Page 780: Electronic Hydraulic Control System (E-Epos)
ELECTRONIC HYDRAULIC CONTROL SYSTEM (e-EPOS) Control System Schematic E/G speed order FG018898 Figure 155 Electrical System SP002337 Page 92...
Page 781 Reference Reference Description Description Number Number Instrument Panel Solenoid Valve (Boost) e-EPOS Controller Solenoid Valve (High-speed) Engine Controller (ECU) Solenoid Valve (Breaker) Main Pump Travel Motor Aux Pump Main Relief Valve Control Valve Engine Control Dial Pressure Switch Jog Switch Control Panel Pump Pressure Sensor Auto Travel Selector Switch Electromagnetic Proportional...
Page 782: Power Plus Mode Control
POWER PLUS MODE CONTROL FG018899 Figure 156 Reference Reference Description Description Number Number Instrument Panel (Power Mode Electromagnetic Proportional Selector Switch) Pressure Reducing Valve (Mode Control) e-EPOS Controller Engine Control Dial Engine Controller (ECU) Aux Mode Switch Main Pump Aux Mode Resistor Aux Pump Jog Switch Control Panel Control Valve...
Page 783 The Jog Switch Control Panel permits the selection of the appropriate engine power depending on the working condition. One of the four. Power Plus Mode, Power Mode, Standard Mode or Economy Mode setting can be selected. When the engine starter switch is turned "ON," the power mode is automatically defaulted to standard mode.
Page 784: Operation
Operation Power Plus Mode This mode should be selected for high-speed work. In this mode the engine output is most efficiently utilized because of the discharged oil volume being controlled based on the equivalent horsepower curve at various loaded pressures. The e-EPOS controller compares the target engine speed with the actual engine speed and controls the signal to the EPPR (Electromagnetic Proportional Pressure Reducing)
Page 785 Power Mode, Standard Mode, Economy Mode Power Mode, Standard Mode or Economy Mode is selected on the work type. When the standard/economy mode is selected it will reduce noise and fuel consumption in comparison with Power Plus Mode. The EPOS controller compares the target engine speed with the actual engine speed and controls the signal to the EPPR valve which in turn varies the pump output quantity and it is the same...
Page 786: Power Mode Control - Circuit Diagram
POWER MODE CONTROL - CIRCUIT DIAGRAM 6-12 1-77 6-13 1-78 CAN A 1-59 1-61 2-119 1-62 1-81 2-114 1-34 HIGH 1-46 1-16 1-47 1-13 (+5V) 1-10 1-52 1-05 1-75 1-28 1-03 1-26 1-01 1-25 1-49 1-73 1-11 1-74 1-69 AMP 040 36P 24 23 22 14 13 12 11 10...
Page 787 Reference Reference Description Description Number Number Instrument Panel Battery Engine Controller Battery Relay e-EPOS Controller Fuse EPPR Valve (Electromagnetic Fusible Link Proportional Pressure Reducing) Starter Switch Engine Control Dial Jog Switch Control Panel Aux Mode Switch Engine Emergency Stop Switch Aux Mode Resistor Circuit Breaker Electrical System...
Page 788: Engine Control System
ENGINE CONTROL SYSTEM (Drive Signal) (Command Signal) FG000584 Figure 162 Reference Reference Description Description Number Number Engine Controller Engine Control Dial e-EPOS Controller When the engine control dial is moved the output voltage changes according to the dial position. The e-EPOS controller converts this output voltage of dial to digital signal and sends it to the engine controller by CAN line.
Page 789: Engine Control Dial
ENGINE CONTROL DIAL 1st Step 7th Step 13th Step Mechanical Mechanical Stop Stop 4.0V 2.5V 1.0V Step ..7th ..12th 13th Stop Stop FG018941 Figure 163 Reference Reference Description Description Number Number Knob Hall Effect Sensor The engine control dial has a built in potentiometer. When the control knob is moved the output voltage (through "2 and 3"...
Page 790: Engine Control Circuit Diagram
ENGINE CONTROL CIRCUIT DIAGRAM 6-12 1-77 (BREAKER) 6-13 1-76 1-78 CAN A (RS1) 1-59 1-61 1-62 1-81 1-34 HIGH 1-46 1-16 1-47 1-13 (+5V) 1-10 1-52 1-05 1-75 1-28 1-03 1-26 1-01 1-25 1-49 1-73 1-69 AMP 040 36P 24 23 22 14 13 12 11 10 28 27 26 25...
Page 791 Reference Reference Description Description Number Number Instrument Panel Fusible Link Engine Controller Starter Switch e-EPOS Controller Jog Switch Control Panel EPPR Valve (Electromagnetic Engine Emergency Stop Switch Proportional Pressure Reducing) Circuit Breaker Engine Control Dial Solenoid Valve (Pressure Up) Battery Power Boost Switch Battery Relay Fuse...
Page 792: Automatic Deceleration Control (Auto Idle Control)
AUTOMATIC DECELERATION CONTROL (AUTO IDLE CONTROL) FG018916 Figure 165 Reference Reference Description Description Number Number Jog Switch Control Panel Engine Controller (Auto Idle Switch) Engine Control Dial e-EPOS Controller Pressure Sensor Electrical System SP002337 Page 104...
Page 793 If the machine is idling without the controls being operated or is waiting for a dump truck the engine speed is automatically lowered. Once the controls are operated and work is being started the machine will be restored to the previous settings. As a result, noise and fuel consumption will be reduced.
Page 794: Engine Overheat Protection System
ENGINE OVERHEAT PROTECTION SYSTEM (Pump control signal) (E/G overheating signal) (E/G overheating signal) FG018917 Figure 166 Reference Reference Description Description Number Number Instrument Panel Control Valve e-EPOS Controller EPPR Valve (Electromagnetic Proportional Pressure Reducing Engine Controller Valve) Main Pump Warning Buzzer Aux Pump Electrical System SP002337...
Page 795 When the engine coolant temperature increases to over 107°C (225°F), the engine controller detects it from the sensor mounted in the coolant line and will send a signal to the e-EPOS controller. The e-EPOS controller sends a overheat signal to the instrument panel turning "ON"...
Page 796: Power Boost Mode
POWER BOOST MODE Operation FG018918 Figure 167 Reference Reference Description Description Number Number Instrument Panel Solenoid Valve (Boost) e-EPOS Controller Main Relief Valve Engine Controller Jog Switch Control Panel Main Pump Power Boost Switch (Top of Right Work Lever) Aux Pump Control Valve Electrical System SP002337...
Page 797 The Power Boost function is used to temporarily increase the main relief pressure to enhance excavation ability. When the Work Mode is set to "BOOST" by the jog switch control panel and the power boost button on the right-hand work lever (joystick) is pressed during work, the e-EPOS controller will activate the power boost solenoid valve and increase the relief valve pressure from 350 to 370 kg/cm...
Page 798: Power Boost Control - Circuit Diagram
Power Boost Control - Circuit Diagram 6-12 1-77 (BREAKER) 6-13 1-76 1-78 CAN A (RS1) 1-59 1-61 1-62 1-81 1-34 HIGH 1-46 1-16 1-47 1-13 (+5V) 1-10 1-52 1-05 1-75 1-28 1-03 1-26 1-01 1-25 1-49 1-73 1-69 AMP 040 36P 24 23 22 14 13 12 11 10...
Page 799 Reference Reference Description Description Number Number Instrument Panel Starter Switch Engine Controller Jog Switch Control Panel e-EPOS Controller Circuit Breaker Engine Control Dial Solenoid Valve (Pressure Up) Battery Power Boost Switch (Top of Right Work Lever) Battery Relay Fuse Fusible Link Electrical System SP002337 Page 111...
Page 800: Automatic Travel Speed Control
AUTOMATIC TRAVEL SPEED CONTROL FG016914 Figure 169 Reference Reference Description Description Number Number e-EPOS Controller Pump Pressure Sensor Engine Controller Solenoid Valve (High-speed) Main Pump Travel Motor Aux Pump Engine Control Dial Control Valve Selector Switch For Automatic Travel Pressure Switch (Py Port) Electrical System SP002337 Page 112...
Page 801 If the automatic travel speed control switch is set to the "OFF" position, the travel motor will run in the I-speed (low speed) range. If the selector switch is set to the "I" position, the travel motor will run in the II-speed (high-speed) range. If the selector switch is set to the "II"...
Page 802: Automatic Travel Speed Control - Circuit Diagram
Automatic Travel Speed Control - Circuit Diagram 1-19 1-37 (C3) 1-18 1-36 1-75 1-56 1-13 +(5V) 1-16 1-34 HIGH AMP 040 36P 24 23 22 14 13 12 11 10 28 27 26 25 4 3 2 1 4 3 2 1 20 19 81 80 79 78 76 75 74 73 72...
Page 803: Self-Diagnostic Function
SELF-DIAGNOSTIC FUNCTION e-EPOS Controller The system operation status and malfunction codes can be checked through the display on top of the e-EPOS controller box the rear cover behind the operator's seat. FG000588 Figure 171 Reference Reference Description Description Number Number Upper Digit Power Monitor (Stays "ON"...
Page 804 Normal Operation Display Readout Display System Mode Condition Higher Digit Lower Digit Normal Operation P+, P Power Mode HAOH340L HAOH340L FG018940 Normal Operation Power Mode Standard Mode FG018940 FG018938 Normal Operation Economy Mode HAOH350L FG018940 Normal Operation Digging Digging Mode HAOH370L FG018940 Work Mode...
Page 805: Air Conditioner System
AIR CONDITIONER SYSTEM Outline FG019033 Figure 172 Solid-type heater and air conditioner are installed in the cover behind the operator's seat. Temperature of the operator's cabin is adjusted automatically to the temperature set by operator. (Please refer to the Operation and Maintenance Manual for detailed full automatic control.
Page 806: Internal And External Filters
Outlets by vent modes Modes Outlets Internal and External Filters Internal and external air purification filters are installed for the operator's room. Filters should be cleaned every 500 hours. machine operates excessively contaminated environment, filters should be cleaned more frequently and if necessary, replaced with new ones.
Page 807 Turn marked knobs at the rear side of the cabin to open the cover. Remove filter attached to the cover and clean the contaminated filter using compressed air. Close the cover, replace the knobs, and secure the cover to the support with butterfly bolts. FG016044 Figure 175 SP002337...
Page 808: Air-Conditioning System Layout
Air-Conditioning System Layout FG016941 Figure 176 Reference Reference Description Description Number Number Air Conditioner/heater Unit Liquid Hose (1) Condenser Liquid Hose (2) Compressor Ambient Temperature Sensor Receiver Dryer Sun Sensor Discharge Hose Control Panel Suction Hose Electrical System SP002337 Page 120...
Page 809: Air Conditioner/Heater Circuit Diagram
Air Conditioner/heater Circuit Diagram 0.5RW FUSIBLE LINK LAMP SWITCH STARTER SWITCH BATTERY RELAY AIRCON UNIT BATT. A/C CONTROL PANEL 1.25LR CN11-2 LED 1~12 130C CN9-6 0.85LR CN10-8 CN9-11 0.5WR CN10-18 CN9-5 1.25LR 0.85BW 0.85LR RECEIVER DRIER BLOWER RELAY RELAY COMPRESSOR 168B CN8-10 CN10-16...
Page 810: Air Conditioner/Heater Unit
Air Conditioner/heater Unit Airflow Diagram External Air Inlet Internal Air Inlet External Air VENT COOL DOOR -INTAKE DOOR -MIX Internal Air WARM Evaporator Heater Core FOOT FG016942 Figure 178 Electrical System SP002337 Page 122...
Page 811 Door Open by Vent Modes Mode Door Vent Bi-level Foot Def/foot Vent Foot Main Components Internal Air Sensor Blower Motor Actuator - Internal/external Air Exchanger Internal Air Filter FG016943 Figure 179 SP002337 Electrical System Page 123...
Page 812 Actuator - Airflow Direction Control Change of discharged airflow according to selected airflow direction mode Change of airflow direction: Direction changes in the order of VENT→ BI-LEVEL → FOOT → FOOT/DEF → VENT. Actuator - Temperature Control Change of discharged air temperature by controlling the position of temperature control door.
Page 813 Actuator - Internal/external Air Exchange CN10-20 CN10-2 FG001055 Figure 181 Mode Output Terminal Output Moving of exchange door Intake P1 (+), P2 (-) by selecting intake. Moving of exchange door Recirculate P1 (-), P2 (+) by selecting recirculate. Airflow Control Module Airflow is controlled through the control of voltage between GATE and SOURCE.
Page 814 Relay - Blower: Power is supplied to the blower motor when the system is turned "ON." 87 85(-) Specifications Rated voltage Rated current 86(+) FG001057 FG001057 Figure 183 Relay - A/C: Power is supplied to the magnetic clutch of the compressor.
Page 815: Ambient Air Temperature Sensor
Coolant Temperature Gauge Sensor: senses temperature of coolant water in the heater core. Temperature (°C) Resistance (KΩ) 55.8 ± 1.7 32.9 ± 0.9 15.76 ± 0.5 10.0 ± 0.3 6.5 ± 0.2 Figure 186 Internal Air Temperature Sensor: Built in the internal air filter, it senses the internal temperature.
Page 816: Sun Sensor
Sun Sensor Built beside the socket of spare power, it senses the quantity of the sun radiation to regulate discharge temperature and airflow as set by operator. 83.7 76.2 67.7 58.8 46.6 36.0 21.4 1.0 2.0 3.0 4.0 5.0 6.0 7.0 LUX(x10,000) FG001062 Figure 189...
Page 817 Terminal Terms Term No. Terms Term No. Terms Temperature control Coolant temperature (warm) gauge sensor Sensor ground Duct sensor Temperature control Sun sensor Power (5V) Ambient air temperature Mix feedback sensor Internal air temperature Power (KEY "ON") sensor Backup A/C output (LOW) Ground D.P.S CHECK Illumination...
Page 818 Control Logic Categories Inputs System Operation AUTO Set temperature Automatically adjust room temperature as set and then next items. Internal air temperature sensor Temperature, airflow direction, Recirculate/Intake, Airflow, Compressor Ambient air temperature sensor Auto mode is released when manually setting any switch except, Temperature Control switch in Auto mode.
Page 819 Categories Inputs System Operation Starting Auto mode Prevention of discharge of hot air before discharge Control of temperature drops enough in hot summer weather Duct sensor Cooling Start conditions (AND condition) A/C on (AUTO or manual) Temperature sensed by the duct sensor is above 30°C Airflow: Auto mode One time control in the cycle of engine OFF →...
Page 820 Categories Inputs System Operation Start condition (AND condition) When airflow direction mode is one of the following modes in the Auto or manual control mode - BI-LEVEL, FOOT or FOOT/DEF The coolant temperature gauge sensor is stable and the coolant temperature gauge < 73°C Airflow: Auto mode Set temperature >...
Page 821 Categories Inputs System Operation Starting Coolant temperature Entry condition (AND condition) control of gauge sensor Auto Mode heating (2) Ambient air temperature Ambient air temperature < 5°C and difference sensor between ambient and internal air temperature ≤ 5°C Internal air temperature Failure of coolant temperature gauge sensor sensor Only one time of engine OFF →...
Page 822 Self-diagnossi How to start self-diagnosis Starter Switch ON Set temp to 25 C Set temp to 77 F Press the SEL switch more than 3 times in 5 secs while pressing the A/C switch Auto diagnosis starts after every graphic in LCD displays twice every 0.5 sec.
Page 823 Error codes Code Description Normal Internal air temperature sensor short Internal air temperature sensor open Ambient air temperature sensor short Ambient air temperature sensor open Duct sensor short Duct sensor open Sun sensor short Sun sensor open Coolant temperature gauge sensor short Coolant temperature gauge sensor open D.P.S open Position error of airflow direction actuator...
Page 824: Compressor
Compressor Categories Specifications Relief Valve Output 155.3 cc/rev Oil Level 120 cc (ND-OIL8) Refrigerant R134a Rated Voltage Open: 35 - 42.2 kg/cm Relief Valve Close: 28.1 kg/cm Compressor sucks in refrigerant which evaporates completely in FG001365 the evaporator and discharges it to the condenser. Figure 193 Refrigerant undergoes repeated status change in the order of liquid, gas, and liquid in the freezing cycle, and the compressor...
Page 825: Troubleshooting
TROUBLESHOOTING Refrigerant Pressure Check Open all doors and windows. Install manifold gauge set. Start engine and maintain engine speed at 1,800 - 2,000 rpm. Figure 196 Check high / low-pressure of refrigerant. High-pressure: 8.0 - 10.0 kg/cm (114 - 142 psi) Low-pressure: Approximately 1.0 kg/cm (14 psi) Possible Cause: Low Refrigerant Level...
Page 826 High-pressure: Over 6 kg/cm (85 psi) Low-pressure: Approximately 760 mmHg (Negative Pressure) Possible Cause: Refrigerant does not circulate Step Inspection Item Remedy Connect manifold gauge and start engine. Turn on air conditioner. Moisture in system, replace receiver dryer. Set blower switch to HIGH position. Turn air conditioner OFF and wait 10 minutes.
Page 827: Weight Of R134A Gas Used In Machines
Weight of Gas DX140LC-3 800 ± 20 grams (28 ± 0.7 oz) DX180LC-3 800 ± 20 grams (28 ± 0.7 oz) DX225LC-3 800 ± 20 grams (28 ± 0.7 oz) DX255LC-3 800 ± 20 grams (28 ± 0.7 oz) DX300LC-3 800 ±...
Page 828: Refrigerant System Repairs
REFRIGERANT SYSTEM REPAIRS WARNING AVOID DEATH OR SERIOUS INJURY Always wear safety goggles and gloves when handling refrigerant. If refrigerant comes in contact with the skin or eyes, immediately flush with clean, running water and consult a physician. Select a clean and well ventilated area to work. The refrigerant container is under high-pressure and should be stored below 40°C (104°F).
Page 829: Repair And Replacement Procedure
The new refrigerant has improved cooling characteristics than the old type and care should be used not to overcharge the system. Do not over tighten connections when working on refrigerant system. The new refrigerant system standards require new tools, equipment and parts. DO NOT attempt to use equipment use in servicing the old refrigerant system.
Page 830 INSTALL REPAIR TOOL RECOVER REFRIGERANT REPAIR / REPLACE DEFECTIVE PARTS VACUUM SYSTEM (OVER 5 MINUTES) CHECK SYSTEM FOR AIR LEAKAGE REPAIR VACUUM SYSTEM (OVER 20 MINUTES) CHARGE SYSTEM (APPROXIMATELY 100 g) CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHARGE SYSTEM TO PROPER LEVEL (Standard Capacity less Initial Charge) CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHECK FOR PROPER REFRIGERANT LEVEL...
Page 831: Refrigerant Recovery
Refrigerant Recovery Reference Description Number To Compressor Low-pressure Side High-pressure Side From Receiver Refrigerant Recovery Tank Attach the manifold gauges and the refrigerant recovery unit to the refrigerant lines as shown. HDA6067L Figure 199 Be careful not to switch the connections for the NOTE: low and high-pressure valves.
Page 832 Check system for vacuum leak. Allow system to sit for 10 minutes and check whether the system is holding the pressure. If the pressure has dropped, it must be repaired before proceeding to the next step. Vacuuming Procedure If the system is holding the pressure and it has not changed for 10 minutes, vacuum out the system for an additional 20 minutes.
Page 833: Leakage Check
Leakage Check Perform leakage check after completing NOTE: vacuuming process. After attaching the manifold gauge, open the high side valve. Charge system until low side gauge dial indicates a pressure of 1 kg/cm (14 psi) and close the high side valve. Using a refrigerant leak detector or soapy water check each joint for leakage.
Page 834 If refrigerant does not flow freely into system, try starting engine first before operating air conditioner. • Temperature control switch setting: Maximum Cooling Blower Speed Setting: Hi (3 step) Engine Speed: 1,300 - 1,500 rpm WARNING AVOID DEATH OR SERIOUS INJURY When charging refrigerant system with the engine running: •...
Page 835: Inspecting System For Leakage
Inspecting System For Leakage After completing charging procedures, clean all joints and connections with a clean dry cloth. Using a refrigerant leak detecting device or soapy water, inspect system for leaks starting from the high-pressure side. When the refrigerant circulation has been stopped NOTE: the high-pressure will start to decrease and the low-pressure will start to increase until they are...
Page 836: Wiper System
WIPER SYSTEM Wiper Circuit (Continuous mode) (Intermittent 1 mode) (Intermittent 2 mode) (Washer mode) AMP MIC 13P CN12 CN13 KET 8P AMP MIC 13P (CN12) (Wiper Motor) (CN13) FG000589 Figure 206 Reference Reference Description Description Number Number Battery Wiper Controller Battery Relay Wiper Switch Panel Fusible Link...
Page 837: Wiper Operation
Wiper operation Continuous operation - Operation of wiper motor Pressing the successive operation switch on the wiper switch panel (7) changes the voltage of the "5" terminal of the wiper controller (6) from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and current flows by the "3"...
Page 838 Intermittent operation - Intermittent 1st (3-second) Pressing once the Intermittent switch in the switch panel (7) changes voltage of the "8" terminal in the wiper controller (6) from HIGH (about 5.5 ±0.5 V) to LOW (0+0.5 V) and current flows through the "3" terminal in the wiper controller (6) → the "2" and "4"...
Page 839 SP002337 Electrical System Page 151...
Page 840: Lighting System
LIGHTING SYSTEM Lighting System Circuit Diagram 6-10 6-11 6-12 1-74 1-77 1-78 1-59 FG018942 Figure 207 Electrical System SP002337 Page 152...
Page 841: Kind Of Light
Reference Reference Description Description Number Number Battery Front Cabin Light / Rear Work Light Relay Battery Relay Instrument Panel Fuse Box e-EPOS Controller Light Switch Headlight (2 ea.) Cabin Light Switch Work Light (2 ea.) Headlight Relay (Work Light Indicate Light) Front Cabin Light (4 ea.) Work Light Relay Rear Cabin Light (2 ea.)
Page 842: Overload Warning Device
OVERLOAD WARNING DEVICE Overload Warning Device Circuit Diagram 1-45 1-20 1-38 FG018950 Figure 208 Reference Reference Description Description Number Number Battery e-EPOS Controller Battery Relay OWD Selector Switch Fuse Box Pressure Sensor Electrical System SP002337 Page 154...
Page 843: Audio Controller
AUDIO CONTROLLER Audio Controller Circuit Diagram Stereo ANT. Vcc(+5V) MI C OM 0.5WR 10A 15A (RH) (LH) 9 10 13 14 15 1 2 3 4 11 12 15 16 18 19 (Audio Control Panel) (Stereo) (Handsfree Unit) FG018951 Figure 209 Reference Reference Description...
Page 844 Electrical System SP002337 Page 156...
Page 845 SP002508 ELECTRICAL SCHEMATICSP002508 Electrical Schematic Edition 1 Electrical Schematic SP002508 Page 1...
Page 846 MEMO Electrical Schematic SP002508 Page 2...
Page 847 Table of Contents Electrical Schematic Safety Instructions ..........5 Applicable Models ..........5 DX140LC-3/DX180LC-3/DX225LC-3/ DX255LC-3 ............7 Electrical Schematic SP002508 Page 3...
Page 848 MEMO Electrical Schematic SP002508 Page 4...
Page 849 MODEL SERIAL NUMBER RANGE DX140LC-3 1001 and Up, 50001 and Up DX180LC-3 1001 and Up, 50001 and Up DX225LC-3 1001 and Up, 50001 and Up DX255LC-3 1001 and Up, 50001 and Up Electrical Schematic SP002508 Page 5...
Page 850 Electrical Schematic SP002508 Page 6...
Page 851 DX140LC-3/DX180LC-3/DX225LC-3/DX255LC-3 AIR COMPRESSOR (OPT) PURGE V/V AIR COMP. CONTROLLER (XXXX-XXXXXX ) Relay Unit AIR COMP. MOTOR 2.5WR 2.5B 298B 298A 2.5R PRESSURE S/W 0.85YW 295B 297A 297B 295A 0.85Y TERMINAL NO STOP 296B 0.5R 2.5B 0.85B CAR STEREO GPS ANT.
Page 853 Attachments...
Page 855 SP002505 BOOM AND ARM SP002505 Boom and Arm Edition 1 Boom and Arm SP002505 Page 1...
Page 856 MEMO Boom and Arm SP002505 Page 2...
Page 857 Table of Contents Boom and Arm Safety Instructions ..........5 Applicable Models ..........5 Front Attachment Pin Specifications..... 6 DX225LC-3..............7 Front Attachment - Removal and Installation..8 Arm Removal Procedure ..........8 Boom Removal Procedure ..........10 Installation ............11 Arm Installation Procedure ..........
Page 858 MEMO Boom and Arm SP002505 Page 4...
Page 859: Boom And Arm
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX225LC-3 1001 and Up, 50001 and Up Boom and Arm SP002505 Page 5...
Page 860: Front Attachment Pin Specifications
NOTE: Some mounting pins must be drilled and tapped for lubrication fittings and piping, or may have other required specifications. Consult DOOSAN After Sales Service for information on wear tolerances and replacement limits for mounting pins. FG018705...
Page 861 DX225LC-3 Criteria Mark Measuring Part Tolerance Remedy Standard Standard Clearance Size Clearance Limit Hole 90 mm -0.10 +0.18 Boom Foot 0.13 - 0.33 (3.543") -0.15 +0.03 80 mm -0.06 +0.18 Boom Cylinder Head 0.09 - 0.29 (3.150") -0.11 +0.03 80 mm -0.06...
Page 862: Front Attachment - Removal And Installation
AVOID DEATH OR SERIOUS INJURY This procedure is intended for routine removal or replacement of the attachment by ONLY authorized and trained service persons. Call you local Doosan distributor for assistance. DO NOT allow other personnel to go under the boom, arm or attachment sections, if not properly supported.
Page 863 Park the excavator away from obstructions and all traffic on clear, flat, level ground. Extend the arm cylinder and crowd the arm into the boom. Partially retract the boom cylinder so the boom is stretched out in front of the excavator, as low to the ground as possible, with the arm crowded under the boom.
Page 864: Boom Removal Procedure
IMPORTANT To make sure that polished surfaces of cylinder rod ends damaged during disassembly removal procedures, wrap exposed rod surfaces (especially those of boom cylinders) with a protective covering material. Immediately following disassembly and removal, cylinder rods should always be fully retracted. This eases handling problems and avoids possible damage.
Page 865: Installation
Lift Ratings, Working Range Diagrams and Weights of Materials sections in the Operation and Maintenance Manual. Consult your dealer or DOOSAN After Sales Service for more information if you have any questions. Begin with the arm securely supported on blocking in front of the excavator.
Page 866: Start-Up Procedures
START-UP PROCEDURES Once the boom has been serviced, it should be lubricated as outlined in the initial start-up procedures of the operation manual. Refer to the appropriate operation and maintenance manual for unit. Boom and Arm SP002505 Page 12...
Page 867 SP002506 BUCKET SP002506 Bucket Edition 1 Bucket SP002506 Page 1...
Page 868 MEMO Bucket SP002506 Page 2...
Page 869 Table of Contents Bucket Safety Instructions ..........5 Applicable Models ..........5 Bucket Tooth Inspection and Replacement ..6 Bucket O-ring Replacement ......... 7 Attachments............9 Bucket Replacement and Reversal ......... 9 Replacement ..............10 Reversal ................ 11 Bucket SP002506 Page 3...
Page 870 MEMO Bucket SP002506 Page 4...
Page 871 The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX140LC-3 1001 and Up, 50001 and Up DX180LC-3 1001 and Up, 50001 and Up DX225LC-3 1001 and Up, 50001 and Up DX255LC-3 1001 and Up, 50001 and Up Bucket SP002506 Page 5...
Page 872: Bucket Tooth Inspection And Replacement
BUCKET TOOTH INSPECTION AND REPLACEMENT There are several different types of attachment methods for replaceable bucket teeth. Some of the most common types are shown in the following drawings. Bucket teeth are usually replaced in sets but it may sometimes be necessary to replace individual teeth.
Page 873: Bucket O-Ring Replacement
BUCKET O-RING REPLACEMENT WARNING AVOID DEATH OR SERIOUS INJURY Prevent injury from flying metal objects. Always wear safety helmet, protective gloves and eye protection when changing pins. Inspect the bucket O-rings on a routine basis. If worn or damaged, replacement is necessary. FG019862 Figure 4 Roll the old O-ring (1, Figure 5) onto the boss (2) around...
Page 874 Roll the new O-ring (1, Figure 7) into the O-ring groove. FG019075 Figure 7 Bucket SP002506 Page 8...
Page 875: Attachments
ATTACHMENTS Bucket Replacement and Reversal WARNING AVOID DEATH OR SERIOUS INJURY When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equipment. When the bucket is removed, place it in a stable condition.
Page 876: Replacement
Replacement Place the bucket in contact with a flat surface. IMPORTANT When removing the pins, place the bucket so it is in light contact with the ground. If the bucket is lowered strongly to the ground, the FG020108 resistance will be increased and it will be difficult to Figure 8 remove pins.
Page 877: Reversal
Reversal Place the bucket in contact with a flat surface. IMPORTANT When removing the pins, place the bucket so it is in light contact with the ground. If the bucket is lowered strongly to the ground, the resistance will be increased and it will be difficult to remove pins.
Page 878 Bucket SP002506 Page 12...

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