Doosan 50001 Manuals

Manuals and User Guides for Doosan 50001. We have 1 Doosan 50001 manual available for free PDF download: Shop Manual

Doosan 50001 Shop Manual

Doosan 50001 Shop Manual (898 pages)

Brand: Doosan | Category: Excavators | Size: 56.99 MB

Table of Contents

Table of Contents

11
- Safety Precautions
  13
- Applicable Models
  13
- To the Operator of a Excavator
  14
- General Safety Essentials
  18
- Location of Safety Labels
  19
- Summary of Safety Precautions for Lifting in Digging Mode
  19
- Unauthorized Modifications
  21
- General Hazard Information
  21
- Before Starting Engine
  30
- Machine Operation
  34
- Maintenance
  41
- Battery
  52
- Towing
  54
- Lifting with Sling
  55
- Shipping and Transportation
  55
Table of Contents

61
Table of Contents

89
Table of Contents

109
- Applicable Models
  111
- Safety Precautions
  111
- Standard Torques
  111
- Torque Values for Standard Metric Fasteners
  112
- Torque Values for Standard U.S. Fasteners
  113
- Type 8 Phosphate Coated Hardware
  115
- Torque Values for Hose Clamps
  116
- Torque Values for Split Flanges
  116
- Torque Multiplication
  117
- Torque Wrench Extension Tools
  117
- Other Uses for Torque Wrench Extension Tools
  118
- Tightening Torque Specifications (Metric)
  119
Table of Contents

127
- Applicable Models
  129
- Safety Precautions
  129
- Removal
  130
- Installation
  134
Table of Contents

139
- Applicable Models
  141
- Safety Precautions
  141
- Swing Bearing
  141
- Measuring Bearing Lateral Play
  142
- Measuring Swing Bearing Axial Play
  142
- Operating Recommendation
  142
- Swing Bearing Maintenance
  142
- Rebuilding Swing Bearing
  143
- Swing Bearing Basic Operation
  143
Table of Contents

149
- Applicable Models
  151
- Safety Precautions
  151
- Track Assembly
  151
- Specification and Construction
  152
- Tracks
  152
- Track Tension
  153
- Cleaning and Inspection (Wear Limits and Tolerances)
  155
- Rubber Track Features
  155
- Steel Tracks
  157
- Track Frame Spring
  158
- Idler
  159
- Steel Tracks
  159
- Spring Specifications
  160
- Lower Roller
  161
- Steel Track
  161
- Rubber Track
  162
- Upper Roller
  163
- Sprocket
  164
- Track Removal
  165
- Track Removal and Installation
  165
- Track Installation
  166
- Replacement of Rubber Tracks with Steel Tracks
  167
- Replacement of Steel Tracks with Rubber Tracks
  168
- Idler
  169
- Disassembly
  170
- Reassembly
  170
- Parts List
  171
- Track Tension Adjusting Cylinder
  171
- Disassembly
  172
- Reassembly
  172
Table of Contents

183
- Applicable Models
  187
- Safety Precautions
  187
- Safety
  188
- Safety Precautions
  188
- Component Identification
  211
- General Service Information
  211
- Location of Labels
  212
- Function of Major Engine Components
  213
- Main Electronic Control Components and Features
  214
- Function of Cooling System Components
  216
- Diesel Fuel
  217
- Engine Oil
  221
- Engine Coolant
  223
- Principal Engine Specifications
  226
- Engine Service Standards
  227
- Tightening Torques for Standard Bolts and Nuts
  228
- Before You Begin Servicing
  230
- Periodic Maintenance
  230
- Introduction
  244
- Periodic Maintenance Schedule
  245
- Periodic Maintenance Procedures
  247
- Before You Begin Servicing
  272
- Engine
  272
- Cylinder Head Specifications
  275
- Introduction
  275
- Camshaft and Timing Gear Train Specifications
  277
- Crankshaft and Piston Specifications
  278
- Cylinder Block Specifications
  280
- Special Torque Chart
  281
- Special Service Tools
  282
- Measuring Instruments
  284
- 4-Valve Cylinder Head
  286
- Measuring and Adjusting Valve Clearance
  303
- Crankshaft and Camshaft Components
  308
- EGR System
  340
- Before You Begin Servicing
  347
- Fuel System
  347
- Introduction
  350
- Fuel System Specifications
  354
- Special Service Tools
  354
- Measuring Instruments
  355
- Fuel System Diagram
  356
- Fuel System Components
  358
- Fuel Injection Pump
  360
- Checking and Adjusting Fuel Injection Timing
  369
- Fuel Injectors
  374
- Before You Begin Servicing
  380
- Cooling System
  380
- Cooling System Diagram
  383
- Introduction
  383
- Engine Coolant Pump Components
  384
- Engine Coolant Pump
  385
- Engine Coolant System Check
  385
- Before You Begin Servicing
  390
- Lubrication System
  390
- Introduction
  392
- Oil Pump Service Information
  392
- Lubrication System Diagram
  393
- Checking Engine Oil Pressure
  394
- Trochoid Oil Pump
  394
- Before You Begin Servicing
  398
- Starter Motor
  398
- Introduction
  400
- Starter Motor Specifications
  400
- Starter Motor Troubleshooting
  401
- Starter Motor Components
  402
Table of Contents

457
- Applicable Models
  459
- Drive Coupling (Main Pump)
  459
- Safety Precautions
  459
- Drive Coupling
  460
- Installation of Drive Coupling
  461
- Installation Procedure
  461
Table of Contents

467
- Applicable Models
  469
- Safety Precautions
  469
- General Description
  470
- Specifications
  472
Table of Contents

475
- Applicable Models
  477
- Center Joint (Swivel)
  477
- Safety Precautions
  477
- Disassembly Diagram
  478
- General Description
  478
- Disassembly
  479
- Reassembly
  481
Table of Contents

487
- Applicable Models
  489
- Safety Precautions
  489
- General Description
  490
- Theory of Operation
  490
- Parts List
  492
- Piston Nut
  500
- Special Tools and Materials
  500
- Piston Jig
  501
- Steel Bushing Jig
  502
- Dust Wiper Jig
  503
- Slipper Seal Jig
  504
- Slipper Seal Straightening Jig
  505
- Disassembly
  506
- Assembly
  512
Table of Contents

517
- Applicable Models
  519
- Safety Precautions
  519
- Swing Motor
  519
- Indication of Type
  520
- Specifications
  521
- Construction
  522
- Construction and Principles of Working
  522
- Principles of Working
  524
- External Load of Shaft
  528
- Inspection
  528
- Precaution in Use
  528
- Rotation Direction
  528
- Hydraulic Fluids and Range of Temperature
  529
- Filter
  530
- Installation and Piping
  530
- Oil Filling
  531
- Precaution in Starting Operations
  531
- General Cautions
  532
- Investigation Manner of the Motor Body
  532
- Troubleshooting
  532
- Condition and Countermeasures of Troubles
  533
- Disassembling and Assembling
  535
- Necessary Tools
  535
- Tightening Torque of Bolts
  535
- Disassembly of Motor
  537
- Assembly of Motor
  542
- Disassembly of Reduction Gear
  548
- Assembly of Reduction Gear
  551
- Maintenance Standards
  555
- Part Replacement Standards for Hydraulic Motor
  555
- Part Replacement Standards for Reduction Gear
  556
- Standard for Correcting Sliding Surfaces
  557
Table of Contents

561
- Travel Motor
  563
- Applicable Models
  564
- Safety Precautions
  564
- Configuration
  565
- Features
  565
- General
  565
- Structural Diagram of the Travelling System
  566
- Structural Diagram of the Axial Piston Motor
  567
- Operating Principle
  568
- When Travelling
  568
- When Counterbalance Operates
  569
- When Brake Functions
  570
- Operating Principle of Parking Brake
  571
- Speed Limiting Function
  572
- Hydraulic Motor
  574
- Parts List
  574
- Reduction Gear
  576
- Special Tools and Materials
  578
- Standard Tools
  578
- Equipment and Materials
  579
- Measuring Devices
  579
- Manufacturing Tools
  580
- Tightening Torque
  584
- Weight Table
  584
- Counterbalance Valve
  585
- Travel Motor
  585
- Travel Motor Troubleshooting
  585
- 2-Speed Change over
  586
- Parking Brake
  586
- Relief Valve
  586
- Disassembly
  587
- General Suggestions When Working
  587
- Preparations
  587
- Disassembly Procedure
  588
- Seals
  607
- Service Preparations
  607
- Service Standards for Parts Subject to Wear
  607
- Assembly
  609
- General Suggestions When Working
  609
- Preparation
  609
- Assembly Procedure
  610
- Performance Confirmation Test
  630
- Clearance Adjustment Part Dimensions
  631
Table of Contents

635
- Applicable Models
  637
- Main Control Valve
  637
- Safety Precautions
  637
- Composition, Function and Operation
  638
- Function of Control Valve
  638
- Operation of Main Section
  639
- Disassembly
  641
- Disassembly of Accessory
  641
- Disassembly of Arm2, Bucket, Right Run, Left Run, Arm1, Dozer, Swing, Boom Swing Section
  641
- Disassembly of Boom1 Section (Figure 30)
  642
- Disassembly of Boom2/Aux Section (Figure 35)
  642
- Disassembly of Inlet Section (Figure 32)
  642
- Disassembly of Straight Travel Section (Figure 39)
  642
- Take off of Load Check Poppet Type
  643
- Disassembly of Valve Housing
  644
- Cleaning
  645
- Inspection
  645
- Assembly
  646
- Assembly of Valve Housing
  646
- Assembly of Arm2, Bucket, Right Run, Left Run, Arm1, Dozer, Swing, Boom2/Aux, Boom Swing
  647
- Assembly of Boom1 Section (Figure 30)
  647
- Assembly of Boom2/Aux Section (Figure 35)
  647
- Assembly of Inlet Section (Figure 32)
  647
- Assembly of Straight Travel (Figure 39)
  647
- Inserting of Load Check
  648
- Accessory Adherence
  649
- Main Relief Valve (P1, P2, P3)
  650
- Relief Valve
  650
- Overload Relief Valve
  652
- Pressure Adjustment of Relief Valve
  654
- Mounting
  656
- Operation
  656
- SPEC of Control Valve
  656
- Failure and Troubleshooting
  657
- Overall Control Valve
  657
- Overall Pneumatic System
  658
- Relief Valve
  658
Table of Contents

683
- Applicable Models
  685
- Main Pump
  685
- Safety Precautions
  685
- General Description
  686
- Description of Ports
  687
- Components of the Pump
  688
- Operation Principle and Function of Components
  688
- Operation Principle
  691
- Adjustment
  695
- Driving
  695
- Hydraulic Oil
  695
- Installation
  695
- Procedures for Test Operation
  696
- Maintenance and Protection
  697
- Checking Filters
  698
- Filter Replacement
  698
- Hydraulic Fluid Leakage Check
  699
- Replacement of Hydraulic Oil
  699
- Diagnosis of Troubles and Actions to be Taken
  700
- Diagnosis of Troubles with the Pump
  700
- Solenoid Valve and Relief Valve
  701
- Disassembling and Reassembling Hydraulic Pump
  702
- Necessary Tools and Jigs
  702
- Reminders for Disassembly and Assembly
  703
- Disassembling Procedure
  704
- Standard Values for Maintenance
  715
- Reassembly Procedure
  717
Remote Control Valve (Work Lever / Joystick)/Remote Control Valve (Work Lever / Joystick)

737
- Applicable Models
  739
- Remote Control Valve (Work Lever / Joystick)
  739
- Safety Precautions
  739
- Structure Diagram
  740
- Parts List
  741
- Hydraulic Pressure Circuit Diagram
  742
- Performance Specification
  742
- Disassembly and Assembly Tool
  743
- Disassembly Method
  743
- Assembly Method
  746
Table of Contents

753
- Applicable Models
  755
- Dozer Valve
  755
- Safety Precautions
  755
- Structure Diagram
  756
- Hydraulic Pressure Circuit Diagram
  757
- Performance Specification
  757
- Parts List
  758
- Disassembly
  759
- Disassembly and Assembly Tool
  759
- Assembly Method
  762
Table of Contents

769
- Applicable Models
  771
- Safety Precautions
  771
- Travel Contorl Valve
  771
- General Description
  772
- Parts List
  772
- Hydraulic Pressure Circuit Diagram
  773
- Performance Specification
  773
- Maintenance
  774
- Required Tool and Tightening Torque
  774
- Maintenance Standard
  775
- Disassembly
  776
- Assembly
  781
- General Caution
  787
- Troubleshooting
  787
- Troubleshooting and Resolution
  787
Table of Contents

791
- Applicable Models
  793
- Pedal Valve
  793
- Safety Precautions
  793
- General Description
  794
- Parts List
  794
- Specifications
  795
- Tools and Materials
  795
- Disassembly
  796
- Assembly
  798
Table of Contents

815
- Applicable Models
  817
- Electrical System
  817
- Safety Precautions
  817
- Overview
  819
- Electrical Supply System
  820
- Engine Starting
  822
- Start Operation
  822
- After Start
  824
- Engine Preheating System
  825
- Engine Stop
  827
- Charging System
  828
- Instrument Panel
  829
- Instrument System
  829
- Function Check
  830
- Gauge
  831
- Operation
  831
- Warning Lights
  832
- Circuit Diagram of Instrument Panel
  834
- Control Unit Circuit
  835
- Engine Control System
  836
- Performance Specification
  836
- Engine Control Dial
  837
- Engine Control Circuit Diagram
  838
- Automatic Deceleration Control (Auto Idle Control)
  839
- Engine Overheat Protection System
  840
- Engine Control Unit
  841
- Control Failure Detection
  842
- Flashing Patterns of Engine Check Lamp
  845
- Fuel Injection Pump
  846
- EGR Valve
  847
- Refrigerant Circulation
  848
- Air-Conditioning System Circuit Diagram
  850
- Air Flow Control
  851
- Air Flow Control Motor
  852
- Blower Motor
  852
- Coolant Flow Control Valve
  853
- Temperature Level Control and Display
  854
- Weight of R134A Gas Used in Machines
  855
- Refrigerant Safe Handling Procedures
  856
- Refrigerant System Repairs
  856
- Repair and Replacement Procedure
  857
- Refrigerant Recovery
  859
- Vacuuming Refrigerant System
  859
- Leakage Check
  861
- Refrigerant Charging
  861
- Inspecting System for Leakage
  863
- Refrigerant Pressure Check
  864
- Troubleshooting
  864
- Applicable Models
  881
- Boom and Arm
  881
- Safety Precautions
  881
- Front Attachment Pin Specifications
  882
- Arm Removal Procedure
  884
- Front Attachment - Removal and Installation
  884
- Boom Removal Procedure
  886
- Arm Installation Procedure
  887
- Boom Installation Procedure
  887
- Installation
  887
- Start-Up Procedures
  887
- Applicable Models
  893
- Safety Precautions
  893
- Bucket Tooth Replacement
  894
- Bucket O-Ring Replacement
  896
- Bucket Attachment, Removal and Reversal
  897
- Detaching the Bucket
  897
- Attaching the Bucket
  898
- Reversing the Bucket
  898

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