Doosan 5001 Manuals

Manuals and User Guides for Doosan 5001. We have 2 Doosan 5001 manuals available for free PDF download: Instructions Manual, Operation & Maintenance Manual

Doosan 5001 Instructions Manual

Doosan 5001 Instructions Manual (810 pages)

Track Excavator

Brand: Doosan | Category: Excavators | Size: 49 MB

Table of Contents

Table of Contents

11
- Track Excavator Safety
  13
- Safety Precautions
  13
- Applicable Models
  13
- To the Operator of a DOOSAN Excavator
  14
- General Safety Essentials
  17
- Location of Safety Labels
  18
- Summary of Safety Precautions for Lifting in Digging Mode
  18
- Unauthorized Modifications
  19
- General Hazard Information
  19
- Before Starting Engine
  28
- Machine Operation
  32
- Maintenance
  39
- Battery
  47
- Towing
  49
- Shipping and Transportation
  50
- Lifting with Sling
  50
Table of Contents

55
- Applicable Models
  57
- Safety Precautions
  57
- General Description
  59
- Component Locations
  60
- General Dimensions
  62
- Working Range
  64
- General Specifications
  66
- Engine Performance Curves (Per DIN 6270 Standard)
  68
- Approximate Weight of Workload Materials
  70
- Performance Tests
  72
- Excavator Performance Standards
  73
- Test Conditions
  73
- Travel Speed and Travel Motor Balance (Steering Deviation) Tests
  73
- Swing Speed and Deceleration Force Test
  75
- Cylinder Performance Tests
  77
Table of Contents

83
Table of Contents

103
- Applicable Models
  105
- Safety Precautions
  105
- Torque Values for Standard Metric Fasteners
  106
- Torque Values for Standard U.S. Fasteners
  107
- Type 8 Phosphate Coated Hardware
  109
- Torque Values for Hose Clamps
  110
- Torque Values for Split Flanges
  111
- Torque Multiplication
  112
- Torque Wrench Extension Tools
  112
- Other Uses for Torque Wrench Extension Tools
  113
- Tightening Torque Specifications (Metric)
  114
Table of Contents

121
- Applicable Models
  123
- Cabin
  123
- Safety Precautions
  123
- Removal
  124
- Installation
  128
Table of Contents

133
- Applicable Models
  135
- Safety Precautions
  135
- General
  136
- Warning for Counterweight and Front Attachment Removal6
  136
- Removal
  138
- Installation
  139
Table of Contents

143
- Applicable Models
  145
- Safety Precautions
  145
- General Description
  146
- Parts List
  146
- Specifications
  147
- Removal
  148
- Installation
  152
- Start-Up Procedures
  155
Table of Contents

159
- Applicable Models
  161
- Safety Precautions
  161
- General Description
  162
- Theory of Operation
  162
- Replacement of Rotor and Vane
  163
- Troubleshooting
  163
- Replacement of Armature
  164
- Replacement of Rear Cover
  164
Table of Contents

167
- Applicable Models
  169
- Safety Precautions
  169
- Measuring Bearing Lateral Play
  170
- Measuring Swing Bearing Axial Play
  170
- Operating Recommendation
  170
- Swing Bearing Maintenance
  170
- Disassembly
  171
- Swing Bearing Basic Operation
  171
- Assembly
  173
Table of Contents

177
- Applicable Models
  179
- Safety Precautions
  179
- General Description
  181
- Theory of Operation
  181
- Parts List
  182
- Specifications
  183
- Troubleshooting, Testing and Adjustment
  184
- Removal
  185
- Disassembly
  186
- Cleaning and Inspection (Wear Limits and Tolerances)
  195
- Assembly of Carrier Subassemblies
  196
- Reassembly
  196
- Shaft and S/R Bearing Heat-Fit
  196
- Assembly of Main Case
  202
- Assembly of Motor
  218
- Installation
  222
- Start-Up Procedures
  223
Table of Contents

229
- Applicable Models
  231
- Safety Precautions
  231
- General Description
  232
- Track Tension
  233
- Cleaning and Inspection
  235
- Track Shoe
  236
- Lower Roller
  238
- Upper Roller
  239
- Front Idler
  240
- Track Removal
  241
- Track Shoes and Links
  241
- Track Installation
  242
- Front Idler Roller
  244
- Parts List
  244
- Front Idler Roller Disassembly
  245
- Front Idler Roller Reassembly
  247
- Lower Roller
  248
- Parts List
  248
- Lower Roller Disassembly
  249
- Lower Roller Removal
  249
- Lower Roller Reassembly
  250
- Lower Roller Installation
  251
- Parts List
  252
- Upper Roller
  252
- Upper Roller Disassembly
  253
- Upper Roller Removal
  253
- Upper Roller Reassembly
  255
- Parts List
  256
- Track Spring and Track Adjusting Cylinder
  256
Table of Contents

261
- Applicable Models
  263
- Safety Precautions
  263
- Drive Coupling
  264
- Special Tools
  265
- Drive Coupling Installation
  266
- Installation Procedure
  268
Hydraulic System Troubleshooting, Testing and Adjustment/Hydraulic System Troubleshooting, Testing and Adjustment

273
- Hydraulic System Troubleshooting, Testing and Adjustment
  274
- Applicable Models
  275
- Safety Precautions
  275
- General Notes
  276
- Hydraulic System - General Notes
  276
- Boom down Circuit
  279
- Boom Operating Circuit
  279
- Boom up Circuit
  279
- Operation of Working Components
  279
- Arm Crowd Circuit
  280
- Arm Dump Circuit
  280
- Arm Operating Circuit
  280
- Bucket Crowd Circuit
  281
- Bucket Dump Circuit
  281
- Bucket Operating Circuit
  281
- Swing Operating Circuit
  281
- Left Swing Operating Circuit
  282
- Right Swing Operating Circuit
  282
- Swing Relief Valve and Makeup Valve
  282
- Travel Operating Circuit
  282
- Forward Travel Circuit
  283
- Reverse Travel Circuit
  283
- Initial Checks and Tests to Establish Operating Condition of the Excavator
  284
- Procedural Troubleshooting Baseline Recommendations
  284
- Adjustment and Testing
  286
- Pilot Pressure
  286
- Current Signal and Hydraulic Pressure Adjustments
  287
- Power Mode Valve
  287
- Checks and Adjustments
  288
- Pressure up Valve
  288
- Pump Input Power Control
  290
- Pump Regulator Adjustment
  290
- Flow Meter and Flow Meter Kit Installation and Testing
  293
- Precautions/Initial Checks
  295
- Swing System Troubleshooting
  295
- Swing Relief Valve Checking and Adjustment
  296
- Troubleshooting - Swing Gearbox
  298
- Troubleshooting - Hydraulic Problems
  299
- Troubleshooting - Control Valve
  301
- Troubleshooting - Travel Control Valve
  302
- Troubleshooting - Joystick Control Valve
  303
Table of Contents

307
- Applicable Models
  309
- Safety Precautions
  309
- General Description
  310
- Specifications
  312
Table of Contents

315
- Applicable Models
  317
- Safety Precautions
  317
- General Description
  318
- Parts List
  319
- Inspection
  320
- Testing
  320
- Troubleshooting, Testing and Adjustment
  320
- Disassembly
  321
- Reassembly
  324
Table of Contents

329
- Applicable Models
  331
- Safety Precautions
  331
- General Description
  332
- Theory of Operation
  332
- Parts List
  334
- Piston Nut
  336
- Special Tools and Materials
  336
- Piston Jig
  338
- Steel Bushing Jig
  340
- Dust Wiper Jig
  342
- Slipper Seal Jig
  344
- Slipper Seal Straightening Jig
  346
- Disassembly
  348
- Reassembly
  353
Table of Contents

359
- Applicable Models
  361
- Safety Precautions
  361
- General Description
  362
- Theory of Operation
  362
- Makeup Check Valve
  365
- Operation of Swing Reactionless Valve
  365
- Operation of Time Delay Valve
  365
- Parts List
  366
- Specifications
  368
- Torques
  368
- Tools
  369
- Tools and Materials
  369
- General Precautions
  370
- How to Check Faults of Hydraulic Motor
  370
- Troubleshooting
  370
- Troubleshooting, Testing and Adjustment
  370
- Disassembly
  372
- General Cautions
  372
- Cleaning and Inspection (Wear Limits and Tolerances)
  379
- Assembly
  380
- General Cautions
  380
- Reassembly
  380
- Assembly of Cylinder Block Assembly Subassembly
  383
- Assembly of Rear Cover Assembly Subassembly
  387
- Air Pressure Test
  393
- Oil Leakage Check
  393
Table of Contents

397
- Applicable Models
  399
- Safety Precautions
  399
- General Description
  401
- Structure
  401
- Operation Basics
  402
- Parts List
  408
- Connection Torque
  410
- Specifications
  410
- General Precautions
  412
- How to Check Faults of Hydraulic Motor
  412
- Troubleshooting
  412
- Troubleshooting, Testing and Adjustment
  412
- Disassembly
  414
- General Cautions
  414
- Disassembly of Cylinder Subassembly
  420
- Cleaning and Inspection
  422
- Maintenance Standard
  422
- Tolerances)
  422
- General Cautions
  426
- Reassembly
  426
- Reassembly of Drive Shaft Subassembly
  426
- Assembly of Valve Casing Subassembly
  427
- Assembly of Cylinder Subassembly
  431
- Assembly of Motor Body
  433
Table of Contents

441
- Applicable Models
  443
- Safety Precautions
  443
- Axial Piston Pump
  444
- General Description
  444
- Model Number Designation
  444
- Theory of Operation
  445
- Parts List
  446
- Torques
  448
- Tools
  449
- Troubleshooting, Testing and Adjustment
  451
- Disassembly
  453
- Cleaning and Inspection (Wear Limits and Tolerances)
  456
- Worn Part Replacement Criteria
  456
- Correction Criteria for Cylinder, Valve Plate and
  457
- Plate (Shoe Plate)
  457
- Reassembly
  458
- Cautions During Starting Operation
  462
- Oil Filling and Air Venting
  462
- Start-Up Procedures
  462
- General Description
  463
- Model Number Designation
  463
- Regulator for Axial Piston Pump
  463
- Parts List
  464
- Outline
  465
- Functional Explanations
  467
- Specifications
  467
Table of Contents

487
- Applicable Models
  489
- Gear Pump
  489
- Safety Precautions
  489
- Disassembly
  490
- Single Gear Pump
  490
- Reassembly
  492
- Disassembly
  496
- Double Gear Pump
  496
- Reassembly
  498
Table of Contents

505
- Parts List
  540
- Specifications
  545
- Troubleshooting
  546
- Troubleshooting, Testing and Adjustment
  546
- Adjustment of Valves
  547
- Disassembly
  549
- Cleaning
  559
- Cleaning and Inspection (Wear Limits and Tolerances)
  559
- Inspection
  559
- Caution on Assembly
  560
- Reassembly
  560
- Sequence of Subassembly
  561
- Maintenance of Relief Valves
  567
- Installation
  570
- Start-Up Procedures
  570
Table of Contents

573
- Applicable Models
  575
- Safety Precautions
  575
- General Description
  577
- Theory of Operation
  577
- Parts List
  578
- Specifications
  580
- Tools and Materials
  580
- Torques
  580
- Disassembly
  581
- Cleaning and Inspection
  585
- Reassembly
  585
- Tolerances)
  585
- Start-Up Procedures
  592
Table of Contents

621
- Applicable Models
  623
- Safety Precautions
  623
- 5-Solenoid Valve
  624
- Parts List
  624
- Functions of 5-Solenoid Valve Assembly
  625
- Assembly Diagram and Tools Required
  628
- Cautions During Disassembly and Reassembly
  629
- Solenoid Valve Diagram
  630
- Check Points and Solutions for Problems
  631
- 2-Solenoid Valve
  632
- Parts List
  632
- Assembly Diagram and Tools Required
  633
- Cautions During Disassembly and Reassembly
  634
- Solenoid Valve Diagram
  635
Table of Contents

639
- Applicable Models
  641
- Breaker EPPR Valve (Opt)
  641
- Safety Precautions
  641
- Numbers and Names of Parts
  642
- Structure
  642
- Cautions for Operation
  643
- Functions and Operation
  643
- Maintenance
  644
- Maintenance Instructions
  644
- Disassembly
  645
- Assembly
  646
Table of Contents

661
- Applicable Models
  664
- Safety Precautions
  664
- Introduction
  665
- Electrical Supply System
  666
- Engine Starting Circuit
  668
- Engine Preheating System
  672
- Engine Stop
  674
- Charging System
  676
- Monitoring System
  677
- Operation
  682
- Warning and Indicator Lights
  684
- Initial Operation
  687
- Mode Selector Switch
  687
- Graphic Information Area Display
  688
- Main Menu
  690
- Special Menu
  695
- Electronic Hydraulic Control System (E-EPOS)
  712
- Power Mode Control
  714
- Power Mode Control - Circuit Diagram
  719
- Engine Control System
  720
- Engine Control Motor
  721
- Engine Control Dial
  722
- Engine Control Circuit Diagram
  723
- Automatic Deceleration Control (Auto Idle Control)
  724
- Engine Overheat Protection System
  726
- Power Boost Mode
  728
- Automatic Travel Speed Control
  730
- Self-Diagnostic Function
  733
- Air Conditioner System
  735
- Troubleshooting
  755
- Weight of R134A Gas Used in Machines
  757
- Refrigerant System Repairs
  758
- Wiper System
  766
- Lighting System
  768
- Overload Warning Device
  770
- Audio Controller
  771
Table of Contents

785
- Applicable Models
  787
- Boom and Arm
  787
- Safety Precautions
  787
- Front Attachment Pin Specifications
  788
- Dx300Lc
  789
- Dx340Lc / Dx350Lc
  790
- Dx420Lc
  791
- Dx480Lc / Dx520Lc
  792
- Arm Removal Procedure
  793
- Front Attachment - Removal and Installation
  793
- Boom Removal Procedure
  795
- Arm Installation Procedure
  796
- Boom Installation Procedure
  796
- Installation
  796
- Start-Up Procedures
  797
- Applicable Models
  803
- Bucket
  803
- Safety Precautions
  803
- Bucket Tooth Inspection and Replacement
  804
- Bucket O-Ring Replacement
  805
- Bucket Shimming Procedures
  807
- New Bucket Installation
  807
- Attaching the Bucket
  809
- Bucket Attachment, Removal and Reversal
  809
- Detaching the Bucket
  809
- Reversing the Bucket
  810

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Doosan 5001 Operation & Maintenance Manual

Doosan 5001 Operation & Maintenance Manual (296 pages)

Brand: Doosan | Category: Excavators | Size: 34 MB

Table of Contents

Table of Contents
5
EC Declaration of Conformity
9
To the Operator of Adoosan Excavator
11
Safety Decals
14
Visibility Information
28
Summary of Safety Precautions for Lifting in Digging Mode
30
Unauthorized Modifications
31
General Hazard Information
31
Before Starting Engine
40
Machine Operation
45
Maintenance
53
Battery
62
Towing
64
Shipping and Transportation
65
Excavator Rated Lift Capacity Tables
66
Operating Controls

77
- Component Locations
  78
- Operator's Area
  80
- Operational Controls and Panels
  82
- Instrument Panel
  95
- Multifunction Gauge and Graphic Information
  101
- Mode Selector Buttons
  107
- Setting Main Menu
  109
- Flow Control
  118
- Operation Selection Display
  120
- Heater and Air Conditioner Control Panel
  123
- Stereo
  128
- Miscellaneous Electrical Devices
  129
- Seat Adjustment
  131
- Ceiling Cover
  135
- Front Windows
  136
- Door Side Latch
  138
- Cabin Storage Compartments
  139
- Ashtray
  139
- Sun Visor
  140
- Hanger
  140
- Cup Holder
  140
- Emergency Glass Breaking Tool
  141
- Miscellaneous Access Covers and Doors
  142
Operation

143
- To Handle a New Excavator
  143
- Starting and Stopping the Engine
  144
- Safety Lever
  155
- Travel
  156
- Operating Instructions
  163
- Operating Precautions
  169
- Parking Excavator
  174
- Towing Procedure
  175
- Hydraulic Attachments (Optional)
  176
- Adjusting the Pump Flow
  181
- Lifting Objects
  184
- Operation under Unusual Conditions
  186
Inspection, Maintenance and Adjustment

191
Transportation

275
- Loading and Unloading
  275
- Lifting Machine
  280
Specification

281
- Standard Specification
  281
- Overall Dimensions
  282
- Working Range
  284
- Approximate Weight of Workload Materials
  286
Index

289

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