Doosan 5221 Crawler Excavator Manuals

Manuals and User Guides for Doosan 5221 Crawler Excavator. We have 1 Doosan 5221 Crawler Excavator manual available for free PDF download: Instructions Manual

Doosan 5221 Instructions Manual

Doosan 5221 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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