Doosan DX235LCR Manuals

Manuals and User Guides for Doosan DX235LCR. We have 1 Doosan DX235LCR manual available for free PDF download: Shop Manual

Doosan DX235LCR Shop Manual

Doosan DX235LCR Shop Manual (1032 pages)

Brand: Doosan | Category: Excavators | Size: 31.73 MB

Table of Contents

English

13
- Table of Contents
  13
- Applicable Models
  15
- Safety Precautions
  15
- To the Operator of a Excavator
  16
- General Safety Essentials
  19
- Location of Safety Labels
  20
- Summary of Safety Precautions for Lifting in Digging Mode
  21
- General Hazard Information
  22
- Unauthorized Modifications
  22
- Before Starting Engine
  32
- Machine Operation
  36
- Maintenance
  44
- Battery
  53
- Towing
  55
- Lifting with Sling
  56
- Shipping and Transportation
  56
- Specification for DX140LCR
  63
  - Safety Precautions
    63
  - Applicable Models
    63
  - General Description
    64
  - Component Locations
    64
  - General Dimensions
    66
    
    One - Piece Boom
    66
    
    Two - Piece Boom
    67
  - Working Range
    68
    
    One - Piece Boom
    68
    
    Two - Piece Boom
    69
  - General Specifications
    70
  - Engine Performance Curves (Per DIN 6270 Standard)
    72
  - Approximate Weight of Workload Materials
    74
  - Performance Tests
    76
  - Excavator Performance Standards
    77
    
    Test Conditions
    77
    
    Travel Speed and Travel Motor Balance (Steering Deviation) Tests
    77
    
    Swing Speed and Deceleration Force Test
    79
    
    Cylinder Performance Tests
    81
- Applicable Models
  89
- General Maintenance Procedures
  89
- Safety Precautions
  89
- Welding Precautions and Guidelines
  90
- Hydraulic System - General Precautions
  91
- Maintenance Service and Repair Procedure
  93
  - General Precautions
    93
- Hydraulic System Cleanliness and Oil Leaks
  94
  - Maintenance Precautions for Hydraulic System Service10
    94
  - Oil Leakage Precautions
    95
- Cleaning and Inspection
  96
  - General Guidelines
    96
  - Bearing Inspection
    97
- Applicable Models
  109
- Safety Precautions
  109
- Standard Torques
  109
- Fasteners
  110
- Torque Values for Standard Metric
  110
- Torque Values for Standard U.S. Fasteners
  111
- Type 8 Phosphate Coated Hardware
  113
- Torque Values for Hose Clamps
  114
- Torque Values for Split Flanges
  115
- Torque Wrench Extension Tools
  116
- Applicable Models
  127
- Safety Precautions
  127
- Cab Identification
  128
  - Roll over Protective Structure (ROPS) When Required by Local Regulations
    128
- Removal
  130
- Installation
  134
- Applicable Models
  141
- Safety Precautions
  141
- General
  142
  - Warning for Counterweight and Front Attachment Removal
    142
- Removal
  154
- Installation
  158
- Applicable Models
  167
- Fuel Transfer Pump
  167
- Safety Precautions
  167
- General Description
  168
- Theory of Operation
  168
- Replacement of Rotor and Vane
  169
- Troubleshooting
  169
- Replacement of Armature
  170
- Replacement of Rear Cover
  170
- Applicable Models
  175
- Safety Precautions
  175
- Swing Bearing
  175
- Swing Bearing Maintenance
  176
  - Operating Recommendation
    176
  - Measuring Swing Bearing Axial Play
    176
  - Measuring Bearing Lateral Play
    176
  - Swing Bearing Basic Operation
    177
  - Disassembly
    177
  - Assembly
    179
- Applicable Models
  185
- Safety Precautions
  185
- Swing Reduction Gear
  185
- General Description
  187
  - Theory of Operation
    187
- Reassembly
  188
  - Parts List
    188
- Shrinkage Fitting of Shaft and Flexible Bearing
  190
- Reassembly of Carrier Sub
  193
- Assembly of the Main
  200
- Test
  212
- Reassembly of Motor
  215
- Applicable Models
  229
- Safety Precautions
  229
- Track Assembly
  229
- General Description
  230
- Track Tension
  230
- Cleaning and Inspection
  233
  - Track Shoe
    234
  - Lower Roller
    236
  - Upper Roller
    237
  - Front Idler
    238
- Track Shoes and Links
  239
  - Track Removal
    239
  - Track Installation
    240
- Front Idler
  241
  - Parts List
    241
  - Disassembly of Front Idler
    242
  - Reassembly of Front Idler
    243
- Lower Roller
  245
  - Parts List
    245
  - Lower Roller Removal
    246
  - Lower Roller Disassembly
    246
  - Lower Roller Reassembly
    247
  - Lower Roller Installation
    248
- Upper Roller
  249
  - Parts List
    249
  - Upper Roller Removal
    250
  - Upper Roller Disassembly
    250
  - Upper Roller Reassembly
    252
- Track Spring and Track Adjusting Cylinder
  253
  - Parts List
    253
- Applicable Models
  263
- Safety Precautions
  263
- QSB4.5 Engine
  264
  - Important Reference Numbers
    265
- General Information
  266
  - To the Owner and Operator
    266
  - About the Manual
    266
  - General Safety Instructions
    268
  - General Repair Instructions
    271
  - General Cleaning Instructions
    273
  - Fuel System
    280
  - Acronyms and Abbreviations
    281
- Engine Identification
  282
  - Engine Data Plate
    282
  - Cummins Engine Nomenclature
    284
  - Fuel Injection Pump Dataplate
    284
  - ECM Data Plate
    284
  - Air Compressor (Not Used)
    285
  - Engine Diagrams
    286
  - Fan Control
    291
  - Water-In-Fuel Sensor
    292
  - Idle Shutdown
    293
  - Accelerator Optionals
    295
  - Intermediate Speed Control (ISC)
    296
  - Alternate Droop
    298
  - Switchable (Alternate) Torque
    299
  - Multiple Unit Synchronization
    300
  - Hot Shutdown Monitor
    301
  - Automatic Boost Power
    302
  - Fuel Consumption Rate Logger
    303
- Operating Instructions
  304
  - Operating Instructions -Overview
    304
  - General Information
    304
  - Normal Starting Procedure
    306
  - Jump Starting
    308
  - Cold Weather Starting
    309
  - Starting Procedure after Extended Shutdown or Oil Change
    309
  - Operating the Engine
    309
  - Engine Operating Range
    312
  - Engine Shutdown
    313
  - Electromagnetic Interference (EMI)
    313
- Maintenance Guidelines
  315
  - Maintenance Guidelines -Overview
    315
  - Tool Requirements
    315
  - Maintenance Schedule
    316
  - Oil Drain Intervals
    317
- Maintenance Procedures at Daily Interval
  318
  - Daily Maintenance Procedures - Overview
    318
  - Air Tanks and Reservoirs
    319
  - Crankcase Breather Tube
    319
  - Fuel-Water Separator
    320
  - Lubricating Oil Level
    321
  - Drive Belts
    321
  - Air Cleaner Restriction
    323
  - Air Compressor (Not Used)
    324
  - Charge-Air Cooler
    324
  - Charge-Air Piping
    324
  - Radiator Hoses
    325
  - Air Intake Piping
    325
  - Fan, Cooling
    326
  - Coolant Level
    327
- Maintenance Procedures at 500 Hours or 6 Months
  328
  - Maintenance Procedures - Overview
    328
  - Cooling System
    328
  - Fuel Filter (Spin-On Type)
    333
  - Lubricating Oil and Filters
    335
- Maintenance Procedures at 1,000 Hours or 1 Year
  338
  - Maintenance Procedures - Overview
    338
  - Fan Hub, Belt Driven
    339
- Maintenance Procedures at 2,000 Hours or 2 Years
  340
  - Air Compressor Discharge Lines (Not Used)
    340
  - Cooling System
    342
  - Vibration Damper, Rubber
    347
  - Vibration Damper, Viscous
    347
  - Overhead Set
    348
  - Alternator
    354
  - Charge-Air Cooler
    360
  - Coolant Thermostat
    365
  - Cooling Fan Belt Tensioner
    370
  - Drive Belt, Cooling Fan
    371
  - Fan Spacer and Pulley
    372
  - Starting Motor
    374
- System Diagrams
  379
  - General Information
    379
  - Fuel System
    380
  - Lubricating Oil System
    382
  - Cooling System
    387
  - Air Intake System
    388
  - Exhaust System
    389
  - Compressed Air System
    391
- Service Literature
  392
- Service Assistance
  398
- Troubleshooting Symptoms
  451
  - Troubleshooting Procedures and Techniques
    451
  - Troubleshooting Symptoms Charts
    451
- Applicable Models
  549
- Hydraulic System Troubleshooting, Testing and Adjustment
  549
- Safety Precautions
  549
- Hydraulic System - General Notes
  550
- Hydraulic Schematic
  551
  - General Notes
    551
- Operation of Working Components
  553
  - Boom Operating Circuit
    553
  - Boom up Circuit
    553
  - Boom down Circuit
    553
  - Arm Operating Circuit
    554
  - Arm Crowd Circuit
    554
  - Arm Dump Circuit
    554
  - Bucket Operating Circuit
    555
  - Bucket Crowd Circuit
    555
  - Bucket Dump Circuit
    555
  - Swing Operating Circuit
    555
  - Right Swing Operating Circuit
    556
  - Left Swing Operating Circuit
    556
  - Swing Relief Valve and Makeup Valve
    556
  - Travel Operating Circuit
    556
  - Forward Travel Circuit
    557
  - Reverse Travel Circuit
    557
- Procedural Troubleshooting Baseline Recommendations
  558
  - Initial Checks and Tests to Establish Operating Condition of the Excavator
    558
- Pilot Pressure
  560
  - Adjustment and Testing
    560
- Power Mode Valve
  561
  - Current Signal and Hydraulic Pressure Adjustments
    561
- Swing Priority Valve
  562
  - Control Valve Pressure and Current Adjustments
    562
- Pressure up Valve
  563
  - Checks and Adjustments
    563
- Pump Input Power Control
  565
  - Pump Regulator Adjustment
    565
- Flow Meter and Flow Meter Kit Installation and Testing
  569
- Swing System Troubleshooting
  571
  - Precautions/Initial Checks
    571
  - Swing Relief Valve Checking and Adjustment
    572
- Troubleshooting - Swing Gearbox
  574
- Troubleshooting - Hydraulic Problems
  575
- Troubleshooting - Control Valve
  577
- Troubleshooting - Travel Control Valve
  578
- Troubleshooting - Joystick Control Valve
  579
- Applicable Models
  585
- Safety Precautions
  585
- General Description
  586
  - Specifications
    588
- Applicable Models
  593
- Center Joint (Swivel)
  593
- Safety Precautions
  593
- General Description
  594
  - Parts List
    595
- Troubleshooting, Testing and Adjustment
  596
  - Inspection
    596
  - Testing
    596
- Disassembly
  597
- Reassembly
  598
- Applicable Models
  603
- Safety Precautions
  603
- General Description
  604
  - Theory of Operation
    604
  - Parts List
    606
- Special Tools and Materials
  608
  - Piston Nut
    608
  - Piston Jig
    610
  - Steel Bushing Jig
    612
  - Dust Wiper Jig
    614
  - Slipper Seal Jig
    616
  - Slipper Seal Straightening Jig
    618
- Disassembly
  620
- Reassembly
  625
- Swing Motor
  632
- Applicable Models
  633
- Safety Precautions
  633
- Instruction Manual
  634
  - Construction and Principles of Working
    636
  - Precaution in Use
    643
  - Troubleshooting
    647
- Maintenance Manual
  650
  - Disassembling and Assembling
    650
- Applicable Models
  669
- Safety Precautions
  669
- Product Overview
  670
- External Dimensions
  671
- General Description
  672
- Operating Description
  675
  - Reduction Gear
    675
  - Hydraulic Drives
    676
  - Tubing
    685
  - Fluid Selection
    685
- Maintenance and Inspection
  686
  - Daily Inspection
    686
  - Changing Fluid
    687
  - Changing Lubrication
    687
- Seals Table
  689
- Troubleshooting
  690
- Outline of Maintenance
  692
  - Tools
    692
  - Bolts
    692
  - Equipments
    693
  - Fabricated Tools
    693
  - Torque
    697
  - Weight Table
    697
- Disassembling
  698
  - Work Preparation
    698
  - General Precautions for Work
    698
  - Disassembling Order
    699
- Maintenance Standards
  716
  - Seals
    716
  - Maintenance Standards for Wearable Parts
    716
- Assembling
  718
  - Preparation
    718
  - General Precautions for Assembling Work
    718
  - Order of Assembling
    719
- Applicable Models
  741
- Main Pump
  741
- Safety Precautions
  741
- Disassembling and Reassembling Procedures
  742
  - Tool
    742
  - Disassembling Procedures
    743
  - Reassembling Procedures
    747
- Pump Maintenance Criteria
  751
  - Worn Part Replacement Criteria
    751
- Applicable Models
  759
- Safety Precautions
  759
- General Description
  760
  - Theory of Operation
    761
  - Composite Operation
    772
  - Anti-Drift Valve
    773
- Disassembly
  775
  - Precautions for Disassembly
    775
  - Disassembling Procedures
    775
- Inspection
  781
- Washing
  781
- Assembling
  782
  - Sub-Assembly
    782
  - Assembling Control Valve
    785
- Relief Valve
  791
  - Main Relief Valve
    791
  - Overload Relief Valve
    795
  - Negacon Relief Valve
    798
  - Adjusting Relief Valve
    800
- Installation
  801
- Operation
  801
- Control Valve Specification
  802
- Troubleshooting
  803
  - Control Valve: Overall
    803
  - Hydraulic System: Overall
    804
  - Torques
    814
- Tools and Materials
  814
- Disassembly
  815
- Cleaning and Inspection
  818
- Reassembly
  819
- Start-Up Procedures
  825
  - Specification
    840
  - Torques
    840
- Removal
  841
- Disassembly
  842
- Cleaning and Inspection
  844
- Reassembly
  845
- Installation
  850
- Start-Up Procedures
  851
- Applicable Models
  857
- Safety Precautions
  857
- Solenoid Valve Assembly
  857
- Parts List
  858
- Functions of 5-Solenoid Valve Assembly Package
  859
- Applicable Models
  871
- Safety Precautions
  871
- Structure
  872
  - Numbers and Names of Parts
    872
- Cautions for Operation
  873
- Functions and Operation
  873
- Maintenance Instructions
  874
  - Maintenance
    874
  - Disassembly
    875
  - Assembly
    876
- Applicable Models
  893
- Safety Precautions
  893
- Introduction
  894
- Electrical Supply System
  895
- Engine Starting Circuit
  897
- Engine Preheating System
  901
- Engine Stop
  903
- Charging System
  905
- Monitoring System
  906
- Operation
  911
- Warning and Indicator Lights
  913
- Initial Operation
  916
- Mode Selector Switch
  916
- Graphic Information Area Display
  917
- Main Menu
  919
- Special Menu
  923
- Electronic Hydraulic Control System (E-EPOS)
  941
- Power Mode Control
  943
- Power / Economy Mode Control - Circuit Diagram
  949
- Engine Control Dial
  950
- Air Conditioner System
  968
- Troubleshooting
  981
- Weight of R134A Gas Used in Machines
  983
- Refrigerant System Repairs
  984
- Wiper System
  992
- Lighting System
  995
- Overload Warning Device
  997
- Audio Controller
  998
Unknown

1002
- Table of Contents
  1002
- Applicable Models
  1013
- Boom and Arm
  1013
- Safety Precautions
  1013
- Front Attachment Pin Specifications
  1014
  - One-Piece Boom
    1014
  - Two-Piece Boom
    1015
- Front Attachment - Removal and Installation
  1016
  - Arm Removal Procedure
    1016
  - Boom Removal Procedure
    1018
- Installation
  1019
  - Arm Installation Procedure
    1019
  - Boom Installation Procedure
    1019
- Start-Up Procedures
  1019
- Applicable Models
  1025
- Bucket
  1025
- Safety Precautions
  1025
- Bucket Tooth Inspection and Replacement
  1026
- Bucket O-Ring Replacement
  1027
- Bucket Attachment, Removal and Reversal
  1029
  - Detaching the Bucket
    1029
  - Attaching the Bucket
    1029
  - Reversing the Bucket
    1030

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