Doosan DX180LC-5 Excavator Shop Manual 950106-01144E – PDF DOWNLOAD
DESCRIPTION:
Doosan DX180LC-5 Excavator Shop Manual 950106-01144E – PDF DOWNLOAD
- Know how to operate your machine.
- Know the purpose of all controls, gauges, signals, indicators and monitor displays.
- Know the rated load capacity, speed range, braking and steering characteristics, turning radius and operating clearances.
- Keep in mind that rain, snow, ice, loose gravel, soft ground, slopes etc., can change operating capabilities of your machine.
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 test all attachments that owners may want to install on their machines, contact DOOSAN for written authorization and approval of attachments, and their compatibility with optional kits.
- Attachments and attachment control systems that are compatible with the machine are required for safe and reliable machine operation.
- Do not exceed maximum operating weight (machine weight plus attachment) that is listed on ROPS certification plate. Make sure that all guards and shields are in place on machine and on work tool.
- Depending on type or combination of work equipment, there is a potential that work equipment could interfere with the cabin or other parts of machine.
- Before using unfamiliar work equipment, check if there is any potential of interference, and operate with caution.
- While you are performing any maintenance, testing, or adjustments to attachments, stay clear of the following areas: cutting edges, pinch points, and crushing surfaces. Never use attachment as a work platform or manlift.
- Contact your DOOSAN distributor about auxiliary hydraulic kits for attachments installation. If you are in doubt about compatibility of a particular attachment with a machine, consult your DOOSAN distributor.
Doosan DX180LC-5 Excavator Shop Manual 950106-01144E – PDF DOWNLOAD
DX180LC-5…………………………………………………………………………………………………… 0
NOTICE………………………………………………………………………………………………….. 7
Table of Contents………………………………………………………………………………………… 9
Safety………………………………………………………………………………………………….. 11
Track Excavator Maintenance Safety……………………………………………………………………… 13
Safety Instructions……………………………………………………………………………….. 17
Safety Messages…………………………………………………………………………………… 17
General………………………………………………………………………………………….. 18
Safe Operation is Operator’s Responsibility………………………………………………………. 18
Know Your Machine……………………………………………………………………………… 18
Proper Work Tools and Attachments……………………………………………………………….. 19
Pressurized Fluids…………………………………………………………………………….. 19
Flying or Falling Objects………………………………………………………………………. 20
Personal Protective Equipment (PPE)……………………………………………………………… 21
Correction of Machine Problems………………………………………………………………….. 21
Crushing and Cutting…………………………………………………………………………… 21
Hot Coolant and Oils – Burn Prevention…………………………………………………………… 22
Fire and Explosion Prevention…………………………………………………………………… 23
Fire Extinguisher and First-aid Kit (Emergency Medical Kit)………………………………………… 26
Electrical System and Electrical Shock…………………………………………………………… 27
Roll-over Protective Structure (ROPS)……………………………………………………………. 27
Transportation……………………………………………………………………………………. 31
Obey State and Local Over-the-Road Regulations……………………………………………………. 31
Loading and Unloading………………………………………………………………………….. 31
Transporting Machine…………………………………………………………………………… 32
Operation………………………………………………………………………………………… 33
Before Engine Starting…………………………………………………………………………. 33
Work Site…………………………………………………………………………………….. 34
Mounting/Dismounting…………………………………………………………………………… 35
Cleaning……………………………………………………………………………………… 36
Operator Station………………………………………………………………………………. 36
Seat Belt…………………………………………………………………………………….. 37
Visibility Information…………………………………………………………………………. 38
Boost Starting or Charging Engine Batteries………………………………………………………. 39
Swinging or Traveling………………………………………………………………………….. 41
Lifting and Digging……………………………………………………………………………. 43
Operation on Slopes……………………………………………………………………………. 44
Towing……………………………………………………………………………………….. 45
Attachment……………………………………………………………………………………. 46
Equipment Lowering with Engine Stopped…………………………………………………………… 46
Engine Stop…………………………………………………………………………………… 47
Parking Machine……………………………………………………………………………….. 47
Preservation/Storing Machine……………………………………………………………………. 48
Maintenance………………………………………………………………………………………. 50
Cleaning……………………………………………………………………………………… 53
Proper Tools and Clothing………………………………………………………………………. 53
Disassembling Precautions………………………………………………………………………. 53
Use of Lighting……………………………………………………………………………….. 53
Fire and Explosion Prevention…………………………………………………………………… 54
Burn Prevention……………………………………………………………………………….. 55
Rubber That Contains Fluorides………………………………………………………………….. 56
Rubber and Plastics……………………………………………………………………………. 57
Welding Repairs……………………………………………………………………………….. 58
Warning for Counterweight and Front Attachment Removal…………………………………………….. 59
Lock Inspection Covers…………………………………………………………………………. 60
Working on Machine…………………………………………………………………………….. 60
Accumulator…………………………………………………………………………………… 61
Compressed Air………………………………………………………………………………… 61
Track Tension Adjustments………………………………………………………………………. 62
Supports and Blocking for Work Equipment…………………………………………………………. 62
High-pressure Lines, Tubes and Hoses…………………………………………………………….. 63
Battery………………………………………………………………………………………. 64
Environment and Circumstances………………………………………………………………………. 66
Work Site Areas Requiring Extra Caution………………………………………………………….. 66
High-voltage Cables……………………………………………………………………………. 68
Underground Operation………………………………………………………………………….. 69
Working in Water………………………………………………………………………………. 69
Working in Contaminated Environment……………………………………………………………… 69
Operation in Extreme Conditions…………………………………………………………………. 70
Exhaust Ventilation……………………………………………………………………………. 74
Asbestos Information…………………………………………………………………………… 75
Silica Dust Information………………………………………………………………………… 75
Disposal of Hazardous Materials…………………………………………………………………. 76
Sound………………………………………………………………………………………… 76
Vibration Information………………………………………………………………………….. 77
Specifications…………………………………………………………………………………………… 79
Specifications……………………………………………………………………………………….. 81
Safety Instructions……………………………………………………………………………….. 85
General Description……………………………………………………………………………….. 85
Component Locations……………………………………………………………………………….. 86
Overall Dimensions………………………………………………………………………………… 90
One – Piece Boom………………………………………………………………………………. 90
Two – Piece Boom………………………………………………………………………………. 91
Working Range…………………………………………………………………………………….. 92
One – Piece Boom………………………………………………………………………………. 92
Two – Piece Boom………………………………………………………………………………. 94
General Specifications…………………………………………………………………………….. 96
Approximate Weight of Workload Materials…………………………………………………………….. 98
Performance Tests…………………………………………………………………………………. 100
Purpose of Performance Tests……………………………………………………………………. 100
Kinds of Tests………………………………………………………………………………… 100
Performance Standards………………………………………………………………………….. 100
Precautions for Evaluation of Test Data………………………………………………………….. 100
Definition of “Performance Standard”…………………………………………………………….. 100
Preparation for Performance Tests…………………………………………………………………… 101
The Machine…………………………………………………………………………………… 101
Test Area…………………………………………………………………………………….. 101
Precautions…………………………………………………………………………………… 101
Make Precise Measurement……………………………………………………………………….. 101
Operational Performance Standard Table………………………………………………………………. 102
Operational Performance Test……………………………………………………………………….. 104
Hydraulic Cylinder Cycle Time…………………………………………………………………… 104
Travel Speed………………………………………………………………………………….. 106
Track Revolution Speed…………………………………………………………………………. 107
Mistrack Check………………………………………………………………………………… 109
Swing Speed…………………………………………………………………………………… 111
Swing Function Drift Check……………………………………………………………………… 112
General Maintenance………………………………………………………………………………………. 113
General Maintenance Instructions……………………………………………………………………….. 115
Safety Instructions……………………………………………………………………………….. 119
Welding Precautions and Instructions………………………………………………………………… 120
Hydraulic System – General Precautions………………………………………………………………. 121
Maintenance Service and Repair Procedure…………………………………………………………….. 123
General Precautions……………………………………………………………………………. 123
Hydraulic System Cleanliness and Oil Leaks…………………………………………………………… 124
Maintenance Precautions for Hydraulic System Service………………………………………………. 124
Oil Leakage Precautions………………………………………………………………………… 125
Cleaning and Inspection……………………………………………………………………………. 126
General Instructions…………………………………………………………………………… 126
Bearing Inspection…………………………………………………………………………….. 127
Standard Torques……………………………………………………………………………………… 135
Safety Instructions……………………………………………………………………………….. 139
Torque Values for Standard Metric Fasteners………………………………………………………….. 140
Torque Values for Standard U.S. Fasteners……………………………………………………………. 141
Type 8 Phosphate Coated Hardware……………………………………………………………………. 143
Torque Values for Hose Clamps………………………………………………………………………. 144
ORFS Swivel Nut Recommended Torque………………………………………………………………….. 144
Torque Values for Split Flanges…………………………………………………………………….. 145
Torque Wrench Extension Tools………………………………………………………………………. 146
Torque Multiplication………………………………………………………………………….. 146
Other Uses for Torque Wrench Extension Tools……………………………………………………… 147
Tightening Torque Specifications (Metric)………………………………………………………… 148
Engine………………………………………………………………………………………………….. 151
Engine………………………………………………………………………………………………. 153
Safety Instructions……………………………………………………………………………….. 157
Overview…………………………………………………………………………………………. 158
General Information……………………………………………………………………………….. 159
Major Component Location……………………………………………………………………….. 159
Engine Identification………………………………………………………………………….. 164
Engine Lifting………………………………………………………………………………… 166
Maintenance and Storage………………………………………………………………………… 168
Engine Specification………………………………………………………………………………. 171
General Specification………………………………………………………………………….. 171
Engine Performance Curves………………………………………………………………………. 172
Basic Engine……………………………………………………………………………………… 173
Cylinder Block………………………………………………………………………………… 173
Cylinder Head…………………………………………………………………………………. 175
Valve Mechanism Cover………………………………………………………………………….. 187
Crankcase Breather…………………………………………………………………………….. 192
Flywheel and Flywheel Housing…………………………………………………………………… 196
Actuating System………………………………………………………………………………….. 208
Pistons, Rings, and Connecting Rods……………………………………………………………… 208
Crankshaft……………………………………………………………………………………. 223
Gears and Timing Gear Case……………………………………………………………………… 242
Camshaft……………………………………………………………………………………… 265
Rocker Shaft………………………………………………………………………………….. 275
Lubricant System………………………………………………………………………………….. 286
Overview……………………………………………………………………………………… 286
Engine Oil Pump……………………………………………………………………………….. 288
Engine Oil Filter……………………………………………………………………………… 292
Engine Oil Pan………………………………………………………………………………… 294
Engine Oil Pressure – Test……………………………………………………………………… 302
Excessive Bearing Wear – Inspect………………………………………………………………… 302
Excessive Engine Oil Consumption – Inspect……………………………………………………….. 303
Increased Engine Oil Temperature – Inspect……………………………………………………….. 303
Cooling System……………………………………………………………………………………. 304
Overview……………………………………………………………………………………… 304
Water Pump……………………………………………………………………………………. 305
Water Temperature Regulator…………………………………………………………………….. 310
Engine Oil Cooler……………………………………………………………………………… 314
Piston Cooling Jets……………………………………………………………………………. 320
Fuel System………………………………………………………………………………………. 322
Overview……………………………………………………………………………………… 322
High-pressure Fuel System………………………………………………………………………. 323
Water Separator & Pre Fuel Filter (Fuel Prefilter)………………………………………………… 325
Main Fuel Filter………………………………………………………………………………. 329
Fuel Injection Pump……………………………………………………………………………. 331
Fuel Injection Lines…………………………………………………………………………… 339
Fuel Injectors………………………………………………………………………………… 351
Fuel System – Inspect………………………………………………………………………….. 359
Air in Fuel – Test…………………………………………………………………………….. 360
Finding Top Center Position for No. 1 Piston……………………………………………………… 362
Fuel Injection Timing – Check…………………………………………………………………… 363
Fuel Quality – Test……………………………………………………………………………. 364
Fuel System – Prime……………………………………………………………………………. 365
Cleanliness of Fuel System……………………………………………………………………… 366
Air Inlet and Exhaust System……………………………………………………………………….. 368
Exhaust System………………………………………………………………………………… 368
Clean Emissions Module (Diesel Oxidation Catalyst (DOC) and Selective Catalytic Reduction (SCR) System)…. 423
DEF Dosing Control System………………………………………………………………………. 426
Electrical System…………………………………………………………………………………. 447
Electrical Control System………………………………………………………………………. 447
Sensor Locations for the Engine…………………………………………………………………. 450
Sensor Locations for the Clean Emissions Module…………………………………………………… 455
Electronic Control Module (ECM)…………………………………………………………………. 455
Electric Component – Remove and Install………………………………………………………….. 462
Engine Coolant Heater (Option)…………………………………………………………………………. 497
Safety Instructions……………………………………………………………………………….. 501
Disassembly and Assembly…………………………………………………………………………… 501
Changing the Circulating Pump…………………………………………………………………… 501
Changing the Temperature Limiter………………………………………………………………… 503
Changing the Temperature Sensor…………………………………………………………………. 504
Changing the Combustion Air Fan…………………………………………………………………. 506
Changing the Burner, Flame Monitor and Glow Plug………………………………………………….. 508
Changing the Burner Head……………………………………………………………………….. 510
Changing the Heat Exchanger…………………………………………………………………….. 512
Upper Structure………………………………………………………………………………………….. 513
Cabin……………………………………………………………………………………………….. 515
Safety Instructions……………………………………………………………………………….. 519
Cabin Identification………………………………………………………………………………. 519
Roll-over Protective Structure (ROPS)……………………………………………………………. 519
Removal………………………………………………………………………………………….. 521
Installation……………………………………………………………………………………… 527
Completing work…………………………………………………………………………………… 527
Dimensions of Cabin Glass………………………………………………………………………….. 528
Removal and Installation of Cabin Glass……………………………………………………………… 532
Removal of Cabin Glass…………………………………………………………………………. 532
Installation of Cabin Glass…………………………………………………………………….. 534
Installation of Upper Door Glass………………………………………………………………… 539
Installation of Upper Front Glass……………………………………………………………….. 539
Counterweight………………………………………………………………………………………… 541
Safety Instructions……………………………………………………………………………….. 545
General………………………………………………………………………………………….. 546
Warning for Counterweight and Front Attachment Removal…………………………………………….. 546
Removal………………………………………………………………………………………….. 548
Installation……………………………………………………………………………………… 549
Hydraulic Oil Tank……………………………………………………………………………………. 551
Safety Instructions……………………………………………………………………………….. 555
General………………………………………………………………………………………….. 555
Specification…………………………………………………………………………………. 555
Parts List……………………………………………………………………………………. 556
Air Breather………………………………………………………………………………….. 558
Removal………………………………………………………………………………………….. 559
Installation……………………………………………………………………………………… 566
Completing Work…………………………………………………………………………………… 567
Fuel Tank……………………………………………………………………………………………. 569
Safety Instructions……………………………………………………………………………….. 573
General………………………………………………………………………………………….. 573
Specification…………………………………………………………………………………. 573
Parts List……………………………………………………………………………………. 574
Removal………………………………………………………………………………………….. 576
Completing Work…………………………………………………………………………………… 583
Main Pump……………………………………………………………………………………………. 585
Safety Instructions……………………………………………………………………………….. 589
Axial Piston Pump…………………………………………………………………………………. 589
General Description……………………………………………………………………………. 589
Specifications………………………………………………………………………………… 590
Overview……………………………………………………………………………………… 592
Hydraulic Circuit……………………………………………………………………………… 595
Theory of Operation……………………………………………………………………………. 598
Tools………………………………………………………………………………………… 600
Tightening Torque……………………………………………………………………………… 601
Removal………………………………………………………………………………………. 602
Installation………………………………………………………………………………….. 612
Completing Work……………………………………………………………………………….. 613
Disassembly…………………………………………………………………………………… 614
Reassembly……………………………………………………………………………………. 617
Troubleshooting……………………………………………………………………………….. 620
Maintenance Instructions……………………………………………………………………….. 622
Regulator………………………………………………………………………………………… 624
Parts List……………………………………………………………………………………. 624
Functional Explanation…………………………………………………………………………. 626
Adjustment……………………………………………………………………………………. 633
Section View………………………………………………………………………………….. 636
Pilot Gear Pump…………………………………………………………………………………… 638
Specification…………………………………………………………………………………. 638
Parts List……………………………………………………………………………………. 639
Theory of Operation……………………………………………………………………………. 640
Port and Hydraulic Circuit……………………………………………………………………… 640
Precaution……………………………………………………………………………………. 641
Drive Coupling (Main Pump)…………………………………………………………………………….. 643
Safety Instructions……………………………………………………………………………….. 647
General………………………………………………………………………………………….. 647
Specification…………………………………………………………………………………. 647
Section View……………………………………………………………………………………… 650
Tools………………………………………………………………………………………… 651
Main Control Valve……………………………………………………………………………………. 655
Safety Instructions……………………………………………………………………………….. 659
General………………………………………………………………………………………….. 659
Specification…………………………………………………………………………………. 659
Parts List……………………………………………………………………………………. 666
Theory of Operation……………………………………………………………………………. 668
Cautions for Operation…………………………………………………………………………. 692
Precaution……………………………………………………………………………………….. 693
Removal………………………………………………………………………………………….. 694
Installation……………………………………………………………………………………… 708
Completing Work…………………………………………………………………………………… 708
Disassembly………………………………………………………………………………………. 709
Cautions on Disassembly………………………………………………………………………… 709
Sequence of Disassembly………………………………………………………………………… 710
cleaning and inspection……………………………………………………………………………. 718
Cleaning……………………………………………………………………………………… 718
Inspection……………………………………………………………………………………. 718
Reassembly……………………………………………………………………………………….. 719
Caution on Assembly……………………………………………………………………………. 719
Sequence of Reassembly…………………………………………………………………………. 720
Troubleshooting and adjustment……………………………………………………………………… 730
Troubleshooting……………………………………………………………………………….. 730
Adjusting Relief Valve…………………………………………………………………………. 732
Swing Device…………………………………………………………………………………………. 735
Safety Instructions……………………………………………………………………………….. 739
General………………………………………………………………………………………….. 739
Specification…………………………………………………………………………………. 739
Overview……………………………………………………………………………………… 740
Parts List……………………………………………………………………………………. 742
Theory of Operation……………………………………………………………………………. 746
Cautions for Operation…………………………………………………………………………. 754
Precaution……………………………………………………………………………………….. 757
Tools for Disassembly and Assembly………………………………………………………………. 757
Tightening Torque……………………………………………………………………………… 757
Removal………………………………………………………………………………………….. 759
Installation……………………………………………………………………………………… 764
Completing work…………………………………………………………………………………… 764
Section View……………………………………………………………………………………… 766
Disassembly………………………………………………………………………………………. 768
Swing Motor…………………………………………………………………………………… 768
Swing Reduction Gear…………………………………………………………………………… 773
Reassembly……………………………………………………………………………………….. 777
Swing Motor…………………………………………………………………………………… 777
Swing Reduction Gear…………………………………………………………………………… 783
Troubleshooting…………………………………………………………………………………… 791
General Instructions…………………………………………………………………………… 791
Examination of Hydraulic Motor………………………………………………………………….. 791
Troubleshooting……………………………………………………………………………….. 792
Maintenance Instructions…………………………………………………………………………… 795
Replacement Standard of Worn Parts………………………………………………………………. 795
Standard of Sliding Surface Correction…………………………………………………………… 795
Joystick Valve (Work Lever)……………………………………………………………………………. 797
Safety Instructions……………………………………………………………………………….. 801
General………………………………………………………………………………………….. 801
Specifications………………………………………………………………………………… 801
Overview……………………………………………………………………………………… 802
Parts List……………………………………………………………………………………. 804
Theory of Operation……………………………………………………………………………. 806
Tools and Torques……………………………………………………………………………… 807
Section View……………………………………………………………………………………… 808
Removal………………………………………………………………………………………….. 810
Installation……………………………………………………………………………………… 815
Completing work…………………………………………………………………………………… 816
Tools and Torques…………………………………………………………………………………. 817
Disassembly………………………………………………………………………………………. 817
Reassembly……………………………………………………………………………………….. 821
Dozer Joystick Valve (Option)………………………………………………………………………….. 829
Safety Instructions……………………………………………………………………………….. 833
General………………………………………………………………………………………….. 833
Specifications………………………………………………………………………………… 833
Overview……………………………………………………………………………………… 834
Hydraulic Circuit……………………………………………………………………………… 835
Parts List……………………………………………………………………………………. 836
Theory of Operation……………………………………………………………………………. 837
Tools……………………………………………………………………………………………. 839
Removal………………………………………………………………………………………….. 840
Installation……………………………………………………………………………………… 844
Completing work…………………………………………………………………………………… 845
Disassembly………………………………………………………………………………………. 846
Reassembly……………………………………………………………………………………….. 849
Travel Control Valve (with Damper)……………………………………………………………………… 855
Safety Instructions……………………………………………………………………………….. 859
General………………………………………………………………………………………….. 860
Specification…………………………………………………………………………………. 860
Overview……………………………………………………………………………………… 861
Parts List……………………………………………………………………………………. 862
Theory of Operation……………………………………………………………………………. 864
Section View……………………………………………………………………………………… 866
Removal………………………………………………………………………………………….. 867
Installation……………………………………………………………………………………… 872
Completing Work…………………………………………………………………………………… 873
Disassembly………………………………………………………………………………………. 874
Reassembly……………………………………………………………………………………….. 877
Troubleshooting…………………………………………………………………………………… 882
Solenoid Valve……………………………………………………………………………………….. 883
Safety Instructions……………………………………………………………………………….. 887
General………………………………………………………………………………………….. 887
Specification…………………………………………………………………………………. 887
Overview……………………………………………………………………………………… 888
Parts List……………………………………………………………………………………. 890
Theory of Operation……………………………………………………………………………. 891
Disassembly and Reassembly…………………………………………………………………………. 892
Troubleshooting…………………………………………………………………………………… 893
EPPR Valve (One or Two-way)……………………………………………………………………………. 895
Safety Instructions……………………………………………………………………………….. 899
Specification…………………………………………………………………………………. 899
General………………………………………………………………………………………….. 900
Specification…………………………………………………………………………………. 900
Overview……………………………………………………………………………………… 901
Hydraulic Circuit……………………………………………………………………………… 902
Troubleshooting…………………………………………………………………………………… 902
Accumulator………………………………………………………………………………………….. 903
Safety Instructions……………………………………………………………………………….. 907
General………………………………………………………………………………………….. 907
Specifications………………………………………………………………………………… 909
Gear Pump (Rotation)………………………………………………………………………………….. 911
Safety Instructions……………………………………………………………………………….. 915
General………………………………………………………………………………………….. 915
Specification…………………………………………………………………………………. 915
Overview……………………………………………………………………………………… 916
Location……………………………………………………………………………………… 916
Parts List……………………………………………………………………………………. 917
Single Gear Pump………………………………………………………………………………….. 918
Disassembly…………………………………………………………………………………… 918
Reassembly……………………………………………………………………………………. 920
One Spool Valve (Rotating)…………………………………………………………………………….. 925
Safety Instructions……………………………………………………………………………….. 929
General………………………………………………………………………………………….. 929
Specification…………………………………………………………………………………. 929
Overview……………………………………………………………………………………… 930
Port and Hydraulic Circuit………………………………………………………………….. 930
Theory of Operation……………………………………………………………………………. 931
In the Neutral Condition……………………………………………………………………. 931
Spool Operation……………………………………………………………………………. 931
Disassembly and Assembly…………………………………………………………………………… 933
General Cautions………………………………………………………………………………. 933
Replacement of Spool…………………………………………………………………………… 934
Replacement of Main Relief Valve………………………………………………………………… 936
Replacement of Overload Relief Valve…………………………………………………………….. 937
Replacement of Sub-Block……………………………………………………………………….. 939
Lower Structure and Chassis……………………………………………………………………………….. 941
Swing Bearing………………………………………………………………………………………… 943
Safety Instructions……………………………………………………………………………….. 947
General………………………………………………………………………………………….. 948
General Description……………………………………………………………………………. 948
Parts List……………………………………………………………………………………. 948
Maintenance Guidelines…………………………………………………………………………….. 949
Disassembly………………………………………………………………………………………. 950
Reassembly……………………………………………………………………………………….. 952
Center Joint…………………………………………………………………………………………. 953
Safety Instructions……………………………………………………………………………….. 957
General………………………………………………………………………………………….. 957
General Description……………………………………………………………………………. 957
Overview……………………………………………………………………………………… 958
Parts List……………………………………………………………………………………. 959
Section View……………………………………………………………………………………… 960
Removal………………………………………………………………………………………….. 961
Installation……………………………………………………………………………………… 966
Completing Work…………………………………………………………………………………… 966
Reassembly……………………………………………………………………………………….. 970
Troubleshooting, Testing and Adjustment……………………………………………………………… 972
Inspection……………………………………………………………………………………. 972
Testing………………………………………………………………………………………. 972
Center Joint (Dozer)………………………………………………………………………………….. 973
Safety Instructions……………………………………………………………………………….. 977
General………………………………………………………………………………………….. 977
General Description……………………………………………………………………………. 977
Overview……………………………………………………………………………………… 978
Parts List……………………………………………………………………………………. 980
Section View……………………………………………………………………………………… 982
Removal………………………………………………………………………………………….. 983
Installation……………………………………………………………………………………… 988
Completing Work…………………………………………………………………………………… 988
Disassembly………………………………………………………………………………………. 989
Reassembly……………………………………………………………………………………….. 991
Troubleshooting, Testing and Adjustment……………………………………………………………… 993
Inspection……………………………………………………………………………………. 993
Testing………………………………………………………………………………………. 993
Travel Device………………………………………………………………………………………… 995
Safety Instructions……………………………………………………………………………….. 999
General………………………………………………………………………………………….. 999
Specification…………………………………………………………………………………. 999
Overview………………………………………………………………………………………1000
Parts List…………………………………………………………………………………….1002
Theory of Operation…………………………………………………………………………….1006
Cautions for Operation………………………………………………………………………….1014
Precaution………………………………………………………………………………………..1018
Tools List for Disassembly and Reassembly…………………………………………………………1018
Removal…………………………………………………………………………………………..1021
Installation………………………………………………………………………………………1027
Completing Work……………………………………………………………………………………1027
Section View………………………………………………………………………………………1028
Disassembly……………………………………………………………………………………….1030
Preparation……………………………………………………………………………………1030
General Precautions…………………………………………………………………………….1030
Disassembly Procedure…………………………………………………………………………..1031
Reassembly………………………………………………………………………………………..1044
Preparation……………………………………………………………………………………1044
General Cautions……………………………………………………………………………….1044
Reassembly Procedure……………………………………………………………………………1044
Matters to Check after Assembly………………………………………………………………….1060
Performance Test…………………………………………………………………………………..1060
Troubleshooting……………………………………………………………………………………1062
Track Assembly………………………………………………………………………………………..1065
Safety Instructions………………………………………………………………………………..1069
General…………………………………………………………………………………………..1069
Track Tension……………………………………………………………………………………..1070
Track Shoes and Links………………………………………………………………………………1072
Parts List…………………………………………………………………………………….1072
Track Removal………………………………………………………………………………….1073
Track Installation……………………………………………………………………………..1075
Wear Limits and Tolerances………………………………………………………………………1076
Sprocket………………………………………………………………………………………….1078
Wear Limits and Tolerances………………………………………………………………………1078
Front Idler……………………………………………………………………………………….1079
Overview………………………………………………………………………………………1079
Parts List…………………………………………………………………………………….1080
Front Idler Disassembly…………………………………………………………………………1081
Front Idler Reassembly………………………………………………………………………….1082
Wear Limits and Tolerances………………………………………………………………………1084
Upper Roller………………………………………………………………………………………1085
Overview………………………………………………………………………………………1085
Parts List…………………………………………………………………………………….1086
Upper Roller Removal……………………………………………………………………………1087
Upper Roller Disassembly………………………………………………………………………..1087
Upper Roller Reassembly…………………………………………………………………………1089
Wear Limits and Tolerances………………………………………………………………………1090
Lower Roller………………………………………………………………………………………1091
Overview………………………………………………………………………………………1091
Parts List…………………………………………………………………………………….1092
Lower Roller Removal……………………………………………………………………………1093
Lower Roller Installation……………………………………………………………………….1093
Lower Roller Disassembly………………………………………………………………………..1094
Lower Roller Reassembly…………………………………………………………………………1095
Wear Limits and Tolerances………………………………………………………………………1096
Track Adjuster…………………………………………………………………………………….1098
Parts List…………………………………………………………………………………….1098
Disassembly……………………………………………………………………………………1099
Assembly………………………………………………………………………………………1100
Dozer System………………………………………………………………………………………….1103
Safety Instructions………………………………………………………………………………..1107
General Description………………………………………………………………………………..1108
Hydraulic Circuit………………………………………………………………………………….1109
Front……………………………………………………………………………………………………1111
Boom and Arm………………………………………………………………………………………….1113
Safety Instructions………………………………………………………………………………..1117
Specifications…………………………………………………………………………………….1118
One – Piece Boom……………………………………………………………………………….1118
Two – Piece Boom……………………………………………………………………………….1120
Removal…………………………………………………………………………………………..1122
Arm Removal……………………………………………………………………………………1122
Boom Removal…………………………………………………………………………………..1124
Installation………………………………………………………………………………………1125
Arm Installation……………………………………………………………………………….1125
Boom Installation………………………………………………………………………………1125
Completing Work……………………………………………………………………………………1125
Bucket……………………………………………………………………………………………….1127
Safety Instructions………………………………………………………………………………..1131
Bucket Tooth Inspection and Replacement………………………………………………………………1132
Bucket Detaching and Reversal……………………………………………………………………….1135
Detaching……………………………………………………………………………………..1135
Reversal………………………………………………………………………………………1135
Cylinders…………………………………………………………………………………………….1137
Safety Instructions………………………………………………………………………………..1141
General…………………………………………………………………………………………..1141
General Description…………………………………………………………………………….1141
Specification………………………………………………………………………………….1141
Parts List…………………………………………………………………………………….1142
Theory of Operation…………………………………………………………………………….1156
Seal of Cylinder……………………………………………………………………………….1157
Special Tools and Materials………………………………………………………………………… 0
Rod Bushing (DD-bushing) Pushing-in Jig…………………………………………………………..1165
Disassembly……………………………………………………………………………………….1166
Reassembly………………………………………………………………………………………..1171
Troubleshooting……………………………………………………………………………………1175
Hydraulic System………………………………………………………………………………………….1177
Hydraulic System………………………………………………………………………………………1179
Safety Instructions………………………………………………………………………………..1183
Hydraulic System…………………………………………………………………………………..1183
General Description…………………………………………………………………………….1183
Hydraulic Schematic………………………………………………………………………………..1184
General Description…………………………………………………………………………….1184
Hydraulic Component and Oil Flow…………………………………………………………………….1186
Hydraulic Components……………………………………………………………………………1186
Main Oil Circuit……………………………………………………………………………….1188
Pilot Oil Circuit………………………………………………………………………………1189
Return Oil Circuit……………………………………………………………………………..1190
Safety Cutoff Valve Operation……………………………………………………………………….1191
Power Up Valve Operation……………………………………………………………………………1192
Travel High-speed Valve Operation……………………………………………………………………1193
Swing Brake Release Operation……………………………………………………………………….1195
Travel Forward and Backward Operation………………………………………………………………..1197
Boom Up Operation………………………………………………………………………………….1198
Boom Down Operation………………………………………………………………………………..1200
Easy Boom Operation………………………………………………………………………………..1202
Arm Dump Operation…………………………………………………………………………………1204
Arm Crowd Operation………………………………………………………………………………..1206
Bucket Dump Operation………………………………………………………………………………1208
Bucket Crowd Operation……………………………………………………………………………..1210
Combined Bucket Crowd and Boom Up Operation…………………………………………………………..1212
Combined Travel and Boom, Arm, Bucket or Swing Operation……………………………………………….1213
Two Pump Operation…………………………………………………………………………………1214
Hydraulic System Testing and Adjustment………………………………………………………………….1215
Safety Instructions………………………………………………………………………………..1219
Procedural Troubleshooting Baseline Recommendations……………………………………………………1220
Initial Checks and Tests to Establish Operating Condition of the Excavator……………………………1220
Pilot Pressure…………………………………………………………………………………….1222
Adjustment and Testing………………………………………………………………………….1222
Power Mode Valve…………………………………………………………………………………..1223
Current Signal and Hydraulic Pressure Adjustments………………………………………………….1223
Pressure Up Valve………………………………………………………………………………….1224
Checks and Adjustments………………………………………………………………………….1224
Pump Input Power Control……………………………………………………………………………1226
Pump Regulator Adjustment……………………………………………………………………….1226
Flow Meter and Flow Meter Kit Installation and Testing…………………………………………………1229
Swing System Troubleshooting………………………………………………………………………..1231
Precautions/Initial Checks………………………………………………………………………1231
Swing Relief Valve Checking and Adjustment………………………………………………………..1232
Hydraulic System Troubleshooting………………………………………………………………………..1235
Safety Instructions………………………………………………………………………………..1239
Hydraulic System…………………………………………………………………………………..1239
Unusual Noise Comes Out from Pump Connection………………………………………………………1239
Engine Starts but Machine Does Not Operate………………………………………………………..1240
Hydraulic Oil is Cloudy…………………………………………………………………………1241
Hydraulic Oil Overheated………………………………………………………………………..1241
Hydraulic Pump Cavitation……………………………………………………………………….1242
Hydraulic Oil is Contaminated……………………………………………………………………1242
Boom, Arm, Bucket Speed is Slow………………………………………………………………….1243
Boom, Arm or Bucket Power is Weak………………………………………………………………..1244
Cylinder Moves When Remote Control Valve is in the Neutral Position………………………………….1244
TR (L), TR (R) Swing Does Not Operate When Remote Control Valve Operated……………………………..1245
Swing Speed is Slow…………………………………………………………………………….1246
Does Not Operate Boom Floating…………………………………………………………………..1247
Machine Swings but Does Not Stop…………………………………………………………………1247
One Side Speed is Falls and the Machine Curves…………………………………………………….1248
Machine Does Not Stop on a Slope…………………………………………………………………1249
Travel Motor is Powerless (Travel Only)…………………………………………………………..1249
Machine Makes a Curved Travel, When Travel and Actuator Operation are Executed a the Same Time………….1250
Does Not Travel is 2nd Speed or Auto Speed………………………………………………………..1250
Troubleshooting – Swing Gearbox……………………………………………………………………..1251
Troubleshooting – Hydraulic Problems…………………………………………………………………1252
Troubleshooting – Control Valve……………………………………………………………………..1254
Troubleshooting – Travel Control Valve……………………………………………………………….1255
Troubleshooting – Joystick Control Valve……………………………………………………………..1256
Electrical System…………………………………………………………………………………………1257
Electrical System……………………………………………………………………………………..1259
Safety Instructions………………………………………………………………………………..1265
Introduction………………………………………………………………………………………1265
Electrical Supply System……………………………………………………………………………1266
Engine Starting Circuit…………………………………………………………………………….1268
Start Operation………………………………………………………………………………..1268
After Start……………………………………………………………………………………1270
Engine Stop……………………………………………………………………………………….1272
Monitoring System………………………………………………………………………………….1275
Instrument Panel……………………………………………………………………………….1276
Functional Check……………………………………………………………………………….1276
Monitoring System Schematic……………………………………………………………………..1278
Operation…………………………………………………………………………………………1280
Instruments……………………………………………………………………………………1280
Warning and Indicator Lights……………………………………………………………………….. 0
Indication of Multifunction Gauge………………………………………………………………..1285
Initial Operation………………………………………………………………………………….1287
Graphic Information Area Display…………………………………………………………………….1288
Overview………………………………………………………………………………………1288
Main Menus for the Graphic Display Area…………………………………………………………..1288
Menu Selector Buttons…………………………………………………………………………..1288
User Menu…………………………………………………………………………………………1289
User Menu – Access and Escape Methods…………………………………………………………….1289
Special Menu………………………………………………………………………………………1326
Entering/Accessing and Exiting/Escaping Menus……………………………………………………..1326
Special Menu Selections…………………………………………………………………………1327
Failure Code………………………………………………………………………………………1343
Failure Code at Machine…………………………………………………………………………1343
Failure Code at Engine Side……………………………………………………………………..1346
FMIs (Failure Mode Identifier)…………………………………………………………………..1354
Electronic Hydraulic Control System (EPOS)……………………………………………………………1356
Control System Schematic………………………………………………………………………..1356
Power Plus Mode Control…………………………………………………………………………….1358
Operation……………………………………………………………………………………..1360
Power Mode Control…………………………………………………………………………………1362
Smart Power Control (SPC)…………………………………………………………………………..1364
Operation……………………………………………………………………………………..1364
Engine Control System………………………………………………………………………………1367
Engine Control Dial………………………………………………………………………………..1368
Engine Control…………………………………………………………………………………….1370
Automatic Deceleration Control (Auto Idle Control)…………………………………………………….1372
Engine Overheat Protection System……………………………………………………………………1374
Power Boost Mode…………………………………………………………………………………..1377
Operation……………………………………………………………………………………..1377
Power Boost Control…………………………………………………………………………….1378
Automatic Travel Speed Control………………………………………………………………………1380
Water in Fuel Warning System………………………………………………………………………..1383
Operation……………………………………………………………………………………..1383
Self-diagnostic Function……………………………………………………………………………1384
EPOS Controller………………………………………………………………………………..1384
Air Conditioner System……………………………………………………………………………..1386
Outline……………………………………………………………………………………….1386
Internal and External Filters……………………………………………………………………1387
Air-Conditioning System Layout…………………………………………………………………..1388
Air Conditioner/Heater Unit……………………………………………………………………..1392
Ambient Air Temperature Sensor…………………………………………………………………..1397
Receiver Dryer…………………………………………………………………………………1406
Troubleshooting……………………………………………………………………………………1407
Refrigerant System Repairs………………………………………………………………………….1409
Refrigerant Safe Handling Procedures……………………………………………………………..1409
Repair and Replacement Procedure…………………………………………………………………1410
Refrigerant Recovery……………………………………………………………………………1412
Vacuuming Refrigerant System…………………………………………………………………….1412
Leakage Check………………………………………………………………………………….1414
Refrigerant Charging……………………………………………………………………………1414
Inspecting System For Leakage……………………………………………………………………1416
Wiper System……………………………………………………………………………………… 0
Wiper Operation………………………………………………………………………………..1418
Lighting System…………………………………………………………………………………… 0
Kind of Light………………………………………………………………………………….1421
Operation……………………………………………………………………………………..1421
Overload Warning Device…………………………………………………………………………….1422
Overload Warning Device Circuit Diagram…………………………………………………………..1422
Options………………………………………………………………………………………………….1425
One Way………………………………………………………………………………………………1427
Safety Instructions………………………………………………………………………………..1431
General…………………………………………………………………………………………..1431
General Description…………………………………………………………………………….1431
Theory of Operation…………………………………………………………………………….1431
Hydraulic Circuit………………………………………………………………………………1432
Caution for Installation………………………………………………………………………..1433
Installation Procedure……………………………………………………………………………..1434
Main Piping – One and Two-way……………………………………………………………………1434
Main Piping – One Way…………………………………………………………………………..1436
Boom Piping – One and Two-way……………………………………………………………………1442
Arm Piping – One or Two-way……………………………………………………………………..1444
After Installation Precautions…………………………………………………………………..1445
Air Bleeding…………………………………………………………………………………..1445
Completing Work……………………………………………………………………………………1446
Two-way………………………………………………………………………………………………1447
Safety Instructions………………………………………………………………………………..1451
General…………………………………………………………………………………………..1451
General Description…………………………………………………………………………….1451
Theory of Operation…………………………………………………………………………….1451
Structure……………………………………………………………………………………..1452
Hydraulic Circuit………………………………………………………………………………1453
Caution for Installation………………………………………………………………………..1455
Installation Procedure……………………………………………………………………………..1456
Main Piping – One and Two-way……………………………………………………………………1456
Main Piping – Two-way…………………………………………………………………………..1458
Pilot Piping – Two-way………………………………………………………………………….1462
Boom Piping – One and Two-way……………………………………………………………………1466
Arm Piping – One or Two-way……………………………………………………………………..1468
After Installation Precautions…………………………………………………………………..1469
Air Bleeding…………………………………………………………………………………..1469
Completing Work……………………………………………………………………………………1470
Rotating……………………………………………………………………………………………..1471
Safety Instructions………………………………………………………………………………..1475
General…………………………………………………………………………………………..1475
General Description…………………………………………………………………………….1475
Theory of Operation…………………………………………………………………………….1475
Structure……………………………………………………………………………………..1476
Hydraulic Circuit………………………………………………………………………………1477
Caution for Installation………………………………………………………………………..1478
Installation Procedure……………………………………………………………………………..1480
Main Piping – Rotating………………………………………………………………………….1480
Pilot Piping – Rotating…………………………………………………………………………1482
Boom Piping – Rotating………………………………………………………………………….1484
Arm Piping – Rotating…………………………………………………………………………..1486
After Installation Precautions…………………………………………………………………..1487
Air Bleeding…………………………………………………………………………………..1487
Completing Work……………………………………………………………………………………1487
Quick Coupler…………………………………………………………………………………………1489
Safety Instructions………………………………………………………………………………..1493
General…………………………………………………………………………………………..1493
General Description…………………………………………………………………………….1493
Theory of Operation…………………………………………………………………………….1493
Hydraulic Circuit………………………………………………………………………………1494
Caution for Installation………………………………………………………………………..1495
Quick Coupler Operation…………………………………………………………………………….1496
Securing Work Tool……………………………………………………………………………..1496
Attaching Quick Coupler to Excavator……………………………………………………………..1496
Releasing the Work Tool…………………………………………………………………………1498
Installation Procedure……………………………………………………………………………..1500
Main Piping – Quick Coupler……………………………………………………………………..1500
Electric Parts – Quick Coupler…………………………………………………………………..1501
Boom Piping – Quick Coupler……………………………………………………………………..1502
Arm Piping – Quick Coupler………………………………………………………………………1504
After Installation Precautions…………………………………………………………………..1505
Air Bleeding…………………………………………………………………………………..1505
Completing Work……………………………………………………………………………………1505
Two Pump……………………………………………………………………………………………..1507
Safety Instructions………………………………………………………………………………..1511
General…………………………………………………………………………………………..1511
General Description…………………………………………………………………………….1511
Theory of Operation…………………………………………………………………………….1511
Hydraulic Circuit………………………………………………………………………………1512
Caution for Installation………………………………………………………………………..1513
Installation Procedure……………………………………………………………………………..1514
Main Piping – Two Pump………………………………………………………………………….1514
After Installation Precautions…………………………………………………………………..1518
Air Bleeding…………………………………………………………………………………..1518
Schematic………………………………………………………………………………………………..1519
Hydraulic Schematic/ Electrical Schematic………………………………………………………………..1521
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