Doosan DX480LC - Hydraulic System Troubleshooting, Testing and Adjustment

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SP001751

Page 1

Hydraulic System Troubleshooting, Testing and Adjustment

S

P001751

HYDRAULIC SYSTEM TROUBLESHOOTING,

TESTING AND ADJUSTMENTSP001751

Hydraulic System

Troubleshooting,

Testing and

Adjustment

Edition 1

Table of Contents

Table of Contents11
- Track Excavator Safety13
- Safety Precautions13
- Applicable Models13
- To the Operator of a DOOSAN Excavator14
- General Safety Essentials17
- Location of Safety Labels18
- Summary of Safety Precautions for Lifting in Digging Mode18
- Unauthorized Modifications19
- General Hazard Information19
- Before Starting Engine28
- Machine Operation32
- Maintenance39
- Battery47
- Towing49
- Shipping and Transportation50
- Lifting with Sling50
Table of Contents55
- Applicable Models57
- Safety Precautions57
- General Description59
- Component Locations60
- General Dimensions62
- Working Range64
- General Specifications66
- Engine Performance Curves (Per DIN 6270 Standard)68
- Approximate Weight of Workload Materials70
- Performance Tests72
- Excavator Performance Standards73
- Test Conditions73
- Travel Speed and Travel Motor Balance (Steering Deviation) Tests73
- Swing Speed and Deceleration Force Test75
- Cylinder Performance Tests77
Table of Contents83
- Applicable Models85
- Safety Precautions85
- Welding Precautions and Guidelines86
- Hydraulic System - General Precautions87
- General Precautions89
- Maintenance Service and Repair Procedure89
- Hydraulic System Cleanliness and Oil Leaks90
- Maintenance Precautions for Hydraulic System Service1090
- Oil Leakage Precautions91
- Cleaning and Inspection92
- General Guidelines92
- Bearing Inspection93
Table of Contents103
- Applicable Models105
- Safety Precautions105
- Torque Values for Standard Metric Fasteners106
- Torque Values for Standard U.S. Fasteners107
- Type 8 Phosphate Coated Hardware109
- Torque Values for Hose Clamps110
- Torque Values for Split Flanges111
- Torque Multiplication112
- Torque Wrench Extension Tools112
- Other Uses for Torque Wrench Extension Tools113
- Tightening Torque Specifications (Metric)114
Table of Contents121
- Applicable Models123
- Cabin123
- Safety Precautions123
- Removal124
- Installation128
Table of Contents133
- Applicable Models135
- Safety Precautions135
- General136
- Warning for Counterweight and Front Attachment Removal6136
- Removal138
- Installation139
Table of Contents143
- Applicable Models145
- Safety Precautions145
- General Description146
- Parts List146
- Specifications147
- Removal148
- Installation152
- Start-Up Procedures155
Table of Contents159
- Applicable Models161
- Safety Precautions161
- General Description162
- Theory of Operation162
- Replacement of Rotor and Vane163
- Troubleshooting163
- Replacement of Armature164
- Replacement of Rear Cover164
Table of Contents167
- Applicable Models169
- Safety Precautions169
- Measuring Bearing Lateral Play170
- Measuring Swing Bearing Axial Play170
- Operating Recommendation170
- Swing Bearing Maintenance170
- Disassembly171
- Swing Bearing Basic Operation171
- Assembly173
Table of Contents177
- Applicable Models179
- Safety Precautions179
- General Description181
- Theory of Operation181
- Parts List182
- Specifications183
- Troubleshooting, Testing and Adjustment184
- Removal185
- Disassembly186
- Cleaning and Inspection (Wear Limits and Tolerances)195
- Assembly of Carrier Subassemblies196
- Reassembly196
- Shaft and S/R Bearing Heat-Fit196
- Assembly of Main Case202
- Assembly of Motor218
- Installation222
- Start-Up Procedures223
Table of Contents229
- Applicable Models231
- Safety Precautions231
- General Description232
- Track Tension233
- Cleaning and Inspection235
- Track Shoe236
- Lower Roller238
- Upper Roller239
- Front Idler240
- Track Removal241
- Track Shoes and Links241
- Track Installation242
- Front Idler Roller244
- Parts List244
- Front Idler Roller Disassembly245
- Front Idler Roller Reassembly247
- Lower Roller248
- Parts List248
- Lower Roller Disassembly249
- Lower Roller Removal249
- Lower Roller Reassembly250
- Lower Roller Installation251
- Parts List252
- Upper Roller252
- Upper Roller Disassembly253
- Upper Roller Removal253
- Upper Roller Reassembly255
- Parts List256
- Track Spring and Track Adjusting Cylinder256
Table of Contents261
- Applicable Models263
- Safety Precautions263
- Drive Coupling264
- Special Tools265
- Drive Coupling Installation266
- Installation Procedure268
Hydraulic System Troubleshooting, Testing and Adjustment/Hydraulic System Troubleshooting, Testing and Adjustment273
- Hydraulic System Troubleshooting, Testing and Adjustment274
- Applicable Models275
- Safety Precautions275
- General Notes276
- Hydraulic System - General Notes276
- Boom down Circuit279
- Boom Operating Circuit279
- Boom up Circuit279
- Operation of Working Components279
- Arm Crowd Circuit280
- Arm Dump Circuit280
- Arm Operating Circuit280
- Bucket Crowd Circuit281
- Bucket Dump Circuit281
- Bucket Operating Circuit281
- Swing Operating Circuit281
- Left Swing Operating Circuit282
- Right Swing Operating Circuit282
- Swing Relief Valve and Makeup Valve282
- Travel Operating Circuit282
- Forward Travel Circuit283
- Reverse Travel Circuit283
- Initial Checks and Tests to Establish Operating Condition of the Excavator284
- Procedural Troubleshooting Baseline Recommendations284
- Adjustment and Testing286
- Pilot Pressure286
- Current Signal and Hydraulic Pressure Adjustments287
- Power Mode Valve287
- Checks and Adjustments288
- Pressure up Valve288
- Pump Input Power Control290
- Pump Regulator Adjustment290
- Flow Meter and Flow Meter Kit Installation and Testing293
- Precautions/Initial Checks295
- Swing System Troubleshooting295
- Swing Relief Valve Checking and Adjustment296
- Troubleshooting - Swing Gearbox298
- Troubleshooting - Hydraulic Problems299
- Troubleshooting - Control Valve301
- Troubleshooting - Travel Control Valve302
- Troubleshooting - Joystick Control Valve303
Table of Contents307
- Applicable Models309
- Safety Precautions309
- General Description310
- Specifications312
Table of Contents315
- Applicable Models317
- Safety Precautions317
- General Description318
- Parts List319
- Inspection320
- Testing320
- Troubleshooting, Testing and Adjustment320
- Disassembly321
- Reassembly324
Table of Contents329
- Applicable Models331
- Safety Precautions331
- General Description332
- Theory of Operation332
- Parts List334
- Piston Nut336
- Special Tools and Materials336
- Piston Jig338
- Steel Bushing Jig340
- Dust Wiper Jig342
- Slipper Seal Jig344
- Slipper Seal Straightening Jig346
- Disassembly348
- Reassembly353
Table of Contents359
- Applicable Models361
- Safety Precautions361
- General Description362
- Theory of Operation362
- Makeup Check Valve365
- Operation of Swing Reactionless Valve365
- Operation of Time Delay Valve365
- Parts List366
- Specifications368
- Torques368
- Tools369
- Tools and Materials369
- General Precautions370
- How to Check Faults of Hydraulic Motor370
- Troubleshooting370
- Troubleshooting, Testing and Adjustment370
- Disassembly372
- General Cautions372
- Cleaning and Inspection (Wear Limits and Tolerances)379
- Assembly380
- General Cautions380
- Reassembly380
- Assembly of Cylinder Block Assembly Subassembly383
- Assembly of Rear Cover Assembly Subassembly387
- Air Pressure Test393
- Oil Leakage Check393
Table of Contents397
- Applicable Models399
- Safety Precautions399
- General Description401
- Structure401
- Operation Basics402
- Parts List408
- Connection Torque410
- Specifications410
- General Precautions412
- How to Check Faults of Hydraulic Motor412
- Troubleshooting412
- Troubleshooting, Testing and Adjustment412
- Disassembly414
- General Cautions414
- Disassembly of Cylinder Subassembly420
- Cleaning and Inspection422
- Maintenance Standard422
- Tolerances)422
- General Cautions426
- Reassembly426
- Reassembly of Drive Shaft Subassembly426
- Assembly of Valve Casing Subassembly427
- Assembly of Cylinder Subassembly431
- Assembly of Motor Body433
Table of Contents441
- Applicable Models443
- Safety Precautions443
- Axial Piston Pump444
- General Description444
- Model Number Designation444
- Theory of Operation445
- Parts List446
- Torques448
- Tools449
- Troubleshooting, Testing and Adjustment451
- Disassembly453
- Cleaning and Inspection (Wear Limits and Tolerances)456
- Worn Part Replacement Criteria456
- Correction Criteria for Cylinder, Valve Plate and457
- Plate (Shoe Plate)457
- Reassembly458
- Cautions During Starting Operation462
- Oil Filling and Air Venting462
- Start-Up Procedures462
- General Description463
- Model Number Designation463
- Regulator for Axial Piston Pump463
- Parts List464
- Outline465
- Functional Explanations467
- Specifications467
Table of Contents487
- Applicable Models489
- Gear Pump489
- Safety Precautions489
- Disassembly490
- Single Gear Pump490
- Reassembly492
- Disassembly496
- Double Gear Pump496
- Reassembly498
Table of Contents505
- Parts List540
- Specifications545
- Troubleshooting546
- Troubleshooting, Testing and Adjustment546
- Adjustment of Valves547
- Disassembly549
- Cleaning559
- Cleaning and Inspection (Wear Limits and Tolerances)559
- Inspection559
- Caution on Assembly560
- Reassembly560
- Sequence of Subassembly561
- Maintenance of Relief Valves567
- Installation570
- Start-Up Procedures570
Table of Contents573
- Applicable Models575
- Safety Precautions575
- General Description577
- Theory of Operation577
- Parts List578
- Specifications580
- Tools and Materials580
- Torques580
- Disassembly581
- Cleaning and Inspection585
- Reassembly585
- Tolerances)585
- Start-Up Procedures592
Table of Contents621
- Applicable Models623
- Safety Precautions623
- 5-Solenoid Valve624
- Parts List624
- Functions of 5-Solenoid Valve Assembly625
- Assembly Diagram and Tools Required628
- Cautions During Disassembly and Reassembly629
- Solenoid Valve Diagram630
- Check Points and Solutions for Problems631
- 2-Solenoid Valve632
- Parts List632
- Assembly Diagram and Tools Required633
- Cautions During Disassembly and Reassembly634
- Solenoid Valve Diagram635
Table of Contents639
- Applicable Models641
- Breaker EPPR Valve (Opt)641
- Safety Precautions641
- Numbers and Names of Parts642
- Structure642
- Cautions for Operation643
- Functions and Operation643
- Maintenance644
- Maintenance Instructions644
- Disassembly645
- Assembly646
Table of Contents661
- Applicable Models664
- Safety Precautions664
- Introduction665
- Electrical Supply System666
- Engine Starting Circuit668
- Engine Preheating System672
- Engine Stop674
- Charging System676
- Monitoring System677
- Operation682
- Warning and Indicator Lights684
- Initial Operation687
- Mode Selector Switch687
- Graphic Information Area Display688
- Main Menu690
- Special Menu695
- Electronic Hydraulic Control System (E-EPOS)712
- Power Mode Control714
- Power Mode Control - Circuit Diagram719
- Engine Control System720
- Engine Control Motor721
- Engine Control Dial722
- Engine Control Circuit Diagram723
- Automatic Deceleration Control (Auto Idle Control)724
- Engine Overheat Protection System726
- Power Boost Mode728
- Automatic Travel Speed Control730
- Self-Diagnostic Function733
- Air Conditioner System735
- Troubleshooting755
- Weight of R134A Gas Used in Machines757
- Refrigerant System Repairs758
- Wiper System766
- Lighting System768
- Overload Warning Device770
- Audio Controller771
Table of Contents785
- Applicable Models787
- Boom and Arm787
- Safety Precautions787
- Front Attachment Pin Specifications788
- Dx300Lc789
- Dx340Lc / Dx350Lc790
- Dx420Lc791
- Dx480Lc / Dx520Lc792
- Arm Removal Procedure793
- Front Attachment - Removal and Installation793
- Boom Removal Procedure795
- Arm Installation Procedure796
- Boom Installation Procedure796
- Installation796
- Start-Up Procedures797
- Applicable Models803
- Bucket803
- Safety Precautions803
- Bucket Tooth Inspection and Replacement804
- Bucket O-Ring Replacement805
- Bucket Shimming Procedures807
- New Bucket Installation807
- Attaching the Bucket809
- Bucket Attachment, Removal and Reversal809
- Detaching the Bucket809
- Reversing the Bucket810

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