DOOSAN PRODUCT OVERVIEW

Excavator

Mar, 2012
Product Support, AP/E
DICE
TABLE OF CONTENTS

1. PRODUCTS OF DOOSAN
2. PRODUCT NAMING
3. PRODUCT IDENTIFICATION
4 MAJOR COMPONENTS
4.
5. APPLICATIONS
6 OPTIONS
6.
7. WORKING PRINCIPLE

2
CRAWLER EXCAVATOR

Crawler Excavator DX300LC

3
WHEEL EXCAVATOR

Wheel Excavator DX140W

4
WHEEL LOADER

Wheel Loader DL500

5
JOBS OF EXCAVATOR

Digging
X Breaker or others
Lifting

Loading

Material handing

6
TABLE OF CONTENTS

1. PRODUCTS OF DOOSAN
2. PRODUCT NAMING
3. PRODUCT IDENTIFICATION
4 MAJOR COMPONENTS
4.
5. APPLICATIONS
6 OPTIONS
6.
7. WORKING PRINCIPLE

7
PRODUCT NAMING DX / DL
Excavator
Working type
DX 300 LC DX 140 W
VT: Variable track
Model version
W : Wheel
Long Crawler type Wheel type LC : Long Crawler
NLC : Narrow Long Crawler
Machine weight Machine weight
g
LL : Log Loader
Model name Model name SLR : Super Long Reach

Wheel loader
DL 420
Working type
TC: Tool Carrier
Model version
DX225LCA Tier 2 Engine
Bucket capacity (m3)

Model name DX300LCA - Tier 2 Engine

DX140LCR Radius Zero Tail

DX235LCR - Radius Zero Tail

8
PRODUCT NAMING SOLAR / MEGA
Excavator
Working type
Solar 300 LC V Solar 140 W - V
VT: Variable track
Model version Model version
W : Wheel
Long Crawler type Wheel type LC : Long Crawler
NLC : Narrow Long Crawler
Machine weight Machine weight
g
LL : Log Loader
Model name Model name SLR : Super Long Reach

Wheel loader
Mega 400 - V
Working type
TC: Tool Carrier
Model version

Bucket capacity (m3)

Model name
Steer Skid Loader

N special
No i l meaning..
i JJustt callll tto 430
430, 440
440, 450
450.

9
TABLE OF CONTENTS

1. PRODUCTS OF DOOSAN
2. PRODUCT NAMING
3. PRODUCT IDENTIFICATION
4 MAJOR COMPONENTS
4.
5. APPLICATIONS
6 OPTIONS
6.
7. WORKING PRINCIPLE

10
MACHINE IDENTIFICATION

11
MACHINE IDENTIFICATION

12
MACHINE IDENTIFICATION

13
MACHINE IDENTIFICATION

DHK means that this was manufactured in Doosan Korea [factory]

CEBAC means DX225LCA [ [model]]
L is code for checking validation of pin no. [verification code]
A0007202 is machine serial no. [serial no.]

14
ENGINE IDENTIFICATION

15
ENGINE IDENTIFICATION

16
ENGINE IDENTIFICATION

17
TABLE OF CONTENTS

1. PRODUCTS OF DOOSAN
2. PRODUCT NAMING
3. PRODUCT IDENTIFICATION
4 MAJOR COMPONENTS
4.
5. APPLICATIONS
6 OPTIONS
6.
7. WORKING PRINCIPLE

18
 MAJOR COMPONENTS _ OVERVIEW
Arm Cylinder
Boom
Engine hood
Cabin

Arm Hydraulic Oil

Lines Counterweight

Boom Cylinder

Bucker Cylinder

Bucket

Undercarriage (Lower structure)

* FOPS (Falling Object Protective Structure) Cabin
* ROPS (Rolling Over Protective Structure) Cabin , * FOGS (Falling Object Guard Structure) Cabin 19
MAJOR COMPONENTS _ UPPER STRUCTURE

A
B

A B
MAJOR COMPONENTS _ UPPER STRUCTURE

C
MAJOR COMPONENTS _ UPPER STRUCTURE

22
MAJOR COMPONENTS _ UPPER STRUCTURE

23
MAJOR COMPONENTS _ UPPER STRUCTURE
View from top View from side

View from side

View from top

Radiator
- Discharge hot Temp. of engine heat through
coolant to air

Oil cooler
- Discharge hot Temp. of hydraulic oil to air

Intercooler
- Cool down hot intake air temp.of engine by
turbocharger
24
MAJOR COMPONENTS _ FRONT

Guide link

Bucket Pin

Push link

Tooth

Side cutter
Bucket

25
MAJOR COMPONENTS _ HYDRAULIC SYSTEM

Diesel engine
Making mechanical energy from chemical material (Diesel)

Oil cooler & Radiator

Cooling hydraulic oil from actuator return line and
engine
i coolant.
l t

Control valve
g oil to HYD. actuator by
Distribute discharged y
operator control signal

Main pump
Making HYD energy ( Making flow)
Hydraulic oil tank (Pressurized tank)
Storage hydraulic oil,
oil remove air bubble and cleaning oil
- Suction filter : It is placed before main pump suction line
- Full flow filter : It is placed before return oil in-let line

26
MAJOR COMPONENTS _ HYDRAULIC SYSTEM

Swing device
- Swing motor
Change hydraulic
Ch h d li energy to rotating
i mechanical
h i l
energy (High shaft speed Low torque)
- Swing reduction gear
Change high
Ch hi h motor
t speed d tto llow speed
d ffor machine
hi
swing. (Reduce motor shaft speed Increase swing
output power)

Center Joint
Connect hydraulic oil to lower hydraulic actuator
without hose connection

Swing bearing
Connect upper & lower structure and can be swing

27
MAJOR COMPONENTS _ HYDRAULIC SYSTEM

28
MAJOR COMPONENTS _ UNDERCARRIAGE

Track frame

Idler & track

Upper roller spring

Travel device
Track guard
(Travel motor + Track tension
reduction gear) Lower roller adjustment cylinder

Track shoe

Sprocket Track link

29
 MAJOR COMPONENTS _ UNDERCARRIAGE

Upper roller

Idler & track

spring

Travel device
Track shoe
(Travel motor +
reduction
d i gear))

Track guard Lower roller

30
 MAJOR COMPONENTS _ UNDERCARRIAGE

Sprocket

Track Shoe
Track Link

31
MAJOR COMPONENTS _ UNDERCARRIAGE

32
 MAJOR COMPONENTS _ UNDERCARRIAGE

Upper roller
S pport track link
Support

Lower roller
Supportt machine
S hi weight
i ht on
track link
Travel device
- Travel motor ((High/Low
g speed)) Idler
Change hydraulic energy to rotating
mechanical energy
- Travel reduction gear
Track
T k lilink
k
Change high motor speed to low speed for
machine traveling. (Reduce motor speed,
Increase output power)
- Sprocket
Transmit output power from reduction gear to Track spring
track link for traveling Adjust track link tension and absorb tension shock
while traveling

33
MAJOR COMPONENTS _ WHEEL EXCAVATOR

Ram cylinder
Step

Chassis frame

Dozer blade

Front axle with Rear axle Rear axle hub

steering cylinder Drive shaft

Front axle hub

Outrigger
Travel motor & Transmission

34
 MAJOR COMPONENTS _ WHEEL EXCAVATOR

Rear axle Front axle

Transmit transmission power to tire and stop Transmit transmission power to tire
machine traveling
stop machine
hi traveling
li and
d steering
i ffront wheel
h l
Gear oil lubrication
Dozer cylinder Gear oil lubrication

Dozer blade
Stabilize machine and
making flat ground
Drive shaft
Ram cylinder
Transmission
Travel motor Absorb traveling jerk (yawing)
Change machine traveling speed
Change hydraulic energy to rotating
Engine oil lubrication
mechanical energy
35
MAJOR COMPONENTS _ ENGINE SYSTEM

Model Engine Remarks

S010 / S015+ / S018VT / S030+ / S035 / S55-V+ / S55W-V+ / S75-V

Yanmar
DX27Z / DX35Z
S140LC-V/ S175LC-V/ S225LC-V/ S225NLC-V
DB58 Series Turbo, Intercooler (Inline 6)
S255LC-V/ S140W-V/ S160W-V/ S180W-V/ S210W-V / DX225LCA
DX140W / DX140LC / DX180LC / DX190W / DX225(N)
( ) LC /
DL06 Common rail engine (Inline 6 /Tier
/Tier-III)
III)
DX255LC
S290LC-V / S300LC-V / DX300LCA DE08 Series Turbo, Intercooler (Inline 6)
DX300LC / DX340LC DL08 Common rail engine (Inline 6 / Tier-III)
S340LC-V / S420LC-V / S470LC-V / S500LC-V(G) DE12 Series Turbo, Intercooler (Inline 6)
DX420LC/ DX480LC (DX520LC) DV11 Common rail engine (V6 / Tier-III)

M160 / M200-V / M250-V DB58 Series Turbo, Intercooler (Inline 6)

M300-V DE08 Series Turbo, Intercooler (Inline 6)

DL300 DL08 Common rail engine (Inline 6 / Tier-III)

M400-V DE12 Series Turbo Intercooler (Inline 6)

Turbo,
Cummins
DL420 / DL500 ( M500-V) Common rail engine (Inline 6 / Tier-III)
(QSM11)

36
MAJOR COMPONENTS _ ENGINE

DB58 DE08 DE12

DL06 DL08 DV11

37
MAJOR COMPONENTS _ MAIN PUMP

Swash plate axial piston pump Bent axis piston pump

(KAWASAKI pump) (Rexroth pump)
38
MAJOR COMPONENTS _ MAIN PUMP

Making flow

Swash plate axial piston pump Bent axis piston pump

( KAWASAKI pump) ( Rexroth pump)

39
MAJOR COMPONENTS _ MAIN PUMP

Swash plate axial piston pump ( KAWASAKI type pump)

40
MAJOR COMPONENTS _ MAIN PUMP

Bent axis piston pump (Rexroth pump)

41
MAJOR COMPONENTS _ MAIN PUMP

Regulator
- Discharging oil flow is adjusted by machine working condition
(No working machine, low flow oil will be discharged. Working, lots oil flow will be discharged)
Pilot pump (gear pump)
- Supply pilot system oil (Low pressure - 40 bar) such as Joystick (pedal) lever
lever, Swing brake release
release.

Pilot pump

Regulator Regulator

Pilot pump
42
MAJOR COMPONENTS _ MAIN PUMP

Additional pump for option

Additional g
gear pump
p p (Option)
( p ) Additional g
gear pump
p p (STD/Option)
( p )
- Rotation - For Hydraulic cooling fan (DX480/520)
43
MAJOR COMPONENTS _ MAIN PUMP

Pump coupling (Drive coupling - New type)

- Connect engine power to main pump directly (Special plastic material)

Installed on engine fly wheel

34 44
MAJOR COMPONENTS _ MAIN CONTROL VALVE

DX Model (TOSHIBA) - Solar 3

3,V
V model
model, DX model
- DX22 : 13(wheel) ton, Solar- 3,V, DX140W
- DX28 : 17~ 33(wheel) ton, Solar-3,V, DX190W/210W
- UX36 : 40~45 ton, Solar- 3,V

KVMM Model (KAYABA) DX model

- KVMM160 : DX140LC, DX180

KVMG Model (KAYABA) New solar V & DX model

- KVMG 270 : S225,255,300,340 / DX225,255, 300,340
- KVMG 400 : S420,470,500 / DX420,480,520

45
MAJOR COMPONENTS _ MAIN CONTROL VALVE

9 spools
-Travel (L), Travel (R), Option, Swing, Bucket, Boom 1, Boom 2, Arm
1 Arm 2
1,

Main relief valve

- Restrict
R t i t max. system
t pressure (330bar)
(330b )
* Boost pressure (Power up) When press right side joystick switch
- Increase max system pressure (350Bar)

Priority valve
- For priority function swing, boom

Holding valve
- Protect
P t t oilil lleaking
ki ffrom actuator
t t ((cylinder)
li d ) tto control
t l valve
l

Over load valve( Protection valve, Safety valve)

- Protect actuator damage from sudden impact
46
MAJOR COMPONENTS _ MAIN CONTROL VALVE

47
MAJOR COMPONENTS _ SWING DEVICE

Fixed upper structure

Grease lubrication
Upper structure

Swing Bearing

Lower structure
Fixed lower structure

Swing Bearing

38 48
MAJOR COMPONENTS _ SWING DEVICE

Swing motor
- Hydraulic energy through control valve from
pump is changed to rotating energy
(High motor shaft speed / Low torque)

*S
Swing
i bbrake
k
No swing, swing brake is engaged
Swing machine, swing brake is released

*S
Swing
i relief
li f valve
l &RReactionless
ti l valve
l

Swing reduction gear

- Reduce motor speed, increase
torque.

* 2-Stage planetary gear

* Gear oil lubrication

Swing pinion gear

- Contact swing bearing directly and transmit
swing power to bearing for machine swing

39 49
MAJOR COMPONENTS _ SWING DEVICE

Swing motor

50
MAJOR COMPONENTS _ SWING DEVICE

Swing reduction gear

Pi i gear
Pinion

51
MAJOR COMPONENTS _ CENTER JOINT

Center joint
- Upper hydraulic power from hydraulic pump transmits to the lower hydraulic actuator without any hydraulic
hose connection
connection, It places on center of swing bearing

Fixed upper
structure

Fixed lower
structure

52
 MAJOR COMPONENTS _ TRAVEL DEVICE

Forward

Travel device
- Hydraulic energy through control valve from pump is changed to rotating
energy for traveling

- Travel motor : High motor shaft speed / Low torque Reverse

* Parking brake
No traveling, parking brake is engaged.
* High/Low shaft speed

- Reduction gear : Low output shaft speed / High torque

53
MAJOR COMPONENTS _ TRAVEL DEVICE

Travel Motor

Track Guard
54
MAJOR COMPONENTS _ TRAVEL DEVICE

Sprocket
Track frame

Track link & shoe

55
MAJOR COMPONENTS _ TRAVEL DEVICE

Reduction gear
- Planetary, Cluster, RV gear
- Gear oil lubrication

Travel motor

- Variable piston motor

High/ low traveling speed

- Parking brake

- Protect over run traveling

56
MAJOR COMPONENTS _ TRAVEL DEVICE

Variable axial piston motor Variable bent axial piston motor

-13 ~42 ton crawler - 45~ 52 ton crawler

57
MAJOR COMPONENTS _ TRAVEL MOTOR (WEX)

58
MAJOR COMPONENTS _ TRAVEL MOTOR (WEX)

Travel motor

Vent axis piston motor (Rexroth)

- 5 ~ 21 ton wheeled excavator.
- Auto torque control system.
- Over run prevent system.
- Retarding speed system (Hydaulic braking system)

59
MAJOR COMPONENTS _ TRANSMISSION (WEX)

Transmission

3 speed planetary gear transmission (ZF)

- Inching / Low / High travel speed.
- Towing
- Safety shifting system (Shafting inter lock)

60
MAJOR COMPONENTS _ TRANSMISSION (WEX)

Transmission

61
MAJOR COMPONENTS _ AXLE (WEX)

Axle

Planetary gear Axle (ZF)

- Wet type brake system.
- Increase brake system life time

62
MAJOR COMPONENTS _ CYLINDER

Rod cover
Piston
Rod

Tube

Rod side Head side

63
MAJOR COMPONENTS _ CYLINDER

Cylinder cushion (Damping)

Rod side damping Head side damping

48 64
MAJOR COMPONENTS _ REMOTE CONTROL VALVE

Remote control joystick valve

65
TABLE OF CONTENTS

1. PRODUCTS OF DOOSAN
2. PRODUCT NAMING
3. PRODUCT IDENTIFICATION
4 MAJOR COMPONENTS
4.
5. APPLICATIONS
6 OPTIONS
6.
7. WORKING PRINCIPLE

66
ARTI BOOM

Articulated Boom (2 Pieces)

67
ARTI BOOM
ARTI BOOM
ZERO TAIL EXCAVATOR

DX140LCR

70
DEMOLITION

Demolition Machine (3 Pieces)

71
LONG FRONT

Long Front (3 Pieces)

SLR Super Long Reach
72
MATERIAL HANDLER

S200W-VMH
MH Material Handler
73
LOG LOADER

DX300LL
LL Log Loader
74
DIMENSIONS

Arm length
Boom length

Bucket width

75
WORKING RANGE

A. Max. Digging Reach

B. Max. Digging Reach at Ground
Level
C. Max. Digging Depth
D. Max. Digging Height/Max. Cutting
Height
E. Max. Loading Height/Max. Dumping
Height
F. Min. Swing Radius
G Max.
G. M Digging
Di i Depth
D th For
F 8' Level
L l
H. Max. Vertical Wall Digging Depth
I. Max. Bucket Pin Height
J. Min. Loading Height)
K. Shipping Height

76
76
BUCKET

G.P(General Purpose) Bucket: bucket for general loading and digging

H.D(Heavy Duty) Bucket: To increase digging bucket digging force. Round shaped. Abrasion resistant material.
Rock Bucket: suitable for rocky area. No side cutter. Abrasion resistant material.
D.C(Ditch Cleaning) Bucket: wide bucket and drain holes on bottom plate for ditch work.
Narrow Bucket
Sand Bucket
Skeleton Bucket

GP BUCKET HD BUCKET DC BUCKET ROCK BUCKET

NARROW BUCKET SKELETON BUCKET 77

77
BUCKET CAPACITY

CECE 1 : 1/2
PCSA, SAE, ISO 1 : 1

CECE PCSA, SAE

SAE: Society of Automotive Engineers

ISO: International Organization for Standardization
CECE: Committee for European Construction Equipment 78
78
PCSA: Power Crane and Shovel Association
TABLE OF CONTENTS

1. PRODUCTS OF DOOSAN
2. PRODUCT NAMING
3. PRODUCT IDENTIFICATION
4 MAJOR COMPONENTS
4.
5. APPLICATIONS
6 OPTIONS
6.
7. WORKING PRINCIPLE

79
SPECIAL APPLICATION

Thumb Wood Grapple Clamshell

Ripper

Th b
Thumb Orange Grapple Fork

80
SPECIAL APPLICATION

CRUSHER

CLAMSHELL

Hydraulic Q/COUPLER
ROTO TILT Q/COUPLER

81
SPECIAL APPLICATION

SINGLE P
P. RIPPER

RAKE

HYD. THUMB MECHANICAL GRAPPLE MECHANICAL PULVERIZER STUMP SPLITTER

82
SPECIAL APPLICATION

Quick coupler Crusher

Breaker (Side mount / Top mount)

Compactor

83
OPTION PIPING

84
OPTION PIPING

Option Remarks

Main line
Two way breaker pipe
(PE3C) PILOT PEDAL AND ELECTRIC SWITCH OPERATED 3 WAY
Total piping COMBINATION PIPING (2-WAY BREAKER)

Main line
Rotating pipe
PILOT PEDAL AND ELECTRIC SWITCH OPERATED
(PERO) Total piping ROTATING PIPING (ROTATING)

Two pump proportional V/V DX420,480,520LC / TXC420,480,520-2

Fan drive valve, engine hood DX420,480,520LC

Tropical cooling system
Engine pulley DX300,340

85
OPTION PIPING

86
OPTION PIPING

87
OPTION PIPING

88
OPTIONS

Full track guard

STD

Narrow

STD
Dozer Narrow

89
OPTIONS

Full Track Guard

STD Track Guard STD Track Guard 90

 OPTIONS

Mechanical fuel injection

STD counterweight system engine (Injection STD covers
pump)

Electrical fuel injection

system engine (Common rail T
Tropical
i l covers
Additional counterweight engine)
91
OPTIONS

Standard cover vs. Tropical cover

92
 OPTIONS

Long reach arm

STD arm

Long reach boom

STD boom

Arti. boom

Log loader

93
OPTIONS

Log Loader
94
OPTIONS

Skeleton Bucket Dart Bucket

STD Bucket Ditch cleaning

Riser cabin

Rock Bucket Lights

95
OPTIONS

Cabin Riser

Dart Bucket

96
OPTIONS

Triple Grouser Double Grouser Triangle shoe

(For Marshy place)

STD track link Sealed track link

97
OPTIONS

Double Grouser

Triple Grouser
Shoe Width Options 98
OPTIONS

Wide show with double step

STD show with single step 99

OPTIONS

F.O.G.S Guard
F.O.G.S
F O G S Guard for Log Pattern change valve
loader

Front lower Guard

Cabin window guard for US
100
OPTIONS

Rain shield
Sun visor

Coupler
Turbo cleaner
Lock valve

Front breaker piping

Breaker main piping Main

M i piping
i i with
ith
filter
101
OPTIONS

Lock valve

102
OPTIONS

PE3C, PERO

Front rotation piping

P tt
Pattern change
h valve
l

103
 OPTIONS

F / Dozer

F/ Outrigger Double tire

R / Outrigger

Cradle

Single tire

R / Dozer

104
TABLE OF CONTENTS

1. PRODUCTS OF DOOSAN
2. PRODUCT NAMING
3. PRODUCT IDENTIFICATION
4 MAJOR COMPONENTS
4.
5. APPLICATIONS
6 OPTIONS
6.
7. WORKING PRINCIPLE

105
MACHINE OPERATION

LCD monitor
Front control joystick Traveling control panel
joystick
Switch panel

106
LCD PANEL

7 inch LCD Panel

3.8 inch LCD Panel

107
VARIOUS LANGUAGES

108
MACHINE OPERATION

109
COMPONENT FUNCTION

Diesel engine
Making mechanical energy from chemical material (Diesel)

Oil cooler & Radiator

Cooling hydraulic oil from actuator return line and
engine
i coolant.
l t

Control valve
g oil to HYD. actuator by
Distribute discharged y
operator control signal

Main pump
Making HYD energy ( Making flow)
Hydraulic oil tank (Pressurized tank)
Storage hydraulic oil,
oil remove air bubble and cleaning oil
- Suction filter : It is placed before main pump suction line
- Full flow filter : It is placed before return oil in-let line

110
COMPONENT FUNCTION

Swing Device

M i Pump
Main P
Main Control Valve
111
COMPONENT FUNCTION

Swing device
- Swing motor
Change hydraulic
Ch h d li energy to rotating
i mechanical
h i l
energy (High shaft speed Low torque)
- Swing reduction gear
Change high
Ch hi h motor
t speed d tto llow speed
d ffor machine
hi
swing. (Reduce motor shaft speed Increase swing
output power)

Center Joint
Connect hydraulic oil to lower hydraulic actuator
without hose connection

Swing bearing
Connect upper & lower structure and can be swing

112
 COMPONENT FUNCTION

Upper roller
S pport track link
Support

Lower roller
Supportt machine
S hi weight
i ht on
track link
Travel device
- Travel motor ((High/Low
g speed)) Idler
Change hydraulic energy to rotating
mechanical energy
- Travel reduction gear
Track
T k lilink
k
Change high motor speed to low speed for
machine traveling. (Reduce motor speed,
Increase output power)
- Sprocket
Transmit output power from reduction gear to Track spring
track link for traveling Adjust track link tension and absorb tension shock
while traveling

113
 COMPONENT FUNCTION

Center Joint Control Valve Main Pump

Travel Link

Front Idler

Track Travel Motor

Adjuster Upper
U JEIL HYDRAULIC

Roller
Sprocket
Travel Reduction
Lower Roller
Gear
114
 COMPONENT FUNCTION

Rear axle Front axle

Transmit transmission power to tire and stop Transmit transmission power to tire
machine traveling
stop machine
hi traveling
li and
d steering
i ffront wheel
h l
Gear oil lubrication
Dozer cylinder Gear oil lubrication

Dozer blade
Stabilize machine and
making flat ground
Drive shaft
Ram cylinder
Transmission
Travel motor Absorb traveling jerk (yawing)
Change machine traveling speed
Change hydraulic energy to rotating
Engine oil lubrication
mechanical energy
115
WORKING PRINCIPLE

Suction line
Supply oil line
Return line
Pilot line
Tank & oil cooler line

116
WORKING PRINCIPLE

117
WORKING PRINCIPLE

Pilot Cut off

,Package Sol valve

118
WORKING PRINCIPLE

Additional pump for option

Additional g
gear pump
p p (Option)
( p ) Additional g
gear pump
p p (STD/Option)
( p )
- Rotation - For Hydraulic cooling fan (DX480/520)
119
WORKING PRINCIPLE

Center joint
- Upper hydraulic power from hydraulic pump transmits to the lower hydraulic actuator without any hydraulic
hose connection
connection, It places on center of swing bearing

Fixed upper
structure

Fixed lower
structure

120
WORKING PRINCIPLE

Center Joint

121
THANK YOU

DX700LC

122