SP000943
CABIN SP000943
Cabin
Edition 1
MEMO
Table of Contents
Cabin
Safety Precautions... 5
Applicable Models... 5
Removal... 7
Installation ... 11
MEMO
SAFETY PRECAUTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and serial number ranges.
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section.
Always use tools and equipment that are in good working order.
Use lifting and hoisting equipment capable of safely handling the load.
Remember, that ultimately safety is your own responsibility.
MODEL SERIAL NUMBER RANGE
DX180LC 5001 and Up
DX225LC 5001 and Up
DX225NLC 5001 and Up
DX255LC 5001 and Up
DX300LC 5001 and Up
DX300LL 5001 and Up
DX340LC 5001 and Up
DX420LC 5001 and Up
DX480LC 5001 and Up
DX520LC 5001 and Up
REMOVAL
1. Park on firm and level ground.
2. Lower front attachment (bucket) to ground.
3. Shut down engine.
4. Set safety lever on "RELEASED" position.
5. Turn starter switch to "I" (ON) position.
6. Fully stroke work levers (joysticks) in all directions to relieve pressure from accumulators.
7. Set safety lever on "LOCK" position.
8. Turn key to "O" (OFF) position and remove from starter switch.
9. Hang maintenance warning tag on controls.
10. Disconnect the battery cable from the negative (-) battery terminal.
11. Prepare cabin shell for removal by disconnecting wiring connectors for:
A. Cabin interior lighting.
B. External light wiring.
C. Radio antenna and connections.
D. Wiper/washer connections.
NOTE: Control console wiring harnesses and hydraulic piping lines that pass through the floor of the cabin do not need to be disassembled.
CAUTION!
Avoid disassembling cabin if there are strong wind gusts, which could catch large surface area of cabin shell and push it sideways during lift.
O I
FG007720
WARNING DON'T TOUCH WHEN PERFORMING INSPECTION
OR MAINTENANCE
Figure 1
WARNING!
If engine must be run while performing maintenance, use extreme care. Always have one person in the cabin at all times. Never leave the cabin with the engine running.
12. Remove floor mat (1, Figure 2).
13. Remove seat (2, Figure 2).
NOTE: Be careful not to damage seat covering.
14. Remove cup holder (3, Figure 2).
Remove front cover (4, Figure 2) and side covers (5 and 6).
When removing cover (4), disconnect hour meter connector.
NOTE: Don't remove monitor panel (7, Figure 2) and switch panel (8).
15. After removing rear mat (1, Figure 3), remove rear center cover (2), cassette cover (3) and rear side covers (4 and 5).
16. Remove fuse box bracket (1, Figure 4) from left sidewall without disassembly harness connector.
17. Disconnect cabin ground cable located near fuse box bracket.
18. Remove cassette bracket (2, Figure 4) and disconnect antenna and speaker wire.
Figure 2
Figure 3
20. Remove air ducts (1, 2, 3 and 4, Figure 5) from cabin rear panel.
21. Remove across bar (5, Figure 5) between left and right side of cabin.
22. Remove air ducts (1, 2, 3, 4 and 5, Figure 6) right side of cabin step by step from the front duct.
23. Disconnect washer hose located at floor plate bottom.
24. Disconnect cabin wiring connectors from main harness.
25. Remove four mounting nuts from four corners of cabin floor (1, Figure 7).
26. Remove four M12 hex bolts (2, Figure 7) and two M10 hex bolts (3).
Figure 5
Figure 6
Figure 7
27. Using a suitable lifting device, attach slings to four lift points on top of cabin (Figure 8).
NOTE: Cabin weights approximately 315 kg (700 lb).
28. Lift cabin from 25 - 50 mm (1" - 2") above deck height.
Check that all electrical connections have been disconnected and all other items unbolted.
29. Continue lifting with the assist crane to remove cabin shell.
Lower the shell to a prepared safe blocking support.
Figure 8
INSTALLATION
1. Using a suitable lifting device, attach slings to four lift points on top of cabin (Figure 9).
NOTE: Cabin weights approximately 315 kg (700 lb).
2. Lower cabin into position on cabin floor.
3. Install four mounting nuts from four corners of cabin floor (1, Figure 10).
NOTE: Mounting nut torque 21kg•m (205 Nm, 150 lbf ft).
4. Install four M12 hex bolts (2, Figure 10) and two M10 hex bolts (3).
NOTE: Mounting nut torque
M12 - 11kg•m (108 Nm, 80 lbf ft).
M10 - 6.5kg•m (64 Nm, 47 lbf ft).
5. Once cabin is mounted to floor, unhook lifting device.
6. Connect cabin wiring connectors to main harness.
7. Connect washer hose located at floor plate bottom.
8. Install air ducts (1, 2, 3, 4 and 5, Figure 11) right side of cabin step by step from the rear duct.
Figure 9
Figure 10
9. Install across bar (5, Figure 12) between left and right side of cabin.
10. Install air ducts (1, 2, 3 and 4, Figure 12) from cabin rear panel.
11. Install electrical box (4, Figure 13).
12. Install cassette bracket (2, Figure 13) and connect antenna and speaker wire.
13. Connect cabin ground cable located near fuse box bracket.
14. Install fuse box bracket (1, Figure 13) to left sidewall of the cabin.
15. Install rear side covers (4 and 5, Figure 14), cassette cover (3) and rear center cover (2), last install rear mat (1).
Figure 12
Figure 13
16. Install front cover (4, Figure 15), and side covers (5 and 6), when install cover (4) connect hour meter connector.
17. Install seat (2, Figure 15).
NOTE: Be careful not to damage seat covering.
18. Install floor mat (1, Figure 15).
19. Connect negative (-) battery cable leading to frame from battery.
Figure 15
SP000940 COUNTERWEIGHT SP000940
Counterweight
Edition 1
MEMO
Table of Contents
Counterweight
Safety Precautions... 5 Applicable Models... 5 General ... 6
Warning for Counterweight and Front Attachment
Removal ... 6
Removal... 8
Installation ... 10
MEMO
SAFETY PRECAUTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and serial number ranges.
CAUTION!
Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section.
Always use tools and equipment that are in good working order.
Use lifting and hoisting equipment capable of safely handling the load.
Remember, that ultimately safety is your own responsibility.
MODEL SERIAL NUMBER RANGE
DX180LC 5001 and Up
DX225LC 5001 and Up
DX225NLC 5001 and Up
DX255LC 5001 and Up
DX300LC 5001 and Up
DX340LC 5001 and Up
GENERAL
Warning for Counterweight and Front Attachment Removal
Before any attempt is made to begin removal or installation of the counterweight, the excavator must be parked on a firm and level supporting surface, with no sloping surfaces or soft or muddy ground in the area where the assist lift crane will be working. Position all accessories in the overnight storage position.
FG000371 Figure 1
DANGER!
DOOSAN warns any user, that the removal of the counterweight from the machine, front attachment or any other part, may affect the stability of the machine. This could cause unexpected movement, resulting in death or serious injuries. DOOSAN is not liable for any misuse.
Never remove counterweight or front attachment unless the upper structure is in-line with the lower structure.
Never rotate the upper structure once the counterweight or front attachment has been removed.
WARNING!
The weight of counterweight is given in the following table.
Use only rated and approved slings and hardware when removal or installation lifts are being made. Lifting slings, shackles and all other hardware must be rigged safely. An assist crane that is rated above weight capacity is required.
Model Weight of Counterweight
DX180LC 3,000 kg (6,614 lb)
DX225LC 4,100 kg (9,039 lb)
All members of the working crew should know and understand the signals that will be used between the lifting leader, the assist crane operator and the remainder of the work crew.
To maintain stability the counterweight should be removed whenever the front attachment is taken off the machine.
When loading an excavator (either track or wheeled type) on a trailer for transport after the front attachment has been removed, always go backwards up the loading ramp. The counterweight end of the deck has to get on the trailer first, while the cabin is still going up the ramp (Figure 1).
WARNING!
If the turntable deck has been unbalanced by removal of weight from one end only, traveling the excavator, swinging the turntable, movement over bumps or sloping and uneven surfaces could cause loss of control and possible accidents or injuries.
FG000325 15
90 ~ 110
Figure 1
FG000326 15
Figure 2
REMOVAL
1. Park on firm and level ground.
2. Lower front attachment (bucket) to the ground.
3. Shut down engine.
4. Set safety lever on "RELEASED" position.
5. Turn starter switch to "I" (ON) position.
6. Fully stroke work levers (joysticks) in all directions to relieve any pressure from accumulators.
7. Set safety lever on "LOCK" position.
8. Turn key to "O" (OFF) position and remove from starter switch.
9. Hang maintenance warning tag on controls.
10. Disconnect the battery cable from the negative (-) battery terminal.
11. Remove engine compartment cover.
O I
FG006745
WARNING DON'T TOUCH WHEN PERFORMING INSPECTION
OR MAINTENANCE
Figure 3
WARNING!
If engine must be run while performing maintenance, use extreme care. Always have one person in the cabin at all times. Never leave the cabin with the engine running.
12. Remove two caps (1, Figure 4) from counterweight (2).
13. Install two lifting eyes in lifting holes (3, Figure 4).
14. Using a suitable lifting device capable of handling a heavy load, partially support counterweight (2, Figure 4) before loosening four bolts (4). Stop lifting with assist crane as soon as lifting slings are taut.
15. Remove four bolts (4, Figure 4) and washers (5) from counterweight (2).
NOTE: Heat bolts if necessary, to free them.
16. When bolts (4, Figure 4) and washers (5) have been removed, lift counterweight (2) a very short distance above support frame (6) and stop. Check slings and make sure counterweight is being supported evenly.
Figure 4
Model Lifting Eye Size
DX180LC
INSTALLATION
1. Using suitable lifting device capable of handling a heavy load, raise counterweight (2, Figure 5) into position just above support frame (6) leaving counterweight suspended.
Verify that counterweight is level and even.
NOTE: Leave counterweight (2, Figure 5) suspended 3 mm (0.125") above support frame (6) until all four mounting bolts (4) are started in counterweight mounting holes.
2. Slide washers (5, Figure 5) onto bolts (4). Apply Loctite
#242 to mounting bolt threads.
3. Install four bolts (4, Figure 5) with washers (5) into counterweight until washers contact support frame. Fully lower counterweight onto support frame and finish tightening bolts.
NOTE: Torque bolts (4, Figure 5) to values shown in following table.
4. Remove lifting device and lifting eyes from counterweight lifting holes (3, Figure 5).
5. Install two caps (1, Figure 5) in lifting holes (3).
6. Install engine compartment cover.
7. Connect negative (-) battery cable to battery.
Figure 5
Model Bolt Torque
DX180LC