Basic Excavator Training

Excavator

Jan, 2010
Overseas Product Support Team
Text No. OPR0014
History of Doosan Infracore Products

Excavator

DH Series(78’) → Solar Series(85’) → Solar–3 Series(93’) → Solar-V Series(97’) → DX Series(05’)

Wheel loader

DL Series(90’) → Mega Series(92’) → Mega–3 Series(96’) → Mega-V Series(00’) → DL Series(05’)

2
Product Line-up (1)

Summary

Item Model Class

Mini Excavator 14 1 ton ~ 8 ton

Crawler Excavator 23 8 ton ~ 52 ton

Wheel Excavator 10 5 ton ~ 21 ton

Forest Excavator 4 22 ton, 30 ton

Wheel Loader 14 104HP ~ 335HP

Steer Skid Loader 5 2.5 ton ~ 3.3 ton

3
Product Line-up (2)

Mini Excavators (14)

S010 / S015Plus / S018VT / S030Plus/ S035 / S55-V Plus / S75-V
DX15/18 / DX27Z / DX30Z / DX35Z / DX55 / DX60R / DX80R
Crawler Excavators (23)
S140LC-V / S175LC-V / S225LC-V / S225NLC-V / S255LC-V
S300LC-V / S340LC-V / S420LC-V / S470LC-V / S500LC-VG
DX140LC / DX140R / DX180LC / DX225LC / DX225LCA / DX225NLC
DX255LC / DX300LC / DX340LC / DX350LC / DX420LC / DX480LC
DX520LC
Wheel Excavators (10)
S55W-Vplus / S140W-V / S160W-V / S180W-V / S210W-V
DX55W / DX140W / DX170W / DX190W / DX210W
Forest Crawler Excavators (4)
S225LL / S300LL
DX225LL / DX300LL
Wheel Loaders (14)
M160(TC) / M200-V(TC) / M250-V / M300-V / M400-V / M500-V
DL160 / DL200(TC) / DL250 / DL300 / DL350 / DL400 / DL450 / DL500
Steer Skid Loader (5)
430, 430P / 440P / 450, 450P / 460, 460P / 470P

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Product Naming

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
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

No special meaning.. Just call to 430, 440, 450….

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Major Components (1)

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
DX140W / DX140LC / DX180LC / DX190W / DX225(N) LC /
DL06 Common rail engine (Inline 6 /Tier-III)
DX255LC
DX140R Cummins QSB 4.5
S290LC-V / S300LC-V 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)
Cummins
DL400 / DL500 ( M500-V) Common rail engine (Inline 6 / Tier-III)
(QSL9/QSM11)

430, 440,450,460,470 Cummins Inline 4 (Turbo) / Tier-II

6
Major Components (2)

Model Pump Control valve Power train

Nabutesco
S010/ S015+/ S018VT/ S030+/ S035/ Parker Han-il
Rexroth DANA Axle, DANA
S55-V+/ S55W-V+/ DX27Z,DX35Z KAYABA
Transmission

S75-V Rexroth Rexroth

S140LC-V/ S140W-V/ S160W-V /S225LC-V/ S225NLC-V DX

Tong-Myoung
S255LC-V (Doosan)/KVMG

DX140LC/ DX180LC/ DX225LC/ DX255LC Tong-Myoung KVMG

DX140W/ S175LC-V/ S180W-V/ DX210W Rexroth DX (Doosan) ZF Axle, ZF Transmission

S300LC-V/ DX300LC Kawasaki KVMG (Doosan)

S340LC-V/ S420LC-V/ S470LC-V/ S500LC-V(G)

Rexroth KVMG (Doosan)
DX340LC / DX420LC/ DX480LC/ DX520LC

M160/M200-V/ DL200 Parker HUSGO Clark/ZF Axle, ZF Transmission

M250-V/ M300-V/ DL250/ DL300 Denison KAYABA ZF Axle, ZF Transmission

M400-V/M500-V Denison KAYABA ZF Axle, ZF Transmission

DL400 / DL500 Rexroth Parker ZF Axle, ZF Transmission

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EXCAVATOR
(Basic)

8
Excavator Working

Digging
X Breaker or others
Lifting

Loading

Material handing

9
Machine ID

10
Engine ID

11
 Major Component Name
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 Object Protective Structure) Cabin , * FOGS (Falling Object Guard Structure) Cabin 12
Major Component Name

Guide link

Bucket Pin

Push link

Tooth

Side cutter
Bucket

13
Major Component Name (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

14
Major Component Name (Wheel type)

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

15
Major Component Function (1)

• Diesel engine
Making mechanical energy from chemical material (Diesel)

• Oil cooler & Radiator

Cooling hydraulic oil from actuator return line and
engine coolant.

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

• Main pump
Making HYD energy ( Making flow)
• Hydraulic oil tank (Pressurized tank)
Storage hydraulic 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

16
Major Component Function (2)

• Swing device
- Swing motor
Change hydraulic energy to rotating mechanical
energy (High shaft speed – Low torque)
- Swing reduction gear
Change high motor speed to low speed for machine
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

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 Major Component Function (3)

• Upper roller
Support track link

• Lower roller
Support machine weight on
track link
• Travel device
- Travel motor (High/Low speed) • Idler
Change hydraulic energy to rotating
mechanical energy
- Travel reduction gear
• Track link
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

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 Major Component Function (4)

• Rear axle • Front axle

Transmit transmission power to tire and stop Transmit transmission power to tire
machine traveling
stop machine traveling and steering front wheel
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
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Engines (1)

DB58 DE08 DE12

DL06 DL08 DV11

20
Engines (2)

Model Engine Remarks

S140LC/ S140W/ 175LC-V DB58T Turbo

S225LC/ S225NL / S255LC-V/ S180LC/ S180W/

DB58TI Turbo, Intercooler (Water)
S210W-V

DX140LC/ DX140W/ DX180LC/ DX190W/ DX210W DL06 Common rail engine (Tier-III)

S300LC-V DE08TI Turbo, Intercooler (Water/ Air)

DX300LC / DX340LC DL08 Common rail engine (Tier-III)

S340LC-V/ S360LC-V/ S420LC-V/ S470LC-V/ S500LC-

DE12TI Turbo, Intercooler (Water/ Air)
V(G)

DX420LC/ DX480LC (DX520LC) DV11 Common rail engine (Tier-III)

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Main Pump (1)

• Swash plate axial piston pump • Bent axis piston pump

(KAWASAKI pump) (Rexroth pump)
22
Main Pump (2)

• Making flow

• Swash plate axial piston pump • Bent axis piston pump

( KAWASAKI pump) ( Rexroth pump)

23
Main Pump (3)

• Swash plate axial piston pump ( KAWASAKI type pump)

24
Main Pump (4)

• Bent axis piston pump (Rexroth pump)

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Main Pump (5)

• 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, Swing brake release….

Pilot pump

Regulator Regulator

Pilot pump
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Main Pump (6)

• Additional pump for option

• Additional gear pump (Option) • Additional gear pump (STD/Option)

- Rotation… - For Hydraulic cooling fan (DX480/520)
27
Main Pump (7)

• Pump coupling (Drive coupling - New type)

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

Installed on engine fly wheel

28
Control Valve (1)

• DX Model (TOSHIBA) - Solar 3,V 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

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Control Valve (2)

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

• Main relief valve

- Restrict max. system pressure (330bar)
* 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 oil leaking from actuator (cylinder) to control valve

•Over load valve( Protection valve, Safety valve)

- Protect actuator damage from sudden impact

30
Control Valve (3)

31
Swing Device (1)

Fixed upper structure

Grease lubrication
Upper structure

Swing Bearing

Lower structure
Fixed lower structure

Swing Bearing

32
Swing Device (2)

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

* Swing brake
No swing, swing brake is engaged
Swing machine, swing brake is released

* Swing relief valve & Reactionless valve

• 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

33
Swing Device (3)

Swing motor

34
Swing Device (4)

Swing reduction gear

Pinion gear

35
Center Joint

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

Fixed upper
structure

Fixed lower
structure

36
 Travel Device (1)

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

37
Travel Device (2)

Sprocket
Track frame

Track link & shoe

38
Travel Device (3)

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

• Travel motor

- Variable piston motor

High/ low traveling speed

- Parking brake

- Protect over run traveling

39
Travel Device (4)

• Variable axial piston motor • Variable bent axial piston motor

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

40
Travel Device (Wheel Type)

41
Travel Device (Wheel Type)

• 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)

42
Travel Device (Wheel Type)

• Transmission

• 3 speed planetary gear transmission (ZF)

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

43
Travel Device (Wheel Type)

• Transmission

44
Travel Device (Wheel Type)

• Axle

• Planetary gear Axle (ZF)

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

45
Cylinder (1)

Rod cover
Piston
Rod

Tube

Rod side Head side

46
Cylinder (2)

Cylinder cushion (Damping)

Rod side damping Head side damping

47
Remote Control Valve

Remote control joystick valve

48
Cabin

LCD monitor
Front control joystick Traveling control panel
joystick
Switch panel

49
Machine Operating

50
Boom, Arm & Bucket

Arm length
Boom length

Bucket width

51
Cooling System

• 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

52
Main Piping Oil Circulation (1)

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

53
Main Piping Oil Circulation (2)

54
Main Piping Oil Circulation (3)

Pilot Cut off

,Package Sol valve

55
Front Attachments

Quick coupler Crusher

Breaker (Side mount / Top mount)

Compactor

56
Machine Options (1/19)

Option Remarks

STD frame

Track frame Narrow frame

Mining frame S300,370,420,470LC-V / DX300,380,420,480LC

STD crawler frame (Dozer, W/O Dozer)

Track frame S140LC-V only
Long crawler frame (Dozer, W/O Dozer)

STD frame
Track frame
Narrow frame S470,500LC-V / DX480,520LC / TXC480,520LC-2

STD
Track guard S300,370,420,470LC-V / DX300,380,420,480,520LC (For
Full guard mining machine)

STD

Under Tropical
cover For Europe

Mining S300,370,420,470LC-V / DX300,380,420,480LC

57
Machine Options (2/19)

Full track guard

STD

Narrow

STD
Dozer Narrow

58
Machine Options (3/19)

Option Remarks
Dozer blade 2,500 / 2,600 / 2,700mm S140LC-V only
STD
5.3 ton S220,225LC-V (Super Long)
5.5 ton S290LC-V (Super Long)
5.9 ton S300LC-V / DX300LC (Super Long)
6.3 ton S300LC-V / DX300LC (Demolition)
Counter weight
10.0 ton DX420LC
9.0 ton DX420NLC
9.3 ton S470LC-V (Narrow track)
2.6 ton S470LC-V Additional weight
11.1 ton S470LC-V (STD + Add)
Tier – 1 (Injection pump)
Tier - 2 (Injection pump)
Engine
Tier – 2 (ELE Engine) DX only
Tier – 3 (ELE Engine) Europe, US- DX only
STD
Side cover &
Tropical
Engine hood
Europe

59
 Machine Options (4/19)

Mechanical fuel injection

STD counterweight system engine (Injection STD covers
pump)

Electrical fuel injection

system engine (Common rail Tropical covers
Additional counterweight engine)
60
Machine Options (5/19)

Option Remarks
STD
Short S140,175,220,255,470LC-V / DX520LC
Long S175,290LC-V / DX520LC
Semi super long S470LC-V
Boom
Super long S220,225,290,470LC-V / DX300,520LC
Arti. Boom S175,220,225LC-V, Wheel
Log loader S225,300LL
Mining S300,370,420,470LC-V / DX300,380,420,480LC
STD
S140,175,220,225,255,290,300,340,370,420,470LC-
Short
V,S225NLC-V,/ DX300,340,420,480,520LC
S140,175,220,225,255,290,300,340,370,420,470LC-V /
Long
DX300,340,420,480LC
Arm Semi super long S470LC-V
Super long S220,225,290,300,470LC-V / DX300,520LC
Log loader S225,300LL
Grapple S220LC-V( Indonesia)
Mining S300,370,420,470LC-V / DX300,380,420,480LC

61
 Machine Options (6/19)

Long reach arm

STD arm

Long reach boom

STD boom

Arti. boom

Log loader

62
Machine Options (7/19)

Option Remarks

None

STD bucket
Option (Bucket Volume)
Bucket Dart (Bucket Volume)
Europe S140,220LC-V

Ditch cleaning S140,290,300LC-V

Mining DX300,380,420,480LC

STD
Plastic US, Europe, Australia
Cabin Sun roof
Steel Others

Riser cabin S225/300LL

None
Front 2 lamp
Cabin lamp Front 2 lamp + Rear 2 (Counter W) DX480,520LC, TXC480,520-2

Front 4 / Rear 2 lamp

Front 4 / Rear 2 lamp + Rear 2 (Counter W) DX only

63
Machine Options (8/19)

Skeleton Bucket Dart Bucket

STD Bucket Ditch cleaning

Riser cabin

Rock Bucket Lights

64
Machine Options (9/19)

Option Remarks
500mm S140,175LC-V,S225NLC-V
600mm(STD) S140,175,220,225,255,290,300,340,370,420,470LC-V,S225NLC-V
700mm S140,220,225,255,290,300,340LC-V / DX300,340LC
710mm S175LC-V
750mm S370,420,470LC-V / DX300,420,480,520LC
S175,220,225,255,290,300,340,370,420,470LC-V
800mm
/DX300,340,380,420,480,520LC
850mm S290,300,340LC-V / DX300,340LC
900mm S175,220,225,255,370,420,470LC-V / DX340,380,420,480,520LC
Shoe
910mm damp Area – (Triangle shoe) S220,225,290,300,340LC-V
600mm (Sealed) S220,225,255,340LC-V
700mm (Sealed) S220,225,255,340LC-V
800mm (Sealed) S220,225,255,300,340LC-V
850mm (Sealed) S300,340LC-V
900mm (Sealed) S220,225,255LC-V
600mm (Double grouser) S225,300LL / DX300,380,420,480,520LC
700mm (Double grouser) S225,300LL
800mm (Double grouser) S225,300LL

65
Machine Options (10/19)

Triple Grouser Double Grouser Triangle shoe

(For Marshy place)

STD track link Sealed track link

66
Machine Options (11/19)

Option Remarks
STD Europe – DX model
Beacon
Telescopic
50/60A (STD)
Alternator
80A
Travel US - DX model
Alarm Swing
Swing + Travel
F.O.G.S Guard STD
(Falling Object Guard Structure) Mining S300/370/420/470LC-V
Cabin front lower guard
Cabin window guard for US S290LC-V
Guard for stick cylinder S300LL
Pattern change V/V For US
Overload warning With lock valve
None
Fuel filler pump
STD Europe
STD or Catalysis
Muffler S140LC-V
Europe Low noise

67
Machine Options (12/19)

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

Front lower Guard

Cabin window guard for US
68
Machine Options (13/19)

Option Remarks
Heater
Seat DX only
Heater + Air suspension
Boom
Lock valve
Arm
Sun visor
Rain shield Europe – DX model
STD
Pre cleaner
Turbo
Fuel heater DX only
Fuel filter Water separator
Double
Main line S175/220/225LC-V
Breaker pipe (For arti.)
Total piping
Breaker filter DX only
Quick coupler DX only
Main line S140/175/220LC-V,S225NLC-V
One way breaker pipe
Total piping

69
Machine Options (14/19)

Rain shield
Sun visor

Coupler
Turbo cleaner
Lock valve

Front breaker piping

Breaker main piping Main piping with

filter
70
Machine Options (15/19)

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

Cassette
Player
CD plaer DX only

Mirror

Other Tool kit

Spare parts

71
Machine Options (16/19)

PE3C, PERO

Front rotation piping

Pattern change valve

72
Machine Options (17/19)

Option Remarks

Cradle
Front, Rear outrigger
Front outrigger, Rear dozer
Chassis frame Front dozer, Rear outrigger
Front outrigger, Rear dozer Individual working outrigger
Front dozer, Rear outrigger Individual working outrigger
Rear dozer
STD
Center joint
IND C/Joint Individual working outrigger
Cradle
Front chassis frame Outrigger
Dozer
Rear lamp
Rear chassis frame Outrigger
Dozer
Double
Tire
Single

73
 Machine Options (18/19)

F / Dozer

F/ Outrigger Double tire

R / Outrigger

Cradle

Single tire

R / Dozer

74
Machine Options (19/19)

Thumb Wood Grapple Clamshell

Ripper

Thumb Orange Grapple Fork

75
End of Document

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