Daewoo Doosan DX300LC-5 Excavator Service Repair Manual Instant Download

1
Shop Manual
DX300LC-5 Excavator
Serial Number 1001 and Up Serial Number 50001 and
Up
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.
950106-00980E February 2014
Original Instructions
Copyright DOOSAN 2014
2
Table of Contents
1 Safety

• 1 Track Excavator Maintenance Safety
• 1 Specifications
• General Maintenance Instructions
• Standard Torques

2 Specifications
3 General Maintenance
4 Engine
1 Engine
2 Engine Coolant Heater (Option)
5 Upper Structure
1 Cabin

• Counterweight
• Oil Tank
• Fuel Tank
• Main Pump
• Drive Coupling (Main Pump)
• Main Control Valve
• Swing Device
• Fan Pump for Oil Cooler
• Fan Motor for Oil Cooler
• Gear Pump (Rotation)
• Joystick Valve (Work Lever)
• Travel Control Valve (with Damper)
• Solenoid Valve
• EPPR Valve
• Accumulator
• Swing Bearing

6 Lower Structure and Chassis
Table of Contents Page I
3
7 Front

1. Boom and Arm
2. Bucket
3. Cylinders

8 Hydraulic System

1. Hydraulic System
2. Hydraulic System Testing and Adjustment
3. Hydraulic System Troubleshooting

9 Electrical System

1. Electrical System
2. Electrical System Troubleshooting

10 Options

1. One Way
2. Two-way
3. Rotating
4. Quick Coupler
5. Two Pump

11 Schematic
1 Hydraulic Schematic/Electrical Schematic
Table of Contents Page II
4
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Track Excavator Maintenance
Safety
Edition 1
Track Excavator Maintenance Safety 1-1-1
DX300LC-5
6
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments repairs or service. Untrained operators and failure to follow instructions can cause death or serious injury.
SAFETY MESSAGES Replace with Safety Messages
Section on pages III and IV in the Doosan
Operation Maintenance Manual.
Track Excavator Maintenance Safety 1-1-5
DX300LC-5
7
GENERAL

• Safe Operation is Operator's Responsibility
• Only trained and authorized personnel should
  operate and maintain the machine.
• Follow all safety rules, regulations and
  instructions when operating or performing
  maintenance on machine.
• Do not operate machine if you are under the
  influence of drugs or alcohol. An operator who
  is taking prescription drugs must get medical
  advice to determine if he or she can safely
  operate a machine.
• When working with other personnel on a work site,
  be sure that all personnel know nature of work
  and understand all hand signals that are to be
  used.
• Be sure that all guards and shields are installed
  in their proper location. Have guards and
  shields repaired or replaced immediately if
  damaged.
• Be sure that you understand the use and
  maintenance of all safety features such as
  safety lever and seat belt. Use them properly.
• Never remove, modify or disable any safety
  features. Always keep them in good operating
  condition.
• Always check for and know the location of
  underground and overhead utility lines before
  excavating.
• Failure to use and maintain safety features
  according to instructions in this manual, Safety
  Manual and Shop Manual can result in death or
  serious injury.
• Know Your Machine
• 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.

DX300LC-5
Track Excavator Maintenance Safety 1-1-6
8
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.
Pressurized Fluids Pressurized air or fluids can
cause debris and/or fluids to be blown out. This
could result in death or serious
injury. Immediately after operations are stopped,
coolant, engine oil, and hydraulic oil are at
their highest temperatures and the radiator and
hydraulic tank are still under pressure. Always
wait for temperature to cool down. Follow
specified procedures when attempting to remove
caps, drain oil or coolant, or replacing
filters. Always wait for temperature to cool
down, and follow specified procedures when
performing these operations. Failure to do so
can result in death or serious injury. When
pressurized air and/or pressurized water is used
for cleaning, wear protective clothing,
protective shoes, and eye protection. Eye
protection includes goggles or a protective face
shield. Pressure can be trapped in a hydraulic
system and must be relieved before maintenance
is started. Releasing trapped pressure can cause
sudden machine movement or attachment movement.
Use caution if you disconnect hydraulic lines or
fittings.
FG018457
Figure 1
Track Excavator Maintenance Safety 1-1-7
DX300LC-5
9
High-pressure oil that is released can cause a
hose to whip or oil to spray. Fluid penetration
can result in death or serious injury. If fluid
enters skin or eyes, get immediate medical
attention from a physician familiar with this
injury. Obey all local laws and regulations for
disposal of liquids. To prevent hot coolant from
spraying out, stop engine and wait for coolant
to cool. Using gloves, slowly loosen cap to
relieve pressure.
Flying or Falling Objects On work sites where
there is a potential hazard that flying or
falling objects can hit operator's cabin, select
and use a guard to match operating conditions
for additional operator protection. Working in
mines, tunnels, deep pits, and loose or wet
surfaces, could produce hazard of falling rocks
or flying objects. Additional protection for
operator's cabin could be required such as an
Operator Protection Guard (OPG) or window guards.
Contact your DOOSAN distributor for information
on available protective guards. To prevent
personnel from being struck by flying objects,
keep personnel out of work area.
HAOA110L
Figure 2
HAOA100L
Figure 3
DX300LC-5
Track Excavator Maintenance Safety 1-1-8
10
Engine
Edition 1
DX300LC-5
Engine 4-1-1
11
SAFETY INSTRUCTIONS WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are
necessary before operating or servicing machine.
Read and understand the Operation Maintenance
Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check
for correct function after adjustments repairs
or service. Untrained operators and failure to
follow instructions can cause death or serious
injury.
Engine 4-1-7
DX300LC-5
12
OVERVIEW
FRONT
EX1301800
Figure 1
DX300LC-5
Engine 4-1-8
13
Replacing the Engine
NOTE
Replace coolant hoses if there is clear damage to
the coolant hoses.

1. Drain the oil and coolant.
2. Remove air filter and inlet pipe between the
   turbocharger and air filter. Cover the
   turbocharger inlet pipe.
3. Undo the connections for coolant, charge air
   pipes between engine and charge air cooler, and
   bleed pipe for the expansion tank.

FG020236
4. Undo the cable harness with clamping.
Figure 20
NOTE
The engine lifting eyes 99 637 are designed for
lifting the engine only, not the engine with
connected equipment (high voltage current
generator, gearbox, reverse gear, etc.) or
frame. All three lifting eyes must be used.

1. Fasten the lifting chain 98 094 to the rear
   lifting eyes 99 637.
2. Fasten the lever block 587 308 to the front
   lifting eye.

NOTE
The lifting eyes 99 637 are designed to manage a
maximum inclination angle of 30 when lifting an
engine.

max 30

• Undo the engine insulator bolts and lift away/out
  the engine.
• Engine weight about 950 kg

max 20
FG020237
Figure 21
Engine 4-1-51
DX300LC-5
14
Removal of Engine 1. Depressurize the fuel system
using checking tool.
IMPORTANT
The fuel system has a very high fuel pressure of
up to 3,000 bars. The fuel system must be
depressurized using checking tool before any
work is started. Use checking tool to minimize
the high-pressure in the fuel system. The system
should always be treated as pressurized, even
when the engine is switched off. Wear protective
gloves and goggles. 2. Disconnect the ground
connection from the negative terminal and
disconnect the cable harness from the starter
motor.
NOTE
Help protect the environment. Avoid spillage and
use a suitable container.

1. Drain the coolant.
2. Undo the connections for coolant, charge air
   pipes between engine and charge air cooler, and
   bleed pipe for the expansion tank.
3. Remove air filter and inlet pipe between the
   turbocharger and air filter. Cover the
   turbocharger inlet pipe.
4. Disconnect the fuel pipes to and from the engine.
   Mark the pipes to make reinstalling easier and
   plug the connections.
5. Remove coolant connections for SCR, to engine (1)
   and from engine (2).

2
1
EX1301906
Figure22
DX300LC-5
Engine 4-1-52
15
8. Disconnect connectors C4001 (1) and C4002 (3)
and connector C4022 (4) to SCR.
1

• To be removed depending on the installation
• Unit gearbox.
• Coolant level sensor.
• Protective casing on cooling package and fan.
• Depressurize the pneumatic system and remove
  connections.
• Power take-off, see subgroup 01-55 Power
  take-off.
• Hydraulic pump, see subgroup 13-15 Hydraulic
  pump.
• Disconnect the AC compressor and place it to one
  side.

4
2
3
EX1301907
Figure 23
9. Fasten the lifting chain 98 094 to the rear
lifting eyes 99 637.
NOTE
The engine lifting eyes 99 637 are designed for
lifting the engine only, not the engine with
connected equipment (high-voltage current
generator, gearbox, reverse gear, etc.) or
frame. All three lifting eyes must be used.
10. Fasten the ratchet lever hoist 587 308 to the
front lifting eye.
NOTE
The lifting eyes 99 637 are designed to manage a
maximum inclination angle of 30 when lifting an
engine.

1. Check carefully there is nothing that may be
   removed with the engine or prevent lifting.
2. Undo the engine insulator screws and lift
   away/out the engine.

Engine 4-1-53
DX300LC-5
16
Installing the Engine 1. Fasten the lifting chain
98 094 to the rear lifting eyes.
NOTE
The engine lifting eyes 99 637 are designed for
lifting the engine only, not the engine with
connected equipment (high-voltage current
generator, gearbox, reverse gear, etc.) or
frame. All three lifting eyes must be used.
FG020236
Figure 24 2. Fasten the ratchet lever hoist 587
308 to the front lifting eye.
max 30
EX1301876

• Figure 25
• Lift the engine, position it on the engine
  insulators and screw it into place.
• If removed, reinstall
• Unit gearbox.
• Coolant level sensor.
• Protective casing on cooling package and fan.
• Pneumatic system.
• Power take-off, see subgroup 01-55 Power
  take-off.
• Hydraulic pump, see subgroup 13-15 Hydraulic
  pump.
• AC compressor, see subgroup 18-75 AC compressor.

DX300LC-5
Engine 4-1-54
17
4. Connect connectors C4001 (1) and C4002 (3) and
connector C4022 (4) to SCR. 1
4
2 3
EX1301907
Figure 26
5. Install the coolant connections for SCR, to
engine (1) and from engine (2).
2
1
EX1301906

• Figure27
• Connect the fuel pipes to the high-pressure pump
  and hand pump.
• Install the inlet pipe between the turbocharger
  and the air filter.
• Install the connections for coolant and the
  charge air pipes between the engine and charge
  air cooler. Install the expansion tank bleed
  pipe.
• Fill with coolant.
• Install the cable harness to the starter motor
  and the ground connection to the negative
  terminal.
• Start checking tool and check whether there are
  any fault codes. Rectify the fault codes.
• Clear inactive fault codes.
• Test run the engine to check that no leakage
  occurs. Top up with coolant if necessary.

Engine 4-1-55
DX300LC-5
18
CYLINDER
Cylinder Head Specifications
Intake Valve Intake Valve
Oversize Valve Seat, Outer Diameter 46.254 - 46.265 mm
Valve Seat Position, Outer Diameter 46.200 - 46.216 mm
Valve Seat Position, Deep 11.25 - 11.35 mm
Exhaust Valve Seat Exhaust Valve Seat
Oversize Valve Seat, Outer Diameter 44.281 - 44.292 mm
Valve Seat Position, Outer Diameter 44.200 - 44.216 mm
Valve Seat Position, Deep 11.25 - 11.35 mm

• Remove cylinder head according to the work
  description
• Removal Cylinder Head on page 4-1-57.
• Remove inlet and exhaust valves according to the
  work description Removing Valves on page
  4-1-75.
• Overview

19 18
20
20
8
24
16
25
25A 25B
21
19
25C
14
8
17
30
31 31C 31A 31B
13
11
25C
11 1D
1D
23
1A
22
31C
36
1B 1 1A 1F 1B
9
1C
9 10
1E
1F
15
12
Figure 28
EX1302147
DX300LC-5
Engine 4-1-56
19
Reference Number Description
1 Cylinder Head
1A Sleeve
1B Core Plug
1C Rivet
1D Guide Valve
1E Seal
1F Seal
8 Pin
9 Valve Stem Seal
10 Intake Valve
11 Intake Valve Spring
12 Collar Valve Spring
13 Exhaust Valve
14 Outer Valve Spring
15 Inner Valve Spring
16 Collar Valve Spring
17 Collet Valve Spring
Reference Number Description
18 Pin
19 Gasket
20 Bridge Valve
21 Screw
22 Bracket Assembly
23 Rivet Plug
24 Screw
25 Intake Rocker Arm
26 Adjusting Screw
27 Hex Nut
29 Rivet Plug
30 Retaining Ring
31 Exhaust Arm Rocker
32 Adjusting Screw
33 Hex Nut
35 Rivet Plug
36 Retaining Ring

• Removal Cylinder Head
• Remove water-cooled EGR cooler as instructed in
  the work description Removing the EGR Cooler
  on page 4-1-274.
• Remove brackets for the water-cooled EGR cooler.
• Remove bolts for the exhaust manifold on the
  relevant cylinder and slacken the bolts on the
  adjacent cylinders so the relevant part of the
  exhaust manifold comes loose.
• Remove cooling system bleeder hose, separate the
  quick release coupling at the front lifting eye.
• Remove cable duct from the intake.
• Remove cable ties for the cable harness from the
  engine control unit.

IMPORTANT
The fuel system components are extremely
sensitive to dirt. Clean thoroughly before
dismantling and plug all connections with
lint-free rags and tape.
Engine 4-1-57
DX300LC-5
20

1. Depressurize the fuel system and detach the fuel
   pipe running between the accumulator and fuel
   manifold.
2. Detach the fuel manifold and remove bolts on the
   relevant cylinder.
3. Detach the intake manifold and remove bolts on
   the relevant cylinder.

7 9 8
IMPORTANT
FG020250
Figure 29
All parts in the fuel injection system and valve
mechanism must be marked. Everything must be
reinstalled in the same position.
9. Remove injectors as instructed in the work
description Removing Injector on page
4-1-318. Also remove high-pressure pipes and
connection on the cylinder head at the back
viewed from the coolant pump.
IMPORTANT
If work is done on the 5th cylinder of an engine
with an EGR system, the EGR valve control
cylinder must be detached at the damper and
removed. 10. Remove upper rocker cover and then
the rocker arm housing, valve bridges and
pushrods.
FG020251
Figure 30 11. Pull the cable harness out of the
lower rocker cover and remove it.
NOTE
Take care when pulling the cable harness out of
the rocker cover the cable terminals can be
damaged which can cause the nut securing the
cable harness to the injector to come loose.

1. Work on the adjacent cylinders. Remove upper
   rocker cover, release the cable harness and the
   lower rocker cover so it can be moved.
2. Remove relevant cylinder head. Be careful with
   the adjacent rocker covers.

FG020252
Figure 31
DX300LC-5
Engine 4-1-58
21
NOTE
Mark the cylinder heads if more than one is
being removed at the same time. If all cylinder
heads are removed at the same time, the
turbocharger must be removed or supported
against the frame.
NOTE
Installing Cylinder Head

• Check the liner height.
• Clean the cylinder head and cylinder block.
  Lubricate the threads and below the heads of the
  cylinder head bolts.
• Install a new cylinder head gasket.
• Install the cylinder head.
• Tighten the cylinder head as shown in the
  illustration and according to specification.
• Cylinder head bolts can only be reused three
  times. Make a mark with a center punch on the
  head of the bolt. If any of the bolts already
  has three marks, it must be replaced.

1
5
3
4
6
2
FG020253
Figure 32
1
2
3
4
FG020254
Figure 33 6. Tighten the intake manifold. Use a
new gasket. Tighten the bolts in the order 1 -
20 as illustrated. Tighten the bolts in the same
order again. 2 4 6 8 10 12 14 16 18 20
1
3 5
7 9 11 13 15 17 19
FG020255
Figure 34
Engine 4-1-59
DX300LC-5
22

• Tighten the intake manifold and the exhaust
  manifold. Use new gaskets.
• Install the cable bracket bolt in the lower
  rocker cover and install the following parts
• Lower rocker cover.
• Pushrods.
• Valve bridge.
• Rocker arm housing.

IMPORTANT

• Lubricate the valve bridge and rocker arm housing
  with engine oil.
• Install the injector, high-pressure pipe
  connection and high-pressure pipe as instructed
  in the work description.
• Reset adjacent cylinders.
• Adjust the valve clearance.
• Install the upper rocker covers.
• Install the cooling system vent
• Install the brackets for the water-cooled EGR
  cooler.
• Install the water-cooled EGR cooler as described
  in the work description Installing the EGR
  Cooler on page 4- 1-275.
• Removing and Installing Valves

WARNING
AVOID DEATH OR SERIOUS INJURY Wear protective
goggles for eye protection. 1. Removing Valves

1. Remove split collets, valve spring collars,
   springs and valves. Press down the spring using
   tool 99 322 in a press so the collets can be
   removed.
2. Place the valves in a stand so they can be
   reinstalled in the same position in the cylinder
   head.

99 322
FG020258
Figure 35
DX300LC-5
Engine 4-1-60
23
2. Installing Valves
99 322
NOTE
There are different versions of the combination
valve valve spring collar split collet. Parts
from the different versions must not be mixed
on the same valve.

• Lubricate all parts well with engine oil before
  assembly.
• Insert the valve in the guide. C.
• D.

Install the valve springs and the valve spring
collar. Press together the springs in a press
with tool 99 322 and install the collets. Ensure
that collets are installed in their correct
positions.
FG020259
Figure 36

• Replacing a Valve Stem Seal
• Remove valve according to the work description
• Removing Valves on page 4-1-75.
• Remove valve stem seal with a pair of pliers.
• Install the valve.

FG020261
Figure 37 4. Carefully tap a new valve stem seal
into place using tool 99 323 and a hammer.
99 323
FG020262
Figure 38
Engine 4-1-61
DX300LC-5
24
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Replacing the Valve Seats
1. Remove valve seat inserts with an expanding
sleeve from the kit with puller 587 270 (1,
Figure 39). NOTE Insert, for example, an
aluminum sheet between the cylinder head and
counterhold to protect against damage.
1
2
WARNING
FG020266
AVOID DEATH OR SERIOUS INJURY Wear protective
goggles for eye protection from flying metal
parts.
Figure 39
2. Press in new valve seat inserts. Use drift 99
384 (2, Figure 39) and shank 99 385. Cool the
drift and valve seat insert to about -80C with
dry ice or liquid air. Pressing must be done
rapidly.
99 385
99 384
WARNING
AVOID DEATH OR SERIOUS INJURY
Prevent frost injuries. Be careful when handling
very cold parts and refrigerant.
FG020267
Figure 40
Oversize valve seat inserts can be installed if
the valve seat insert position has been
damaged. The position is then machined using tool
587 277. Replacing the Valve Guides 1. Press out
the valve guides using drift 99 383.
99 383
FG020268
Figure 41
DX300LC-5
Engine 4-1-62
26
2. Press in the new valve guides using drift 99
382. Press the guide down as far as the drift
allows, i.e. until it contacts the spring seat
in the cylinder head.
99 382
FG020269
Figure 42
Replacing the Injector Sleeves The cylinder head
must be removed when replacing the unit injector
sleeve. The valves do not need removing. The
illustrations show the cylinder head with valves
removed to demonstrate clearly the work
described. NOTE Guide and pilot tap on
extension piece 99 397.

FG020272
Figure 43

1. Thread the lower part of the sleeve using the
   pilot tap and guide from tool kit 99 574.
2. Knock out the pilot tap and sleeve from
   underneath. Use a 100 mm long metal rod of
   diameter 9 mm.
3. Degrease and check the contact surfaces of the
   sleeve and cylinder head. Smooth off any burrs
   and irregularities that may score the sleeve.
4. Degrease the new injector sleeve and apply a thin
   film of sealant 561 200 on the sleeve and
   cylinder head contact surfaces.
5. Press in the sleeve using the drift and guide
   from tool kit 99 574.

FG020273
Figure 44
Engine 4-1-63
DX300LC-5
27
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the link into your browser. The full manual is
available for immediate download. https//www.eb
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