Daewoo Doosan DX340LC-5, DX350LC-5 Excavator Service Repair Manual Instant Download (Serial Number 10001 and Up)

1
Shop Manual
DX340LC-5/DX350LC-5
Excavator
Serial Number 10001 and Up
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.
950106-01001E April 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
• Hydraulic 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
• Accumulator
• Two Pump
• 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
10 Options

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

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
DX340LC-5/DX350LC-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
DX340LC-5/DX350LC-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.

DX340LC-5/DX350LC-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
DX340LC-5/DX350LC-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
DX340LC-5/DX350LC-5
Track Excavator Maintenance Safety 1-1-8
10
Personal Protective Equipment (PPE) Do not wear
loose clothing and accessories. Secure long hair.
These items can snag on controls or on other
parts of equipment. Do not wear oily clothes.
They are highly flammable. Do not forget that
some risks to your health may not be immediately
apparent. Exhaust gases and noise pollution may
not be visible, but these hazards can cause
disabling or permanent injuries. Breathing masks
and/or ear protection may be required. Wear a
hard hat, safety shoes, safety goggles, mask,
leather gloves, earplugs and other protective
equipment, as required. While working on machine,
never use inadequate tools. They could break or
slip, or they may not adequately perform intended
functions.
HAOA020L
Figure 4
Correction of Machine Problems If any machine
problems are found during operation and
maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil leakage, etc.), or if any
abnormal warning alerts are displayed on display
monitor, stop the machine and take the necessary
corrective actions. Do not operate machine until
problem has been corrected. Crushing and
Cutting Keep objects away from moving fan blades.
Fan blades can throw and cut objects. Do not use
a wire rope that is kinked or frayed, or a wire
rope with any loss of diameter. Wear leather
gloves when handling a wire rope. When striking
a loose retainer pin, it can fly out and can
cause a serious injury. Make sure that area is
clear of personnel when striking a retainer pin.
To avoid injury to your eyes, wear safety
goggles when striking a retainer pin. Do not put
your hand, arm or any other part of your body
between movable parts. If going between movable
parts is necessary, always position and secure
work equipment so it cannot move. Properly
support equipment before performing any work or
maintenance under raised equipment. If control
levers are operated, clearance between machine
and work equipment will change and this may lead
to serious damage or can result in death or
serious injury. Stay clear of areas that may
have a sudden change in clearance with machine
movement or equipment movement. Stay clear of all
rotating and moving parts. Unless instructed,
never attempt adjustments while machine is
moving or while engine is running.
Track Excavator Maintenance Safety 1-1-9
DX340LC-5/DX350LC-5
11
Do not depend on hydraulic cylinders to support
raised equipment. Equipment can fall if a
control is moved, or if a hydraulic line breaks,
is loosened or disconnected. If it is necessary
to remove guards to perform maintenance, always
install guards after maintenance is completed.
HDO1010L
Figure 5
Hot Coolant and Oils - Burn Prevention Do not
touch any part of an operating engine.
Immediately after operations are stopped,
coolant, engine oil, and hydraulic oil are at
their highest temperatures. The radiator and
hydraulic tank are still under pressure. Always
wait for temperature to cool down. Attempting to
remove caps, drain oil or coolant, or replacing
filters may lead to serious burns, if done when
hot. Relieve all pressure in air system,
hydraulic oil system, lubrication system, fuel
system, and cooling system, before any lines,
fittings or related items are disconnected.
FG019095
Figure 6 To prevent hot oil or coolant from
spraying out, stop engine, wait for oil and
coolant to cool. Using gloves, slowly loosen cap
to relieve pressure.
FG019096
Figure 7
DX340LC-5/DX350LC-5
Track Excavator Maintenance Safety 1-1-10
12
Engine
Edition 1
DX340LC-5/DX350LC-5
Engine 4-1-1
13
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
DX340LC-5/DX350LC-5
14
OVERVIEW
FRONT
EX1301800
Figure 1
DX340LC-5/DX350LC-5
Engine 4-1-8
15

• Mounting the Engine in a Universal Stand
• Preparations before commencing work
• Remove engine from the machine.

2
3
4
1
FG020231
Figure 3
Reference Number Description
1 Engine Control Unit
2 Fuel Filter
Reference Number Description
3 High-pressure Pump and Feed Pump
4 Starter Motor
1. Mount the engine in the universal stand.
Reference Number Description
1 Bolt M10 x 30 (8 off)
2 Nut M16 (4 off)
3 Bolt M16 x 50 (4 off)
2
3 99 331
1
FG020232
Figure 4
Engine 4-1-19
DX340LC-5/DX350LC-5
16
ENGINE IDENTIFICATION Engine Data Plate
Reference Number Description
A Smoke Value
B Engine Type
C Engine Serial Number
A
B
C
FG020225
Figure 5
Figure 6
Reference Number Description
1 Warning! High Fuel Pressure
2 Important Engine Information
3 Valve Clearance
4 Engine Serial Number
5 Engine Power
Figure 7
DX340LC-5/DX350LC-5
Engine 4-1-20
17
Tightening Torques for Engines
IMPORTANT
Tightening torques for threaded joints in
engines. If the tightening torque is not
available in the table for each engine, refer to
the special and normal tightening torques tables.
Engine Assembly Engine Assembly Engine Assembly Engine Assembly Engine Assembly Engine Assembly
Cylinder Block Cylinder Block Cylinder Block Cylinder Block Cylinder Block Cylinder Block
Piston cooling nozzle 23 Nm Piston cooling nozzle 23 Nm Piston cooling nozzle 23 Nm Piston cooling nozzle 23 Nm Piston cooling nozzle 23 Nm Piston cooling nozzle 23 Nm
Main Bearing Cap Main Bearing Cap Main Bearing Cap Main Bearing Cap Main Bearing Cap Main Bearing Cap
NOTE The screws can only be reused 3 times. Mark the NOTE The screws can only be reused 3 times. Mark the
screws each time before fitting. screws each time before fitting. 1 2 3 4

EX1301810
Torx screw (M19) 110 Nm 90 Torx screw (M19) 110 Nm 90
Hexagon screw (M19) 110 Nm 90 Hexagon screw (M19) 110 Nm 90
EX1301811 EX1301811 EX1301811 EX1301811
Connecting Rod Cap Connecting Rod Cap Connecting Rod Cap Connecting Rod Cap Connecting Rod Cap Connecting Rod Cap
NOTE The screws can only be reused 3 times. Mark the
screws each time before fitting. 1 2 3 4

EX1301810
DX340LC-5/DX350LC-5
Engine 4-1-30
18
Torx screw 50 Nm 90 Check torque 170 Nm EX1302070 EX1302070 EX1302070 EX1302070 EX1302070 EX1302070 EX1302070 EX1302070
Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing
Lead-in union 40 Nm 6
Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package
Cylinder Head Cylinder Head Cylinder Head Cylinder Head Cylinder Head Cylinder Head Cylinder Head Cylinder Head Cylinder Head
NOTE The screws can only be reused 3 times. Mark the
screws each time before fitting. 1 2 3 4

EX1301810
Cylinder head bolt, tightened in four stages 3 6 1 2 5 4 FG020253
First stage 60 Nm 3 6 1 2 5 4 FG020253
Second stage 150 Nm 3 6 1 2 5 4 FG020253
Third stage 250 Nm 3 6 1 2 5 4 FG020253
Fourth stage 90 3 6 1 2 5 4 FG020253
Engine 4-1-31
DX340LC-5/DX350LC-5
19
Rocker Cover Rocker Cover
Rocker cover, upper 18 Nm Rocker cover, lower 18 Nm
Rocker cover, upper 18 Nm Rocker cover, lower 18 Nm
Valve Mechanism Valve Mechanism
Adjusting screw nut on rocker arm 35 Nm
Adjusting screw nut on rocker arm 35 Nm
DX340LC-5/DX350LC-5
Engine 4-1-32
20
Screw for rocker arm shaft bearing retainer 90 Nm 60
Roller Tappet Shaft Roller Tappet Shaft
Banjo screw for roller tappet shaft (engines produced earlier) 33 Nm Slotted screw for roller tappet shaft (engines produced later) 40 Nm
Banjo screw for roller tappet shaft (engines produced earlier) 33 Nm Slotted screw for roller tappet shaft (engines produced later) 40 Nm
Banjo screw for roller tappet shaft (engines produced earlier) 33 Nm Slotted screw for roller tappet shaft (engines produced later) 40 Nm
Engine 4-1-33
DX340LC-5/DX350LC-5
21
Crank Mechanism Crank Mechanism
Flywheel Flywheel
M18 flange screw 180 Nm 120
Torsion Damper Torsion Damper
Torsion damper hub 90 Nm 30 Torsion damper hub 90 Nm 30
Timing Gear Timing Gear
Intermediate gear 50 Nm 60 Camshaft gear 20 Nm 40 EX1301830
Lubrication System Lubrication System
Oil sump Cylinder block, 8.8 screw 26 Nm Cylinder block, 10.9 screw 32 Nm Against cylinder block, 8.8 screw with spacer 26 Nm
Oil Sump, Plastic Oil Sump, Plastic
Oil sump, spring screw 20 Nm Oil sump, spring screw 20 Nm
DX340LC-5/DX350LC-5
Engine 4-1-34
22
Oil Plug Oil Plug
Thread insert for oil plug 320 Nm Magnetic oil plug, oiled seal 80 Nm
Thread insert for oil plug 320 Nm Magnetic oil plug, oiled seal 80 Nm
Magnetic oil plug, dry seal 115 Nm
Oil plug for filler connection in oil sump 60 Nm Oil pump, 10.9 screw 32 Nm Oil pump, 8.8 screw 26 Nm Hose connection for cooling system 85 Nm Oil filler pipe, retaining screw 20 Nm Oil plug for filler connection in oil sump 60 Nm Oil pump, 10.9 screw 32 Nm Oil pump, 8.8 screw 26 Nm Hose connection for cooling system 85 Nm Oil filler pipe, retaining screw 20 Nm
Oil Filter Oil Filter
Element type filter, cover 25 Nm Oil filter unit without loose filter element Hand tighten
Engine 4-1-35
DX340LC-5/DX350LC-5
23
Oil Cooler Oil Cooler
Oil cooler core 26 Nm
Centrifugal Oil Cleaner Centrifugal Oil Cleaner
Nut for outer cover 15 Nm
Oil Mist Separator Oil Mist Separator
Nut (M18 x 1.5) 35 5 Nm Nut (M18 x 1.5) 35 5 Nm
Exhaust System Exhaust System
Exhaust Manifold Exhaust Manifold
Cylinder head hexagon screw 40 Nm 60 Cylinder head Torx screw 60 Nm 60 Turbocharger 50 Nm Cylinder head hexagon screw 40 Nm 60 Cylinder head Torx screw 60 Nm 60 Turbocharger 50 Nm
Exhaust pipe from Turbocharger Exhaust pipe from Turbocharger
Turbocharger (V-clamp) 20 Nm EX1301840
Turbocharger Oil Pipe Turbocharger Oil Pipe
Turbocharger lubrication pipe 40 1.2 Nm (3 ) Nut for turbocharger lubrication pipe 35 5 Nm Turbocharger lubrication pipe 40 1.2 Nm (3 ) Nut for turbocharger lubrication pipe 35 5 Nm
Turbocharger Coolant Pipe Turbocharger Coolant Pipe
Water inlet, turbocharger 40 Nm Water inlet, variable geometry turbocharger electric motor 10 Nm Water inlet, turbocharger 40 Nm Water inlet, variable geometry turbocharger electric motor 10 Nm
DX340LC-5/DX350LC-5
Engine 4-1-36
24
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Variable Geometry Turbocharger, Electric Motor Variable Geometry Turbocharger, Electric Motor
To be tightened crosswise in two stages (Screw 12.9) 3 Nm, 11 Nm To be tightened crosswise in two stages (Screw 12.9) 3 Nm, 11 Nm
Silencer Silencer
Exhaust pipe to and from silencer (V-clamp) 20 Nm EX1301840
Reductant Doser Reductant Doser
Nut (M6) 10 Nm
Charge Air Cooler Charge Air Cooler
Pipe connection (V-clamp) 8 Nm EX1301840
Fuel System Fuel System
Injectors Injectors
Nut for cable connection 2 Nm
Engine 4-1-37
DX340LC-5/DX350LC-5
26
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