Daewoo Doosan DX380LC-3 Excavator Service Repair Manual Instant Download (Serial Number 10001 and Up)

1
Shop Manual DX380LC-3 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.
950106-00228E April 2012
Original Instructions
Copyright DOOSAN 2012
2
Table of Contents
Safety Track Excavator Maintenance Safety
..................................................
. SP002322 Specifications Specification for
DX380LC-3 ........................................
........................ SP002604 General
Maintenance General Maintenance Instructions
..................................................
...... SP002454 Standard Torques
..................................................
............................... SP002404 Upper
Structure Cabin ..................................
..................................................
................ SP002324 Counterweight...........
..................................................
.......................... SP002606 Fuel
Tank..............................................
................................................
SP002410 Fuel Transfer Pump (Option)
..................................................
.............. SP002394 Swing Bearing.............
..................................................
........................ SP002329 Lower
Structure and Chassis Track Assembly
..................................................
..................................
SP002607 Engine and Drivetrain Engine Coolant
Heater (Option) ..................................
......................... SP002328 Drive Coupling
(Main Pump).......................................
.......................... SP002411 Hydraulics Hy
draulic System Troubleshooting, Testing and
Adjustment ............... SP002412
Accumulator.......................................
..................................................
. SP002455 Center Joint (Swivel)..................
..................................................
......... SP002545 Cylinders......................
..................................................
....................... SP002422
3
Swing Device .....................................
..................................................
. SP002413 Travel Device..........................
..................................................
............ SP002609 Main Pump...................
..................................................
....................... SP002415 Gear Pump
..................................................
.........................................
SP002568 Fan Motor for Oil Cooler
..................................................
..................... SP002552 Fan Pump
..................................................
...........................................
SP002553 Main Control Valve ......................
..................................................
....... SP002416 Remote Control Valve (Work Lever
/ Joystick) .....................................
SP002450 Travel Control Valve (with
Damper)...........................................
........... SP002381 Solenoid Valve Assembly
..................................................
................... SP002406 Breaker EPPR Valve
(Option) .........................................
..................... SP002458 Hydraulic
Schematic.........................................
....................................
SP002610 Electrical System Electrical System
..................................................
................................
SP002418 Electrical Schematic ....................
..................................................
....... SP002419 Attachments Boom and
Arm...............................................
.......................................
SP002605 Bucket...................................
..................................................
.............. SP002421
4
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Track Excavator Maintenance
Safety
SP002322
Edition 3
Track Excavator Maintenance Safety
SP002322 Page 1
6
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation and 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.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DX140LC-3 1001 and Up, 50001 and Up
DX180LC-3 1001 and Up, 50001 and Up
DX225LC-3 1001 and Up, 50001 and Up
DX255LC-3 1001 and Up, 50001 and Up
DX300LC-3 1001 and Up, 50001 and Up
DX340LC-3 1001 and Up, 10001 and Up
DX350LC-3 1001 and Up, 10001 and Up
DX380LC-3 10001 and Up
DX420LC-3 10001 and Up
DX490LC-3 10001 and Up
DX530LC-3 10001 and Up
SP002322 Page 5
Track Excavator Maintenance Safety
7
SAFETY MESSAGES Safety messages and safety decals
included in this manual and on the machine
provide instructions how to operate, service and
maintain the machine. Safety messages and safety
decals indicate potential hazards and describe
safety precautions required to avoid hazards.
Operator and maintenance personnel should read
and understand these safety messages and decals
before beginning operation or maintenance.
SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and Safety Instructions. This is a Safety Alert Symbol. Wherever it appears in this manual or on safety decals on the machine, you must be alert to the potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures.
Signal Words The signal words "DANGER",
"WARNING", "CAUTION" are used throughout safety
messages and safety decals in this manual or on
the machine. They indicate an existence of, and
the relative seriousness of, a hazard. All three
indicate that a safety risk is involved. Observe
the precautions indicated whenever a Safety
Alert Symbol is present, no matter which signal
word appears next to it.
DANGER
DANGER - This signal word is used on safety messages and safety labels and indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
WARNING - This signal word is used on safety messages and safety labels and indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Track Excavator Maintenance Safety Page 6
SP002322
8
CAUTION
CAUTION - This signal word is used on safety messages and safety labels and indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.
Other Signal Words In addition to safety signal
words, the following signal words are used to
indicate proper and effective use of machine.
IMPORTANT
This signal word identifies procedures which must be followed to avoid damage to machine.
The word "NOTE" identifies information for
effective use.
SAFETY DECALS Location of safety labels (decals)
can vary from unit to unit. Refer to appropriate
Operation and Maintenance Manual, and parts
manual for your unit. Always replace damaged or
faded decals.
SP002322 Page 7
Track Excavator Maintenance Safety
9
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 lock 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.
• 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

Track Excavator Maintenance Safety Page 8
SP002322
10
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. 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.
FG018457
Figure 1
SP002322 Page 9
Track Excavator Maintenance Safety
11
Swing Bearing
SP002329
Edition 3
Swing Bearing
SP002329 Page 1
12
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation and 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.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DX140LC-3 1001 and Up, 50001 and Up
DX180LC-3 1001 and Up, 50001 and Up
DX225LC-3 1001 and Up, 50001 and Up
DX255LC-3 1001 and Up, 50001 and Up
DX300LC-3 1001 and Up, 50001 and Up
DX340LC-3 1001 and Up, 10001 and Up
DX350LC-3 1001 and Up, 10001 and Up
DX380LC-3 10001 and Up
DX420LC-3 10001 and Up
DX490LC-3 10001 and Up
DX530LC-3 10001 and Up
SP002329 Page 5
Swing Bearing
13
SWING BEARING MAINTENANCE
Operating Recommendation The service life of the
swing bearing may be extended if a daily effort
is made to equalize usage over both ends of the
excavator. If the excavator is used in the same
operating configuration day in and day out (for
example, with the travel motors always under the
counterweight, or with the attachment over one
side of the machine more than the other), the
bearing's service life could be reduced.
Repositioning the excavator during the work
shift, to work the opposite end of the bearing,
will provide a more even and gradual rate of wear
and extended service life.
Measuring Swing Bearing Axial Play Regular checks
of bearing displacement must be made at least
twice a year. Use a dial indicator. Push the
attachment against the ground to lift up the
excavator above the ground and take measurements
at 4 points, 90 apart, around the circumference
of the bearing (Figure 1). Record and keep all
measurements. Play in the bearing should
increase minimally from one inspection to the
next. Eventually, however, as the bearing begins
to approach the limit of its service life,
clearance increases become much more pronounced
and the actual measured play in the bearing could
exceed twice the value that was measured when
the machine was new.
1
2
Measuring Bearing Lateral Play When vertical
checks are made, the side to side play in the
bearing can be checked by fully retracting the
arm and bucket cylinders and extending the tip
of the bucket as far forward as it will go. With
the excavator parked on a flat, level surface and
the bucket tip just off the ground, push against
the bucket sideways to take up all the lateral
clearance in the bearing. (Less than 100 lb of
force must be required to move the bucket over
all the way.) Check lateral play in both
directions and record the values. When the
bearing is beginning to approach the end of its
service life, the measured lateral clearance
should start to show increase in value.
FG018734 Figure 1
Swing Bearing Page 6
SP002329
14
Swing Bearing Basic Operation The swing bearing,
which connects the upper structure with the
lower structure, consists of a inner ring, outer
ring and ball bearings. During swing movement,
power from the swing motor is transferred to the
pinion by planetary gears connected to gears on
the inner ring, which is fixed in the
undercarriage. Ball bearings turn the outer ring.
Reference Number Description
1 Outer Ring
2 Inner Ring
3 Tapered Pin
4 Plug
5 Ball
6 Retainer
7 Seal
Figure 2
Disassembly 1. Remove tip of tapered pin (3,
Figure 3) using grinder and tap lightly to
remove debris.
Figure 3 2. Remove plug (4, Figure 4) using a
M10 x P 1.5 bolt.
Figure 4
SP002329 Page 7
Swing Bearing
15
3. Lift outer ring and check that inner ring can
move freely. See Figure 5, if not, replace seal
(7, Figure 6).
Figure 5 4. Turn inner ring and use magnet bar
(C, Figure 6) to remove steel balls (5).
Figure 6 5. Turn inner ring and use wire (D,
Figure 7) to remove retainers (6).
Figure 7
Swing Bearing Page 8
SP002329
16
Assembly 1. Clean (degrease) the seal groove for
the outer and inner seals (7). Apply instant
glue to seal (7). Install both seals respectively
into position.
Figure 8 2. Hoist the outer race by crane
horizontally and match it with the inner race
coaxially. Rotating the outer race, insert balls
(5), support (6) into the plug (4) hole one by
one with a round bar.
Figure 9
Figure 10 3. Top plug (4) into outer race (1)
and then, drive pin (3) into the pinhole. Caulk
the head of pin (3) with a punch. Fill grease
through the grease fitting.
Figure 11
SP002329 Page 9
Swing Bearing
17
Track Assembly
SP002607
Edition 1
Track Assembly
SP002607 Page 1
18
TRACK TENSION
WARNING
AVOID DEATH OR SERIOUS INJURY Measuring track tension requires two people. One person must be in the operator's seat, operating the controls while the other person makes dimensional checks. Block frame to make sure the machine won't move or shift position during service. Warm up the engine to prevent stalls, park the excavator in an area that provides level, uniform ground support and/or use support blocks when necessary. The track adjusting mechanism is under very high-pressure. NEVER release grease pressure too fast. The track tension grease valve should never be loosened more than one (1) complete turn from the fully tightened down position. Bleed off grease pressure slowly. Keep your body away from the valve always. Always wear eye and face protection when adjusting track tension.
Track shoe link pins and bushings wear with
normal usage, reducing track tension. Periodic
adjustment is necessary to compensate for wear
and it may also be required by working
conditions. 1. Track tension is checked by
jacking up one side of the excavator. See Figure
1. Place blocking under frame while taking
measurement. Turn the track backward by 1 - 2
turns.
90 110
FG018383
Figure 1 2. Measuring the distance (A, Figure 2)
between the bottom of the side frame and the top
of the lowest crawler shoe. Recommended tension
for operation over most types of terrain is
distance "B" in below table.
NOTE
Clean off the tracks before checking clearance
for accurate measurements.
A
3. Too little sag in the crawler track (less than
clearance distance "B" in below table) can cause
excessive component wear. The recommended
adjustment can also be too tight causing
accelerated stress and wear if ground conditions
are wet, marshy or muddy.
FG000223
Figure 2
SP002607 Page 7
Track Assembly
19
4. The increased clearance recommended for
muddy, sandy or snowy ground conditions is
between distance "C" in the below table.
Terrain Type Recommended Distance "A"
Normal "B" 380 - 410 mm (14.96 - 16.14 in)
Muddy, Sandy or Snowy "C" 410 - 460 mm (16.14 - 18.11 in)
WARNING
AVOID DEATH OR SERIOUS INJURY The track adjusting mechanism is under very high- pressure. NEVER release grease pressure too fast. The track tension grease valve should never be loosened more than one (1) complete turn from the fully tightened down position. Bleed off grease pressure slowly. Keep your body away from the valve always. Always wear eye and face protection when adjusting track tension.

1. Track tension adjustments are made through the
   grease fitting (1, Figure 3) in the middle of
   each side frame. Adding grease increases the
   length of an adjustment cylinder (2). Extending
   the adjustment cylinder, increases the pressure
   on the tension spring pushing the track idler
   wheel outward.
2. If there is not enough slack or clearance in the
   tracks and the adjustment is too tight, the
   idler wheel and adjusting cylinder can be
   retracted by bleeding off grease through hole in
   adjustment cylinder (2, Figure 3).

2
1
3
FG018365
Figure 3
Track Assembly Page 8
SP002607
20
CLEANING AND INSPECTION (WEAR LIMITS AND
TOLERANCES)
CAUTION
AVOID INJURY Refer to "Welding Precautions and Guidelines" information in "General Maintenance Procedures" section for general recommendations and specific safety precautions, before starting any lower travel frame component rebuilding procedure.
The tables that follow provide factory specified
dimensional limits (as new condition,
recommended service and replacement limit) for
lower travel frame components. Recommended
maintenance to replace most listed components
requires welding on additional material and
grinding off excess. Some components must be
replaced before the service limit is exceeded.
No maintenance or renewal is possible. Compare
the values in the tables with dimensions and
profiles shown in the adjacent figures.
SP002607 Page 9
Track Assembly
21
Track Shoe
8 7
10
7
2
2
9
11
1
3
6
4
5
FG018732
Figure 4
Track Assembly Page 10
SP002607
22
No. Check Item Standard Dimension Standard Dimension Standard Dimension Recommended Limit for Maintenance Recommended Limit for Maintenance Limit for Use (Repair - P or Replace - R)
1 Link Pitch 215.9 mm (8.50") 215.9 mm (8.50") 215.9 mm (8.50")
2 Bushing Outside Diameter 71.4 mm (2.81") 71.4 mm (2.81") 71.4 mm (2.81") 68 mm (2.68") 68 mm (2.68") 66 mm (R) (2.60")
3 Link Height 129 mm (5.08") 129 mm (5.08") 129 mm (5.08") 126 mm (4.96") 126 mm (4.96") 122 mm (P) (4.80")
4 Length at Tip 24 mm (0.94") 24 mm (0.94") 24 mm (0.94")
5 Length at Tip 18 mm (0.71") 18 mm (0.71") 18 mm (0.71")
6 Height 36 mm (1.42") 36 mm (1.42") 36 mm (1.42") 32 mm (1.26") 32 mm (1.26") 30 mm (1.18")
7 Interference between bushing and link Bushing Tolerance Link Tolerance Standard Interference Repair Limit
7 Interference between bushing and link 71.4 mm (2.81") 0.050 0.0 71 mm (2.80") 0.074 0 0.326 - 0.450
8 Interference between regular pin and link Regular Pin Tolerance Link Tolerance Standard Interference Repair Limit
8 Interference between regular pin and link 47 mm (1.85") 0.285 0.135 46.8 mm (1.84") 0.062 0 0.273 - 0.485
9 Clearance between regular pin and bushing Regular Pin Tolerance Bushing Tolerance Standard Clearance Repair Limit
9 Clearance between regular pin and bushing 47mm (1.85") 0.285 0.135 47.9 mm (1.89") 0.5 0 0.615 - 1.265
10 Interference between master pin and link Master Pin Tolerance Link Tolerance Standard Interference Repair Limit
10 Interference between master pin and link 47 mm (1.85") 0.11 0.08 46.8 mm (1.84") 0.062 0 0.218 - 0.310
11 Clearance between master pin and bushing Master Pin Tolerance Bushing Tolerance Standard Clearance Repair Limit
11 Clearance between master pin and bushing 46.8 mm (1.84") 0 -0.2 47.9 mm (1.89") 0.5 0 1.100 - 1.800
SP002607 Page 11
Track Assembly
23
Lower Roller
3
4
5
6
2
1
FG018733
Figure 5
No. Check Item Standard Dimension Standard Dimension Recommended Limit for Maintenance Recommended Limit for Maintenance Limit for Use (Repair - P or Replace - R)
1 Outside Diameter of Flange 250 mm (9.84") 250 mm (9.84")
2 Outside Diameter of Tread 200 mm (7.87") 200 mm (7.87") 194 mm (7.64") 194 mm (7.64") 190 mm (P) (7.48")
3 Width of Tread 55 mm (2.17") 55 mm (2.17") 64 mm (2.52") 64 mm (2.52") 71 mm (P) (2.80")
4 Width of Flange 35 mm (1.38") 35 mm (1.38")
5 Clearance between shaft and bushing Standard Dimension Tolerance Tolerance Standard Clearance Repair Limit
5 Clearance between shaft and bushing Standard Dimension Shaft Hole Standard Clearance Repair Limit
5 Clearance between shaft and bushing 85 mm (3.35") -0.08 -0.13 0.50 0.45 0.530 - 0.630 1.8 mm (R) (0.07")
6 Interference between roller and bushing Standard Dimension Tolerance Tolerance Standard Interference Repair Limit
6 Interference between roller and bushing Standard Dimension Shaft Hole Standard Interference Repair Limit
6 Interference between roller and bushing 92 mm (3.62") 0.23 0.18 0.030 -0.020 0.150 - 0.250
Track Assembly Page 12
SP002607
24
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Upper Roller
4 3
5
6
2
1
FG004352
Figure 6
No. Check Item Standard Dimension Standard Dimension Recommended Limit for Maintenance Recommended Limit for Maintenance Recommended Limit for Maintenance Limit for Use (Repair - P or Replace - R)
1 Outside Diameter of Flange 210 mm (8.27") 210 mm (8.27")
2 Outside Diameter of Tread 180 mm (7.09") 180 mm (7.09") 171 mm (6.73") 171 mm (6.73") 171 mm (6.73") 162.5 mm (P) (6.40")
3 Width of Tread 47.5 mm (1.87") 47.5 mm (1.87")
4 Width of Flange 17.5 mm (0.69") 17.5 mm (0.69") 11.5 mm (0.45")
5 Clearance between shaft and bushing Shaft Tolerance Bushing Tolerance Standard Clearance Repair Limit
5 Clearance between shaft and bushing 60 mm (2.36") -0.05 -0.10 60 mm (2.36") 0.40 0.34 0.390 - 0.500
6 Interference between roller and bushing Standard Dimension Tolerance Tolerance Tolerance Standard Interference Repair Limit
6 Interference between roller and bushing Standard Dimension Shaft Hole Hole Standard Interference Repair Limit
6 Interference between roller and bushing 68 mm (2.68") 0.19 0.13 0.03 -0.02 0.03 -0.02 0.100 - 0.210
SP002607 Page 13
Track Assembly
26
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the link into your browser. The full manual is
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