Daewoo Doosan DX380LC-5 Excavator Service Repair Manual Instant Download (Serial Number 10001 and Up)

1
Shop Manual
DX380LC-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.
950106-01236E October 2014
Original Instructions
Copyright DOOSAN 2014
2
Table of Contents
1 Safety

• 1 Track Excavator Maintenance Safety
• 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
• Joystick Valve (Work Lever)
• Travel Control Valve (with Damper)
• Solenoid Valve
• Accumulator
• Two Pump
• Gear Pump (Rotating)
• One Spool Valve (Rotating)
• Swing Bearing

6 Lower Structure and Chassis
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
DX380LC-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
DX380LC-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.

DX380LC-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
DX380LC-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
DX380LC-5
Track Excavator Maintenance Safety 1-1-8
10
Engine
Edition 1
DX380LC-5
Engine 4-1-1
11
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 N.m Piston cooling nozzle 23 N.m Piston cooling nozzle 23 N.m Piston cooling nozzle 23 N.m Piston cooling nozzle 23 N.m Piston cooling nozzle 23 N.m
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 N.m 90 Torx screw (M19) 110 N.m 90
Hexagon screw (M19) 110 N.m 90 Hexagon screw (M19) 110 N.m 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
DX380LC-5
Engine 4-1-30
12
Torx screw 50 N.m 90 Check torque 170 N.m EX1302070 EX1302070 EX1302070 EX1302070 EX1302070 EX1302070 EX1302070
Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing
Lead-in union 40 N.m 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 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 N.m 3 6 1 2 5 4 FG020253
Second stage 150 N.m 3 6 1 2 5 4 FG020253
Third stage 250 N.m 3 6 1 2 5 4 FG020253
Fourth stage 90 3 6 1 2 5 4 FG020253
Engine 4-1-31
DX380LC-5
13
Rocker Cover Rocker Cover
Rocker cover, upper 18 N.m Rocker cover, lower 18 N.m
Rocker cover, upper 18 N.m Rocker cover, lower 18 N.m
Valve Mechanism Valve Mechanism
Adjusting screw nut on rocker arm 35 N.m
Adjusting screw nut on rocker arm 35 N.m
DX380LC-5
Engine 4-1-32
14
Screw for rocker arm shaft bearing retainer 90 N.m 60
Roller Tappet Shaft Roller Tappet Shaft
Banjo screw for roller tappet shaft (engines produced earlier) 33 N.m Slotted screw for roller tappet shaft (engines produced later) 40 N.m
Banjo screw for roller tappet shaft (engines produced earlier) 33 N.m Slotted screw for roller tappet shaft (engines produced later) 40 N.m
Banjo screw for roller tappet shaft (engines produced earlier) 33 N.m Slotted screw for roller tappet shaft (engines produced later) 40 N.m
Engine 4-1-33
DX380LC-5
15
Crank Mechanism Crank Mechanism
Flywheel Flywheel
M18 flange screw 180 N.m 120
Torsion Damper Torsion Damper
Torsion damper hub 90 N.m 30 Torsion damper hub 90 N.m 30
Timing Gear Timing Gear
Intermediate gear 50 N.m 60 Camshaft gear 20 N.m 40 EX1301830
Lubrication System Lubrication System
Oil sump Cylinder block, 8.8 screw 26 N.m Cylinder block, 10.9 screw 32 N.m Against cylinder block, 8.8 screw with spacer 26 N.m
Oil Sump, Plastic Oil Sump, Plastic
Oil sump, spring screw 20 N.m Oil sump, spring screw 20 N.m
DX380LC-5
Engine 4-1-34
16
Oil Plug Oil Plug
Thread insert for oil plug 320 N.m Magnetic oil plug, oiled seal 80 N.m
Thread insert for oil plug 320 N.m Magnetic oil plug, oiled seal 80 N.m
Magnetic oil plug, dry seal 115 N.m
Oil plug for filler connection in oil sump 60 N.m Oil pump, 10.9 screw 32 N.m Oil pump, 8.8 screw 26 N.m Hose connection for cooling system 85 N.m Oil filler pipe, retaining screw 20 N.m Oil plug for filler connection in oil sump 60 N.m Oil pump, 10.9 screw 32 N.m Oil pump, 8.8 screw 26 N.m Hose connection for cooling system 85 N.m Oil filler pipe, retaining screw 20 N.m
Oil Filter Oil Filter
Element type filter, cover 25 N.m Oil filter unit without loose filter element Hand tighten
Engine 4-1-35
DX380LC-5
17
Oil Cooler Oil Cooler
Oil cooler core 26 N.m
Centrifugal Oil Cleaner Centrifugal Oil Cleaner
Nut for outer cover 15 N.m
Oil Mist Separator Oil Mist Separator
Nut (M18 x 1.5) 35 5 N.m Nut (M18 x 1.5) 35 5 N.m
Exhaust System Exhaust System
Exhaust Manifold Exhaust Manifold
Cylinder head hexagon screw 40 N.m 60 Cylinder head Torx screw 60 N.m 60 Turbocharger 50 N.m Cylinder head hexagon screw 40 N.m 60 Cylinder head Torx screw 60 N.m 60 Turbocharger 50 N.m
Exhaust pipe from Turbocharger Exhaust pipe from Turbocharger
Turbocharger (V-clamp) 20 N.m EX1301840
Turbocharger Oil Pipe Turbocharger Oil Pipe
Turbocharger lubrication pipe 40 1.2 N.m (3 ) Nut for turbocharger lubrication pipe 35 5 N.m Turbocharger lubrication pipe 40 1.2 N.m (3 ) Nut for turbocharger lubrication pipe 35 5 N.m
Turbocharger Coolant Pipe Turbocharger Coolant Pipe
Water inlet, turbocharger 40 N.m Water inlet, variable geometry turbocharger electric motor 10 N.m Water inlet, turbocharger 40 N.m Water inlet, variable geometry turbocharger electric motor 10 N.m
DX380LC-5
Engine 4-1-36
18
Variable Geometry Turbocharger, Electric Motor Variable Geometry Turbocharger, Electric Motor
To be tightened crosswise in two stages (Screw 12.9) 3 N.m, 11 N.m To be tightened crosswise in two stages (Screw 12.9) 3 N.m, 11 N.m
Silencer Silencer
Exhaust pipe to and from silencer (V-clamp) 20 N.m EX1301840
Reductant Doser Reductant Doser
Nut (M6) 10 N.m
Charge Air Cooler Charge Air Cooler
Pipe connection (V-clamp) 8 N.m EX1301840
Fuel System Fuel System
Injectors Injectors
Nut for cable connection 2 N.m
Engine 4-1-37
DX380LC-5
19
Tighten the Injector in Four Stages Tighten the Injector in Four Stages
First stage, injector holder 20 N.m Second stage, connection 20 N.m Third stage, injector holder 56 N.m Fourth stage, connection 56 N.m
First stage, injector holder 20 N.m Second stage, connection 20 N.m Third stage, injector holder 56 N.m Fourth stage, connection 56 N.m
First stage, injector holder 20 N.m Second stage, connection 20 N.m Third stage, injector holder 56 N.m Fourth stage, connection 56 N.m
First stage, injector holder 20 N.m Second stage, connection 20 N.m Third stage, injector holder 56 N.m Fourth stage, connection 56 N.m
DX380LC-5
Engine 4-1-38
20
Pressure Pipe Pressure Pipe
Nut (M20) 38 N.m Nut (M16) 38 N.m Nut (M18 x 1.5) 35 5 N.m
Accumulator Accumulator
End connection 27 N.m 90 Safety valve 27 N.m 90 Pressure sensor 47 N.m End connection 27 N.m 90 Safety valve 27 N.m 90 Pressure sensor 47 N.m
High Pressure Pump High Pressure Pump
Pump gear 300 N.m High pressure pump, cylinder head bolt 68 N.m Screw for feed pump 25 N.m
Pump gear 300 N.m High pressure pump, cylinder head bolt 68 N.m Screw for feed pump 25 N.m
Pump gear 300 N.m High pressure pump, cylinder head bolt 68 N.m Screw for feed pump 25 N.m
Engine 4-1-39
DX380LC-5
21
Insert connection, feed pump 35 N.m Plug for guide pin 25 N.m Nipple, feed pump 55 N.m
Insert connection, feed pump 35 N.m Plug for guide pin 25 N.m Nipple, feed pump 55 N.m
Insert connection, feed pump 35 N.m Plug for guide pin 25 N.m Nipple, feed pump 55 N.m
Overflow Valve Overflow Valve
Overflow valve 55 N.m
DX380LC-5
Engine 4-1-40
22
Fuel Pipe Fuel Pipe
Banjo screw with copper gasket M8 11 N.m M10 15 N.m M12 28 N.m M14 45 N.m M16 55 N.m
Fuel Manifold Fuel Manifold
Straight joint (M16) 55 N.m Joint with check valve 55 N.m End joint, inner 30 N.m End joint, outer 15 N.m Straight joint (M16) 55 N.m Joint with check valve 55 N.m End joint, inner 30 N.m End joint, outer 15 N.m
Fuel Filter Fuel Filter
Fuel filter, cover 25 N.m
Auxiliary Equipment Auxiliary Equipment
Starter Motor Starter Motor
Stud (M10) 24 N.m Connection 30 20 N.m Connection 50 4 N.m
Engine 4-1-41
DX380LC-5
23
Alternator 100A Alternator 100A
Pulley nut (M17) 139 N.m Connection B 12.5 N.m
Hydraulic Pump Hydraulic Pump
Pump gear Tightening to be carried out in two stages. 1 Stage 70 N.m Wait a short while. 2 Stage 110 N.m NOTE After the second tightening, check that the nut has rotated between 20 and 110.
Belt Transmission Belt Transmission
Belt tensioner 50 N.m Fan coupling, double nut (M14) 165 N.m EX1301870
AC Compressor AC Compressor
Turnbuckle lock nuts 200 10 N.m
DX380LC-5
Engine 4-1-42
24
Compressor Compressor
Compressor gear 90 N.m 60
Disengageable Compressor Disengageable Compressor
Gear wheel screw Tightening to be carried out in 2 stages 1 Stage 10 N.m 1 N.m 2 Stage 90 10 Flange nut Tightening to be carried out in 2 stages 1 Stage 45 N.m 5 N.m 2 Stage 90 10 Cylinder head screw (M8) Tightening to be carried out in 3 stages 1 Stage 20 N.m 2 N.m 2 Stage 90 10/-5 3 Stage 90 10/-5 Cylinder head screw (M6) Tightening to be carried out in 2 stages 1 Stage 7 N.m 2 N.m 2 Stage 90 10/-5 Coolant pipe 30 Nm
Gear wheel screw Tightening to be carried out in 2 stages 1 Stage 10 N.m 1 N.m 2 Stage 90 10 Flange nut Tightening to be carried out in 2 stages 1 Stage 45 N.m 5 N.m 2 Stage 90 10 Cylinder head screw (M8) Tightening to be carried out in 3 stages 1 Stage 20 N.m 2 N.m 2 Stage 90 10/-5 3 Stage 90 10/-5 Cylinder head screw (M6) Tightening to be carried out in 2 stages 1 Stage 7 N.m 2 N.m 2 Stage 90 10/-5 Coolant pipe 30 Nm
Gear wheel screw Tightening to be carried out in 2 stages 1 Stage 10 N.m 1 N.m 2 Stage 90 10 Flange nut Tightening to be carried out in 2 stages 1 Stage 45 N.m 5 N.m 2 Stage 90 10 Cylinder head screw (M8) Tightening to be carried out in 3 stages 1 Stage 20 N.m 2 N.m 2 Stage 90 10/-5 3 Stage 90 10/-5 Cylinder head screw (M6) Tightening to be carried out in 2 stages 1 Stage 7 N.m 2 N.m 2 Stage 90 10/-5 Coolant pipe 30 Nm
Engine 4-1-43
DX380LC-5
25
Intake System Intake System
Intake Manifold Intake Manifold
Intake manifold to cylinder head 26 N.m 2 4 6 8 10 12 14 16 18 20 1 3 5 7 9 11 13 15 17 19 FG020255
Pneumatic Throttle Pneumatic Throttle
Nipple on actuator 11 N.m
Balance Axle Balance Axle
Bearing cap screw (M10) 25 N.m 45 Frame screw (M14) 90 N.m 60 Gear 50 N.m 60
Bearing cap screw (M10) 25 N.m 45 Frame screw (M14) 90 N.m 60 Gear 50 N.m 60
DX380LC-5
Engine 4-1-44
26


EGR System EGR System
Water Pipe Water Pipe
Hose clamps 6.5 N.m Retaining strap for EGR cooler, screw (M6) 8 N.m Coolant pipe to actuator 30 N.m Banjo screw, bleed pipe at the control cylinder (M12 x 1.5) 30 N.m
Engine 4-1-45
DX380LC-5
27
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Tightening Torques for Exhaust Gas Aftertreatment
IMPORTANT
Tightening torques for threaded joints in the
system for exhaust gas aftertreatment. If the
tightening torque is not in the table use the
tightening torque for normal tightening
torques. Tightening Torque
Sensor Sensor
NOx sensor 50 N.m Exhaust temperature sensor 38 N.m
NOx sensor 50 N.m Exhaust temperature sensor 38 N.m
Attachment, Trucks
Attachment, screw (M10) 59 N.m
DX380LC-5
Engine 4-1-46
29
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the link into your browser. The full manual is
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