Daewoo Doosan DX340LC-3, DX350LC-3 Excavator Service Repair Manual Instant Download

1
Shop Manual
DX340LC-3/DX350LC-3 Excavator
Serial Number 1001 and Up Serial Number 10001 and
Up (Europe Only)
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.
950106-00225E February 2012
Original Instructions
Copyright DOOSAN 2012
2
Table of Contents
Safety Track Excavator Maintenance Safety
..................................................
. SP002322 Specifications Specification for
DX340LC-3/DX350LC-3...............................
.............. SP002408 General
Maintenance General Maintenance Instructions
..................................................
...... SP002454 Standard Torques
..................................................
............................... SP002404 Upper
Structure Cabin ..................................
..................................................
................ SP002324 Counterweight...........
..................................................
.......................... SP002409 Fuel
Tank..............................................
................................................
SP002410 Fuel Transfer Pump (Option)
..................................................
.............. SP002394 Swing Bearing.............
..................................................
........................ SP002329 Lower
Structure and Chassis Track Assembly
..................................................
..................................
SP002330 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..........................
..................................................
............ SP002414 Main Pump...................
..................................................
....................... SP002415 Gear Pump
(Option) .........................................
.................................... SP002457 Fan
Motor for Oil Cooler .............................
..........................................
SP002552 Fan Pump ................................
..................................................
........... SP002553 Main Control Valve
..................................................
............................. SP002416 PRV (Peak
Reducing Valve)...................................
.............................. SP002459 Sensor
Block.............................................
............................................
SP002460 Remote Control Valve (Work Lever /
Joystick) .....................................
SP002450 Travel Control Valve (with
Damper)...........................................
........... SP002381 Solenoid Valve Assembly
..................................................
................... SP002406 Breaker EPPR Valve
(Option) .........................................
..................... SP002458 Hydraulic
Schematic.........................................
....................................
SP002417 Electrical System Electrical System
..................................................
................................
SP002418 Electrical Schematic ....................
..................................................
....... SP002419 Attachments Boom and
Arm...............................................
.......................................
SP002420 Bucket...................................
..................................................
.............. SP002421
4
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Track Excavator Maintenance
Safety
SP002322
Edition 2
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 should 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.
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.
Track Excavator Maintenance Safety Page 6
SP002322
8
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.
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 worksite,
  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.

SP002322 Page 7
Track Excavator Maintenance Safety
9
Track Assembly
SP002330
Edition 2
Track Assembly
SP002330 Page 1
10
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
DX300LC-3 1001 and Up, 10001 and Up
DX340LC-3 1001 and Up, 10001 and Up
DX350LC-3 1001 and Up, 10001 and Up
SP002330 Page 5
Track Assembly
11

• GENERAL DESCRIPTION
• The track assembly is composed of the following
  major components
• Track
• Front Idler Roller
• Upper Roller
• Lower Roller
• Track Spring and Track Adjustment Cylinder

Track Assembly Page 6
SP002330
12
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 at all times. 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
SP002330 Page 7
Track Assembly
13
4. The increased clearance recommended for
muddy, sandy or snowy ground conditions is
between distance "C" in below table.
Terrain Type Recommended Distance "A"
Normal "B" 320 - 340 mm (12.60 - 13.39 in)
Muddy, Sandy or Snowy "C" 340 - 370 mm (13.39 - 14.57 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 at all times. 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
SP002330
14
CLEANING AND INSPECTION (WEAR LIMITS AND
TOLERANCES)
CAUTION
AVOID INJURY Refer to the "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.
SP002330 Page 9
Track Assembly
15
Track Shoe
10 7
8 7
2
2
9
11
1
3
6
4
5
FG018732
Figure 4
Track Assembly Page 10
SP002330
16
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 216 mm (8.504") 216 mm (8.504") 216 mm (8.504")
2 Bushing Outside Diameter 66.5 mm (2.618") 66.5 mm (2.618") 66.5 mm (2.618") 62.5 mm (2.461") 62.5 mm (2.461") 59 mm (R) (2.323")
3 Link Height 116 mm (4.567") 116 mm (4.567") 116 mm (4.567") 108 mm (4.252") 108 mm (4.252") 103 mm (P) (4.055")
4 Length at Tip 22 mm (0.866") 22 mm (0.866") 22 mm (0.866")
5 Length at Tip 16 mm (0.630") 16 mm (0.630") 16 mm (0.630")
6 Height 30 mm (1.181") 30 mm (1.181") 30 mm (1.181") 24 mm (0.945") 24 mm (0.945") 20 mm (0.787")
7 Interference between bushing and link Bushing Tolerance Link Tolerance Standard Interference Repair Limit
7 Interference between bushing and link 66.91 mm (2.634") 0.050 0.0 66.5 mm (2.618") 0.074 0.0 0.336 - 0.460
8 Interference between regular pin and link Regular Pin Tolerance Link Tolerance Standard Interference Repair Limit
8 Interference between regular pin and link 44.6 mm (1.756") 0.235 0.085 44.35 mm (1.746") 0.062 0.0 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 44.6 mm (1.756") 0.235 0.085 45.45 mm (1.789") 0.500 0.0 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 44.6 mm (1.756") 0.030 0.0 44.35 mm (1.746") 0.062 0.0 0.188 - 0.280
11 Clearance between master pin and bushing Master Pin Tolerance Bushing Tolerance Standard Clearance Repair Limit
11 Clearance between master pin and bushing 44.3 mm (1.744") 0.050 45.45 mm (1.789") 0.500 0.0 1.100 - 1.700
SP002330 Page 11
Track Assembly
17
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 214 mm (8.425") 214 mm (8.425")
2 Outside Diameter of Tread 180 mm (7.087") 180 mm (7.087") 168 mm (6.614") 168 mm (6.614") 166 mm (P) (6.535")
3 Width of Tread 51 mm (2.008") 51 mm (2.008") 57 mm (2.244") 57 mm (2.244") 60 mm (P) (2.362")
4 Width of Flange 36 mm (1.417") 36 mm (1.417")
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 75 mm (2.953") -0.050 -0.100 0.400 0.350 0.400 - 0.500 1.5 mm (R) (0.059")
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 82 mm (3.228") 0.180 0.130 0.030 -0.020 0.100 - 0.200
Track Assembly Page 12
SP002330
18
Upper Roller
4
3
2
6
1
5
FG019393
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 175 mm (6.890") 175 mm (6.890")
2 Outside Diameter of Tread 142 mm (5.591") 142 mm (5.591") 135 mm (5.315") 135 mm (5.315") 135 mm (5.315") 130 mm (P) (5.118")
3 Width of Tread 45 mm (1.772") 45 mm (1.772") 52 mm (2.047") 52 mm (2.047") 52 mm (2.047") 54 mm (P) (2.126")
4 Width of Flange 18.5 mm (0.728") 18.5 mm (0.728")
5 Clearance between shaft and bushing Shaft Tolerance Bushing Tolerance Standard Clearance Repair Limit
5 Clearance between shaft and bushing 55 mm (2.165") 0.080 0.050 55.3 mm (2.177") 0.070 0.030 0.250 - 0.320
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 61 mm (2.402") 0.120 0.090 0.040 -0.030 0.040 -0.030 0.050 - 0.150
SP002330 Page 13
Track Assembly
19
Front Idler
4 3 5
7
6
1 2
FG019394
Figure 7
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 630 mm (24.803") 630 mm (24.803")
2 Outside Diameter of Tread 580 mm (22.835") 580 mm (22.835") 572 mm (22.520") 572 mm (22.520") 568 mm (P) (22.362")
3 Width of Protrusion 102 mm (4.016") 102 mm (4.016")
4 Total Width 190 mm (7.480") 190 mm (7.480")
5 Width of Tread 44 mm (1.732") 44 mm (1.732") 47 mm (1.850") 47 mm (1.850") 49 mm (1.929")
6 Clearance between shaft and bushing Standard Dimension Tolerance Tolerance Standard Clearance Repair Limit
6 Clearance between shaft and bushing Standard Dimension Shaft Hole Standard Clearance Repair Limit
6 Clearance between shaft and bushing 90 mm (3.543") -0.150 -0.200 0.340 0.300 0.450 - 0.540 1.0 mm (R) (0.039")
7 Interference between roller and bushing Standard Dimension Tolerance Tolerance Standard Interference Repair Limit
7 Interference between roller and bushing Standard Dimension Shaft Hole Standard Interference Repair Limit
7 Interference between roller and bushing 98 mm (3.858") 0.190 0.155 0.050 0.0 0.105 - 0.190
Track Assembly Page 14
SP002330
20
TRACK SHOES AND LINKS Track Removal
1. Position machine on a smooth level surface
with adequate room for forward and reverse travel.
FG019247

• Figure 8
• Move machine until master link (4, Figure 9) is
  positioned at approximately 4 o'clock from top
  position on front idle roller.
• Put a wooden block under track shoes, as shown.

2 1 4 FG004355
Figure 9 4. Loosen grease valve (1, Figure 10)
for track adjuster to drain grease out. Use
socket wrench 27 mm
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 at all times. Always wear eye and face protection when adjusting track tension.
1
FG004356
Figure 10

1. Remove four nuts and bolts (1 and 2, Figure 9)
   holding shoe to link. Remove enough shoes to
   make access to master pin.
2. Remove master pin from master link by hammer or
   press. Remove pin after detaching shoe.

SP002330 Page 15
Track Assembly
21
7. Move unit forward until entire track is laying
on ground. NOTE Do not drive unit off track.
FG003911

• Figure 11
• Rotate upper structure to 90 from track. Use
  bucket and boom to raise track frame off track.
• Position blocking under frame.

90 110
FG018383
Figure 12

• Track Installation
• Lay rebuilt or new track into position under
  track frame. End of track should be positioned
  under drive sprocket.
• With upper structure at 90 to track frame. Use
  bucket and boom to raise track frame off
  blocking.
• With blocking removed, lower track frame onto
  track. Make sure all rollers are properly
  positioned on track.

90 110
FG018383

• Figure 13
• Move unit forward while feeding track up over
  drive sprocket. Continue to pull track back
  until it engages front idle roller.
• Align master links and install master pin.
• Install four nuts and bolts (to fix track shoe).
• Apply track tension. Refer to "Track Tension on
  page -7" in this section for procedure.

FG003912
Figure 14
Track Assembly Page 16
SP002330
22
FRONT IDLER ROLLER Parts List
6
9
1
2
8
7 4
3
4 5
6
7
8
9
3
FG003913
Figure 15
Reference Number Description
1 Idler Assembly
2 Idler
3 Bearing
4 Shaft
5 Bushing
Reference Number Description
6 Pin
7 Floating Seal
8 O-ring
9 Plug
Track Assembly Page 18
SP002330
23
Front Idler Roller Disassembly 1. Remove plug (9,
Figure 16) from idler assembly (1), and drain oil
into a suitable container.
9
FG003914
Figure 16 2. Separate the pin (6, Figure 17)
from the bearing (3).
6
3
FG003915
Figure 17
3. Use a press to remove bearing from the axle
(4). Separate the O-ring (8, Figure 18) from the
axle.
4
3
8
FG001482
Figure 18
4. Detach the floating seal (7, Figure 19) from
the idler (2) and bearing (3).
3
7 2 7
3
FG001483
Figure 19
SP002330 Page 19
Track Assembly
24
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5. Use a press to separate the axle (4, Figure
20), O-ring (8) and bearing (3).
8 3
4 FG001484
Figure 20 6. Remove bushing (5, Figure 21) with
the press and special tool (10, ST-1909). 10
5
2
FG001485
Figure 21
SP002330
Track Assembly Page 20
26
Front Idler Roller Reassembly
4 3 8

• Degrease, clean and dry all parts before
  reassembly. Insert bushing (5, Figure 21) into
  the idler (2).
• Grease O-ring (8, Figure 22) and insert it into
  the axle.
• Align the bearing (3, Figure 22) and axle (4)
  holes and pin
• (6) them together.

6
8 FG001486
Figure 22
4. Install floating seal (7, Figure 23) inside
the idler (2) and bearing (3).
3
7
NOTE
Apply clean engine oil to the joint side of the
floating seal. Apply grease to the floating seal
O-ring.
2
7
3
FG001483

• Figure 23
• Install idler (2, Figure 24) on the axle.
• Install bearing (3, Figure 24) and pin (6) to the
  axle.

NOTE
Fill the idler assembly with new gear oil (ISO VG
220 EP/VI 130) with approximately 420 cc (14.2
oz).
6
2
3
7. Install plug (9, Figure 29) on the bearing.
9
FG001488
Figure 24
SP002330 Page 21
Track Assembly
27
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