Daewoo doosan dx235 nlc 5 excavator service repair manual (serial number 1001 and up)
- 1. Original InstructionsCopyright DOOSAN 2015 Serial Number 1001 and Up Shop Manual DX235NLC-5 Excavator 950106-01115E January 2015 DOOSAN and the DOOSAN logo are registered trademarks of DOOSAN Corporation in the United States and various other countries around the world.
- 2. Table of Contents Page I 1Table of Contents 1 Safety 1 Track Excavator Maintenance Safety 2 Specifications 1 Specifications 3 General Maintenance 1 General Maintenance Instructions 2 Standard Torques 4 Engine 1 Engine 5 Upper Structure 1 Cabin 2 Counterweight 3 Hydraulic Oil Tank 4 Fuel Tank 5 Main Pump 6 Drive Coupling (Main Pump) 7 Main Control Valve 8 Swing Device 9 Joystick Valve (Work Lever) 10 Travel Control Valve (with Damper) 11 Solenoid Valve 12 EPPR Valve (One or Two-way) 13 Accumulator 14 Gear Pump (Rotating) 15 One Spool Valve (Rotating)
- 3. Table of Contents Page II 6 Lower Structure and Chassis 1 Swing Bearing 2 Center Joint 3 Travel Device 4 Track Assembly 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 5 Two Pump 11 Schematic 1 Hydraulic Schematic/Electrical Schematic
- 4. Track Excavator Maintenance Safety 1-1-1 DX235NLC-5 Track Excavator Maintenance Safety Edition 1
- 5. Track Excavator Maintenance Safety 1-1-5 DX235NLC-5 SAFETY INSTRUCTIONS SAFETY MESSAGES Replace with Safety Messages Section on pages III and IV in the Doosan Operation & Maintenance Manual. 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.
- 6. DX235NLC-5Track Excavator Maintenance Safety 1-1-6 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.
- 7. Track Excavator Maintenance Safety 1-1-7 DX235NLC-5 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
- 8. DX235NLC-5Track Excavator Maintenance Safety 1-1-8 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
- 10. Engine 4-1-5 DX235NLC-5 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.
- 12. Engine 4-1-7 DX235NLC-5 GENERAL INFORMATION General Description This manual provides the most efficient methods for engine maintenance as well as quick, efficient methods to determine the cause of engine faults to ensure that any actions taken by professionally certified maintenance technicians are done in the most efficient and efficient way possible. If maintenance is performed by unskilled technicians, or maintenance without the specified tools and facilities, serious bodily injury or critical faults in engine performance may occur. Regular inspection and maintenance are required to maintain long-term optimal engine conditions and best performance. In the event that a part must be replaced, only genuine parts as defined by the parts the list (Parts Book) should be used. Doosan shall not be held liable for any critical damage or faults which may be caused by the use of unauthorized or remanufactured parts. The maintenance methods stated in this Operation and Maintenance Manual are the most efficient and safest work procedures. Some work procedures require special tools. For questions about genuine parts and special tools, please contact us. This manual includes 'Danger', 'Warning', and 'Caution' in order to reduce possible injuries and engine faults which may occur while performing maintenance. If workers do not follow the instructions, critical faults in engine performance and operation or serious bodily injury may occurred. 'Danger', 'Warning', and 'Caution' instructions must be followed. However, we inform you that it is not possible to describe all possible and unexpected dangers which may arise while performing engine maintenance. Cautions for Starting the Engine 1. Before starting the engine, please read this manual carefully and fully understand 'Danger', 'Warning', and 'Caution'. If you cannot fully understand it or have any question, please contact us. 2. For safety reasons, attach "Warning" signs around engines in operation to keep people other than workers from accessing the engines. Let engine operators know that they are responsible for the safety of the engine room. 3. Only authorized people may start and operate engines. Unauthorized people should not be allowed to handle engines. 4. Do not access running or rotating parts while the engine is in operation. 5. Be careful not to touch or contact the engine during operation since it becomes hot during operation. 6. Exhaust gas is poisonous. Fully ventilate before starting engine. If the space is airtight, ensure that it is well ventilated.
- 13. DX235NLC-5Engine 4-1-8 Cautions for Inspection and Repair 1. Inspection and repair of engine should be performed only when the engine is stopped. Otherwise, burns or safety accidents may occur, so do not perform inspection or repair while the engine is running. 2. If it is absolutely necessary to perform inspection or repair on the operating engine, do not get close to the rotating parts. 3. Use an engine oil drain container that is large enough to prevent the overflow of engine oil while draining engine oil. 4. Open the engine coolant cap after fully cooling the engine to exchange or replenish coolant. 5. Fuel is highly flammable. Smoking or use of fire around an engine may cause fire. DANGER AVOID DEATH When accessories such as necklaces, rings, watches, or gloves become stuck in rotating parts while the engine is running, serious bodily injury may occur. WARNING AVOID DEATH OR SERIOUS INJURY Do not exchange or disassemble a pipe or horse (from the engine fuel circuit, engine oil circuit, coolant circuit, or compressed air circuit) while the engine is running. The leaked liquid may cause bodily injuries. WARNING AVOID DEATH OR SERIOUS INJURY If the coolant cap is opened while the engine is still hot, hot water will spurt out and may cause burns. Open the engine coolant cap after fully cooling the engine. WARNING AVOID DEATH OR SERIOUS INJURY Only refuel when the engine is stopped.
- 14. Engine 4-1-9 DX235NLC-5 6. Mark and separately manage the containers for storing coolant from beverage containers for avoiding confusion. See a doctor immediately in case of drinking coolant. 7. Follow the instructions provided by the battery manufacturer when checking or handling batteries. 8. Only certified professional technicians should repair and maintain engines. 9. Only appropriate tools should be used. If the jaws of a wrench are worn out, the wrench might slip during use, causing safety accidents. 10. Do not allow other persons to stay or pass under an engine when lifting the engine with a crane. Before lifting the engine, ensure that there is no one around the engine and reserve enough safety space. 11. Before inspecting or replacing the electrical apparatus, disconnect the battery ground wire first. Connect the battery ground wire after completing all required work for checking or replacing the electrical apparatus in order to prevent a short circuit. 12. Before performing electric welding works, turn off engine, block the power supply to the engine, and remove the wire harness connector connected to the engine control unit (ECU). 13. Do not give any electric or mechanical shocks or perform welding works on the electrical apparatus or the ECU. General Repair 1. Wait until the engine is properly cooled down before starting work, since you may get burned by the heated engine. Before performing fuel line work, check the common rail pressure and engine temperature by using the failure diagnosis device. 2. Disconnect the battery ground wire from to prevent damage of wires and sensors caused by a short circuit. 3. Engine oil and coolant may damage paint and should be stored in a separate container and marked for safe management. 4. Store the disassembled parts in a specified space to avoid damage or pollution. WARNING AVOID DEATH OR SERIOUS INJURY Battery fluid is corrosive and dangerous because of its explosiveness and toxicity. Therefore, it should only be handled by a skilled technician who specializes in battery fluid.
- 15. DX235NLC-5Engine 4-1-28 ENGINE DISASSEMBLY Engine Disassembly Disassemble the engine according to the following procedure: 1. Drain coolant. A. Check that the engine and radiator is sufficiently cooled down. B. Place a container in front of the coolant drain plug. C. Remove the radiator cap. D. Open the drain valve on the bottom of the radiator to drain coolant. E. Remove the coolant drain plugs from the cylinder block and oil cooler. F. Drain coolant into the prepared container. G. After draining coolant, install the drain plug. CAUTION AVOID INJURY • Prepare the necessary tools and genuine parts before engine disassembly. • Prepare a shelf to keep removed parts. • Keep the working area well lighted and clean. • Keep your hands clean at all times during service. • Keep parts removed from the engine in the removal order. • Make sure that removed parts are not mixed and do not touch each other. EX1404285Figure 10 EX1404306 Figure 11 DANGER AVOID DEATH • Never open the radiator cap while the engine is hot. If opening the radiator cap while the engine is still hot, hot coolant may spurt, resulting in a severe burn. Open the radiator cap after confirming that the engine is sufficiently cooled down. • Put a label on the coolant container not to get mixed with other containers. If you swallow coolant, seek professional medical help immediately.
- 16. Engine 4-1-29 DX235NLC-5 2. Separate the dipstick. A. Pull out the dipstick. 3. Drain engine oil. A. Place a container under the engine to collect drained engine oil. B. Remove the drain plug from the oil pan and drain engine oil into the prepared container. C. Remove the oil filler cap. D. Remove the engine oil filter. E. After draining engine oil, install the engine oil filter and drain plug. WARNING AVOID DEATH OR SERIOUS INJURY Used coolant should be discarded according to the local regulations. Never discard used engine oil to the ground, ditch, sewer, river, sea, etc. Such action can pollute the environment. Discarding used engine oil improperly can result in punishment due to violation of the corresponding regulation. CAUTION AVOID INJURY When changing coolant, make sure that it is not left on any belt or electric part. Drain Valve EX1403623 Figure 12 WARNING AVOID DEATH OR SERIOUS INJURY Used oil should be discarded according to the local regulations. Never discard used engine oil to the ground, ditch, sewer, river, sea, etc. Such action can pollute the environment. Discarding used engine oil improperly can result in punishment due to violation of the corresponding regulation.
- 17. DX235NLC-5Engine 4-1-30 4. Remove the intercooler. A. Remove all the hoses and air pipes from the intercooler. B. Unscrew the intercooler mounting bolts to remove the intercooler. 5. Remove the cooling fan. A. Remove the fan guide and bracket. B. Unscrew the flange mounting bolt to remove the flange and cooling fan. 6. Remove the belt. A. Unscrew the tension adjusting bolts and mounting bolts of the A/C compressor, air compressor and alternator. B. Remove the belt. 7. Remove the engine from the machine. 8. Disconnect the cables and harnesses of the engine from each sensor. 9. Remove the alternator and A/C compressor. A. Unscrew the mounting bolt to remove the alternator. B. Unscrew the idle puller mounting bolt to remove the A/C compressor. Hot Air by Turbo Charger Compressor Air Flow by Cooling Fan Cooled Air to Intake Stake EX1404312 Figure 13 EX1403625 Electronic Clutch Cooling Fan Figure 14 EX1403626 Figure 15 Aircon Compressor Alternator EX1403627 Figure 16
- 18. Engine 4-1-31 DX235NLC-5 10. Remove the breather. A. Unscrew the mounting clamp screw to disconnect the rubber hose. B. Remove the breather valve assembly. 11. Disconnect the air pipe and remove the air heater. A. Unscrew the mounting bolt to disconnect the air pipe and remove the air heater. 12. Remove the fuel filter. A. Unscrew the hollow screw from the fuel filter and disconnect the fuel hose. B. Unscrew the fuel filter mounting bolt to remove the fuel filter. 13. Disconnect the intake stake. A. Unscrew the mounting bolt to disconnect the air hose. EX1403628 Figure 17 EX1403629 Figure 18 CAUTION AVOID INJURY Never let foreign materials enter the turbocharger. EX1403630 Figure 19 EX1403631 Figure 20
- 19. DX235NLC-5Engine 4-1-32 14. Separate the intake manifold. A. Unscrew the intake manifold mounting bolts to remove the intake manifold from the cylinder block. B. Remove the gasket and clean the gasket mounting surface thoroughly with a scraper. 15. Remove the common rail and high-pressure pipe. A. Disconnect the high-pressure pipe between the fuel high-pressure connector and common rail. B. Unscrew the common rail mounting bolts to remove the common rail. 16. Remove the fuel high-pressure pump. A. Unscrew the fuel high-pressure pump mounting bolts to remove the fuel high-pressure pump. EX1403632 Figure 21 EX1403633 Figure 22 CAUTION AVOID INJURY • Seal the common rail thoroughly after removing it to prevent foreign materials from entering it. • Once the fuel high-pressure pipe is disconnected, it cannot be reused. EX1403634 Figure 23
- 20. Engine 4-1-33 DX235NLC-5 17. Remove the EGR valve. A. Unscrew the EGR valve mounting bolts to remove the EGR valve and exhaust manifold. B. Unscrew the mounting bolts to remove the exhaust pipe from the EGR cooler. C. Disconnect the coolant pipe from the EGR valve. 18. Remove the EGR cooler. A. Unscrew the EGR cooler and bracket connecting bolt to separate the EGR cooler. B. Disconnect the pipe and hose from the EGR cooler. 19. Remove dosing module. Unscrew the mounting bolt of the dosing module to remove it from the UREA tank. EX1403635 Figure 24 CAUTION AVOID INJURY Seal the EGR valve and exhaust pipe thoroughly after removing them to prevent foreign materials from entering them. EX1403636 Figure 25 EX1403637 Figure 26 CAUTION AVOID INJURY Seal the EGR cooler thoroughly after removing it to prevent foreign materials from entering it. EX1404191 Figure 27
- 21. DX235NLC-5Engine 4-1-34 20. Remove the turbocharger. A. Disconnect the intake stake from the turbocharger. B. Disconnect the coolant hose from the turbocharger. C. Disconnect the oil feed pipe and oil drain pipe between the cylinder block and turbocharger. D. Unscrew the turbocharger mounting bolts to separate the turbocharger from the exhaust manifold. 21. Remove the exhaust manifold. A. Unscrew the exhaust manifold mounting bolts to remove the exhaust manifold. 22. Disconnect the coolant pipe and thermostat. A. Unscrew the coolant pipe mounting bolt to disconnect the coolant pipe from the thermostat housing. B. Remove the coolant thermostat and O-ring. C. Clean the gasket mounting surface of the coolant pipe with a scraper thoroughly. EX1404192 Figure 28 EX1403642 Figure 29 CAUTION AVOID INJURY Do not reuse the removed gasket. EX1403643 Figure 30 CAUTION AVOID INJURY Make sure that the gasket residual does not enter the coolant passage.
- 22. Engine 4-1-35 DX235NLC-5 23. Remove the coolant pump. A. Unscrew the bracket mounting bolts for the coolant pump and oil cooler. B. Unscrew the bolt (1 ea) for the oil cooler. C. Unscrew the coolant pump mounting bolts to remove the coolant pump. D. Remove the O-ring for the coolant pump. 24. Remove the start motor. A. Unscrew the start motor mounting nut and remove the start motor with care. Be careful not to damage its gear. 25. Remove the oil filter. A. Remove the oil filter cartridge using a special service tool. EX1403644 Figure 31CAUTION AVOID INJURY Do not reuse the O-ring. EX1403645 Figure 32 EX1403646 Figure 33 Oil Cooler Oil Filter EX1403647 Figure 34
- 23. DX235NLC-5Engine 4-1-36 26. Remove the vibration damper. A. Unscrew the mounting bolts of the vibration damper and crank pulley in the reverse order to remove the vibration damper assembly. 27. Remove the cylinder head cover. A. Unscrew the cylinder head cover mounting bolts to remove the cylinder head cover. B. Unscrew the intermediate cover mounting bolts to remove the intermediate cover. 28. Remove the rocker arm. A. Unscrew the rocker arm bracket mounting bolts in the reverse order to remove the rocker arm assembly. 29. Remove the push rod. A. Remove the push rod. EX1403648 Figure 35 EX1403649 Figure 36 EX1403650 Figure 37 EX1403651 Figure 38
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- 25. Engine 4-1-37 DX235NLC-5 30. Remove the fuel injector. A. Unscrew the fuel high-pressure connector mounting bolts to disconnect the fuel high-pressure connector. B. Remove the harness from the injector. C. Unscrew the injector mounting bracket bolts to remove the injector. D. Remove the seal ring from the nozzle hole from the cylinder head. 31. Remove the cylinder head. A. Unscrew the cylinder head bolts in the reverse order of tightening to remove the cylinder head. – Step 1: Unscrew the bolt for 1 to 2 threads. – Step 2: Unscrew the bolt completely to remove it. B. Remove the cylinder head bolts in these two steps. C. Keep the removed bolts in order with care, being careful not to damage their threads. D. Remove the cylinder head gasket. E. Remove foreign materials from the surface of the cylinder head and block. Fixing Bracket BoltsInjector Type O-ring Seal Ring EX1403652 Figure 39 CAUTION AVOID INJURY Be careful not to damage the nozzle during removing the injector. CAUTION AVOID INJURY To remove the injector, unscrew the fuel high-pressure connector mounting nut to disconnect the fuel high- pressure connector completely. Then, unscrew the caliper mounting bolt to remove the injector. Head Bolt Lifting Hook EX1403741 Figure 40 CAUTION AVOID INJURY Make sure that the bolts are not hit by each other.
- 26. DX235NLC-5Engine 4-1-38 F. Unscrew the mounting bolt of the lifting hook from the cylinder head to remove the lifting hook. 32. Remove the valve and valve stem seal. A. Press the valve spring and retainer with the valve spring compressor to remove the valve cotter. B. Remove the valve spring and retainer. C. Remove the calipers. D. Use a general service tool to remove the valve stem seal. E. Remove valve. F. Unscrew the mounting bolt of the lifting hook from the cylinder block to remove the lifting hook. 33. Remove the oil cooler. A. Unscrew the oil cooler mounting bolts to remove the oil cooler. CAUTION AVOID INJURY Be careful not to damage the mating surface. Valve Spring Copression Jig EX1403742 Figure 41 CAUTION AVOID INJURY Do not reuse the valve stem seal. EX1403743 Figure 42 EX1403653 Figure 43
- 27. Engine 4-1-39 DX235NLC-5 34. Remove the oil pan. A. Unscrew the oil pan mounting bolts to remove the oil pan. B. Remove the oil pan gasket. 35. Remove the front oil seal and cover. A. Remove the oil seal using a oil seal removing tool. B. Unscrew the gear case cover mounting bolt to remove the oil seal cover. 36. Remove the oil pump and disconnect the pipe. A. Unscrew the oil suction pipe mounting bolt to remove the bracket. B. Unscrew the oil pump pipe mounting bolts to disconnect the suction pipe and feed pipe. C. Unscrew the oil pump mounting bolts to remove the oil pump. 37. Remove the flywheel. A. Unscrew the flywheel mounting bolts and install the guide bolt to remove the flywheel. B. Unscrew the bolts in the reverse order of their tightening to remove the flywheel. Oil Pan Fixing Bolt EX1403654 Figure 44 EX1403655 Figure 45 EX1403656 Figure 46 EX1403657 Figure 47