Daewoo doosan dx300 lc 5 excavator service repair manual serial number 50001 and up
- 1. Original InstructionsCopyright DOOSAN 2014 Serial Number 1001 and Up Serial Number 50001 and Up Shop Manual DX300LC-5 Excavator 950106-00980E February 2014 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 2 Engine Coolant Heater (Option) 5 Upper Structure 1 Cabin 2 Counterweight 3 Oil Tank 4 Fuel Tank 5 Main Pump 6 Drive Coupling (Main Pump) 7 Main Control Valve 8 Swing Device 9 Fan Pump for Oil Cooler 10 Fan Motor for Oil Cooler 11 Gear Pump (Rotation) 12 Joystick Valve (Work Lever) 13 Travel Control Valve (with Damper) 14 Solenoid Valve 15 EPPR Valve 16 Accumulator 6 Lower Structure and Chassis 1 Swing Bearing 2 Center Joint 3 Travel Device 4 Track Assembly
- 3. Table of Contents Page II 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 2 Electrical System Troubleshooting 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 DX300LC-5 Track Excavator Maintenance Safety Edition 1
- 5. Track Excavator Maintenance Safety 1-1-5 DX300LC-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. DX300LC-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 DX300LC-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. DX300LC-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 4-1-7 DX300LC-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 4-1-51 DX300LC-5 Replacing the Engine NOTE: Replace coolant hoses if there is clear damage to the coolant hoses. 1. Drain the oil and coolant. 2. Remove air filter and inlet pipe between the turbocharger and air filter. Cover the turbocharger inlet pipe. 3. Undo the connections for coolant, charge air pipes between engine and charge air cooler, and bleed pipe for the expansion tank. 4. Undo the cable harness with clamping. NOTE: The engine lifting eyes 99 637 are designed for lifting the engine only, not the engine with connected equipment (high voltage current generator, gearbox, reverse gear, etc.) or frame. All three lifting eyes must be used. 5. Fasten the lifting chain 98 094 to the rear lifting eyes 99 637. 6. Fasten the lever block 587 308 to the front lifting eye. NOTE: The lifting eyes 99 637 are designed to manage a maximum inclination angle of 30° when lifting an engine. 7. Undo the engine insulator bolts and lift away/out the engine. • Engine weight: about 950 kg FG020236 Figure 20 FG020237 max 30 max 20 Figure 21
- 13. DX300LC-5Engine 4-1-52 Removal of Engine 1. Depressurize the fuel system using checking tool. 2. Disconnect the ground connection from the negative terminal and disconnect the cable harness from the starter motor. NOTE: Help protect the environment. Avoid spillage and use a suitable container. 3. Drain the coolant. 4. Undo the connections for coolant, charge air pipes between engine and charge air cooler, and bleed pipe for the expansion tank. 5. Remove air filter and inlet pipe between the turbocharger and air filter. Cover the turbocharger inlet pipe. 6. Disconnect the fuel pipes to and from the engine. Mark the pipes to make reinstalling easier and plug the connections. 7. Remove coolant connections for SCR, to engine (1) and from engine (2). IMPORTANT The fuel system has a very high fuel pressure of up to 3,000 bars. The fuel system must be depressurized using checking tool before any work is started. Use checking tool to minimize the high-pressure in the fuel system. The system should always be treated as pressurized, even when the engine is switched off. Wear protective gloves and goggles. EX1301906 2 1 Figure22
- 14. Engine 4-1-53 DX300LC-5 8. Disconnect connectors C4001 (1) and C4002 (3) and connector C4022 (4) to SCR. • To be removed depending on the installation: • Unit gearbox. • Coolant level sensor. • Protective casing on cooling package and fan. • Depressurize the pneumatic system and remove connections. • Power take-off, see subgroup 01-55 Power take-off. • Hydraulic pump, see subgroup 13-15 Hydraulic pump. • Disconnect the AC compressor and place it to one side. 9. Fasten the lifting chain 98 094 to the rear lifting eyes 99 637. NOTE: The engine lifting eyes 99 637 are designed for lifting the engine only, not the engine with connected equipment (high-voltage current generator, gearbox, reverse gear, etc.) or frame. All three lifting eyes must be used. 10. Fasten the ratchet lever hoist 587 308 to the front lifting eye. NOTE: The lifting eyes 99 637 are designed to manage a maximum inclination angle of 30° when lifting an engine. 11. Check carefully there is nothing that may be removed with the engine or prevent lifting. 12. Undo the engine insulator screws and lift away/out the engine. 1 2 3 4 EX1301907 Figure 23
- 15. DX300LC-5Engine 4-1-54 Installing the Engine 1. Fasten the lifting chain 98 094 to the rear lifting eyes. NOTE: The engine lifting eyes 99 637 are designed for lifting the engine only, not the engine with connected equipment (high-voltage current generator, gearbox, reverse gear, etc.) or frame. All three lifting eyes must be used. 2. Fasten the ratchet lever hoist 587 308 to the front lifting eye. 3. Lift the engine, position it on the engine insulators and screw it into place. • If removed, reinstall: • Unit gearbox. • Coolant level sensor. • Protective casing on cooling package and fan. • Pneumatic system. • Power take-off, see subgroup 01-55 Power take-off. • Hydraulic pump, see subgroup 13-15 Hydraulic pump. • AC compressor, see subgroup 18-75 AC compressor. FG020236 Figure 24 EX1301876 max 30 Figure 25
- 16. Engine 4-1-55 DX300LC-5 4. Connect connectors C4001 (1) and C4002 (3) and connector C4022 (4) to SCR. 5. Install the coolant connections for SCR, to engine (1) and from engine (2). 6. Connect the fuel pipes to the high-pressure pump and hand pump. 7. Install the inlet pipe between the turbocharger and the air filter. 8. Install the connections for coolant and the charge air pipes between the engine and charge air cooler. Install the expansion tank bleed pipe. 9. Fill with coolant. 10. Install the cable harness to the starter motor and the ground connection to the negative terminal. 11. Start checking tool and check whether there are any fault codes. Rectify the fault codes. 12. Clear inactive fault codes. 13. Test run the engine to check that no leakage occurs. Top up with coolant if necessary. 1 2 3 4 EX1301907 Figure 26 EX1301906 2 1 Figure27
- 17. DX300LC-5Engine 4-1-56 CYLINDER Cylinder Head Specifications • Remove cylinder head according to the work description °×Removal Cylinder Head°± on page 4-1-57. • Remove inlet and exhaust valves according to the work description °×Removing Valves°± on page 4-1-75. Overview Intake Valve Oversize Valve Seat, Outer Diameter 46.254 - 46.265 mm Valve Seat Position, Outer Diameter 46.200 - 46.216 mm Valve Seat Position, Deep 11.25 - 11.35 mm Exhaust Valve Seat Oversize Valve Seat, Outer Diameter 44.281 - 44.292 mm Valve Seat Position, Outer Diameter 44.200 - 44.216 mm Valve Seat Position, Deep 11.25 - 11.35 mm 21 8 20 19 18 16 17 11 1D 1A 1B 1D 11 13 14 19 8 20 24 31A 31B 23 22 1: 1A ~ 1F 25C 25 31C 31C 31 36 1B 9 1C 9 10 1E 12 1F 15 25C 25A 25B 30 EX1302147Figure 28
- 18. Engine 4-1-57 DX300LC-5 Removal Cylinder Head 1. Remove water-cooled EGR cooler as instructed in the work description °×Removing the EGR Cooler°± on page 4-1-274. Remove brackets for the water-cooled EGR cooler. 2. Remove bolts for the exhaust manifold on the relevant cylinder and slacken the bolts on the adjacent cylinders so the relevant part of the exhaust manifold comes loose. 3. Remove cooling system bleeder hose, separate the quick release coupling at the front lifting eye. 4. Remove cable duct from the intake. 5. Remove cable ties for the cable harness from the engine control unit. IMPORTANT The fuel system components are extremely sensitive to dirt. Clean thoroughly before dismantling and plug all connections with lint-free rags and tape. Reference Number Description 1 Cylinder Head 1A Sleeve 1B Core Plug 1C Rivet 1D Guide Valve 1E Seal 1F Seal 8 Pin 9 Valve Stem Seal 10 Intake Valve 11 Intake Valve Spring 12 Collar Valve Spring 13 Exhaust Valve 14 Outer Valve Spring 15 Inner Valve Spring 16 Collar Valve Spring 17 Collet Valve Spring 18 Pin 19 Gasket 20 Bridge Valve 21 Screw 22 Bracket Assembly 23 Rivet Plug 24 Screw 25 Intake Rocker Arm 26 Adjusting Screw 27 Hex Nut 29 Rivet Plug 30 Retaining Ring 31 Exhaust Arm Rocker 32 Adjusting Screw 33 Hex Nut 35 Rivet Plug 36 Retaining Ring Reference Number Description
- 19. DX300LC-5Engine 4-1-58 6. Depressurize the fuel system and detach the fuel pipe running between the accumulator and fuel manifold. 7. Detach the fuel manifold and remove bolts on the relevant cylinder. 8. Detach the intake manifold and remove bolts on the relevant cylinder. 9. Remove injectors as instructed in the work description °×Removing Injector°± on page 4-1-318. Also remove high-pressure pipes and connection on the cylinder head at the back viewed from the coolant pump. 10. Remove upper rocker cover and then the rocker arm housing, valve bridges and pushrods. 11. Pull the cable harness out of the lower rocker cover and remove it. NOTE: Take care when pulling the cable harness out of the rocker cover: the cable terminals can be damaged which can cause the nut securing the cable harness to the injector to come loose. 12. Work on the adjacent cylinders. Remove upper rocker cover, release the cable harness and the lower rocker cover so it can be moved. 13. Remove relevant cylinder head. Be careful with the adjacent rocker covers. 897 FG020250 Figure 29 IMPORTANT All parts in the fuel injection system and valve mechanism must be marked. Everything must be reinstalled in the same position. IMPORTANT If work is done on the 5th cylinder of an engine with an EGR system, the EGR valve control cylinder must be detached at the damper and removed. FG020251 Figure 30 FG020252 Figure 31
- 20. Engine 4-1-59 DX300LC-5 NOTE: Mark the cylinder heads if more than one is being removed at the same time. NOTE: If all cylinder heads are removed at the same time, the turbocharger must be removed or supported against the frame. Installing Cylinder Head 1. Check the liner height. 2. Clean the cylinder head and cylinder block. Lubricate the threads and below the heads of the cylinder head bolts. 3. Install a new cylinder head gasket. 4. Install the cylinder head. 5. Tighten the cylinder head as shown in the illustration and according to specification. Cylinder head bolts can only be reused three times. Make a mark with a center punch on the head of the bolt. If any of the bolts already has three marks, it must be replaced. 6. Tighten the intake manifold. Use a new gasket. Tighten the bolts in the order 1 - 20 as illustrated. Tighten the bolts in the same order again. 1 2 3 4 5 6 FG020253 Figure 32 FG020254 1 2 3 4 Figure 33 1 3 5 7 9 11 13 15 17 19 2 4 6 8 10 12 14 16 18 20 FG020255 Figure 34
- 21. DX300LC-5Engine 4-1-60 7. Tighten the intake manifold and the exhaust manifold. Use new gaskets. 8. Install the cable bracket bolt in the lower rocker cover and install the following parts: • Lower rocker cover. • Pushrods. • Valve bridge. • Rocker arm housing. 9. Install the injector, high-pressure pipe connection and high-pressure pipe as instructed in the work description. 10. Reset adjacent cylinders. 11. Adjust the valve clearance. 12. Install the upper rocker covers. 13. Install the cooling system vent Install the brackets for the water-cooled EGR cooler. Install the water-cooled EGR cooler as described in the work description °×Installing the EGR Cooler°± on page 4- 1-275. Removing and Installing Valves 1. Removing Valves A. Remove split collets, valve spring collars, springs and valves. Press down the spring using tool 99 322 in a press so the collets can be removed. B. Place the valves in a stand so they can be reinstalled in the same position in the cylinder head. IMPORTANT Lubricate the valve bridge and rocker arm housing with engine oil. WARNING AVOID DEATH OR SERIOUS INJURY Wear protective goggles for eye protection. 99 322 FG020258 Figure 35
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- 23. Engine 4-1-61 DX300LC-5 2. Installing Valves NOTE: There are different versions of the combination valve – valve spring collar – split collet. Parts from the different versions must not be mixed on the same valve. A. Lubricate all parts well with engine oil before assembly. B. Insert the valve in the guide. C. Install the valve springs and the valve spring collar. D. Press together the springs in a press with tool 99 322 and install the collets. Ensure that collets are installed in their correct positions. Replacing a Valve Stem Seal 1. Remove valve according to the work description °×Removing Valves°± on page 4-1-75. 2. Remove valve stem seal with a pair of pliers. 3. Install the valve. 4. Carefully tap a new valve stem seal into place using tool 99 323 and a hammer. FG020259 99 322 Figure 36 FG020261 Figure 37 99 323 FG020262 Figure 38
- 24. DX300LC-5Engine 4-1-62 Replacing the Valve Seats 1. Remove valve seat inserts with an expanding sleeve from the kit with puller 587 270 (1, Figure 39). NOTE: Insert, for example, an aluminum sheet between the cylinder head and counterhold to protect against damage. 2. Press in new valve seat inserts. Use drift 99 384 (2, Figure 39) and shank 99 385. Cool the drift and valve seat insert to about -80°C with dry ice or liquid air. Pressing must be done rapidly. Oversize valve seat inserts can be installed if the valve seat insert position has been damaged. The position is then machined using tool 587 277. Replacing the Valve Guides 1. Press out the valve guides using drift 99 383. 2 1 FG020266 Figure 39 WARNING AVOID DEATH OR SERIOUS INJURY Wear protective goggles for eye protection from flying metal parts. 99 385 99 384 FG020267 Figure40 WARNING AVOID DEATH OR SERIOUS INJURY Prevent frost injuries. Be careful when handling very cold parts and refrigerant. 99 383 FG020268 Figure 41
- 25. Engine 4-1-63 DX300LC-5 2. Press in the new valve guides using drift 99 382. Press the guide down as far as the drift allows, i.e. until it contacts the spring seat in the cylinder head. Replacing the Injector Sleeves The cylinder head must be removed when replacing the unit injector sleeve. The valves do not need removing. The illustrations show the cylinder head with valves removed to demonstrate clearly the work described. NOTE: Guide and pilot tap on extension piece 99 397. 1. Thread the lower part of the sleeve using the pilot tap and guide from tool kit 99 574. 2. Knock out the pilot tap and sleeve from underneath. Use a 100 mm long metal rod of diameter 9 mm. 3. Degrease and check the contact surfaces of the sleeve and cylinder head. Smooth off any burrs and irregularities that may score the sleeve. 4. Degrease the new injector sleeve and apply a thin film of sealant 561 200 on the sleeve and cylinder head contact surfaces. 5. Press in the sleeve using the drift and guide from tool kit 99 574. 99 382 FG020269 Figure 42 FG020272 Figure 43 FG020273 Figure 44