Doosan DX300LC-3 Excavator Shop Manual 950106-00215E – PDF DOWNLOAD
DESCRIPTION:
Doosan DX300LC-3 Excavator Shop Manual 950106-00215E – PDF DOWNLOAD
Serial Number 50001 and Up (Europe Only)
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.
TABLE OF CONTENTS:
Doosan DX300LC-3 Excavator Shop Manual 950106-00215E – PDF DOWNLOAD
Safety………………………………………………………………………… 9
Track Excavator Maintenance Safety SP002322……………………………………. 11
Safety Instructions……………………………………………………… 15
Applicable Models……………………………………………………….. 15
Safety Messages…………………………………………………………. 16
General………………………………………………………………… 16
Safe Operation is Operator’s Responsibility…………………………….. 16
Know Your Machine……………………………………………………. 16
Proper Work Tools and Attachments……………………………………… 17
Pressurized Fluids…………………………………………………… 17
Flying or Falling Objects…………………………………………….. 18
Personal Protective Equipment (PPE)……………………………………. 19
Correction of Machine Problems………………………………………… 19
Crushing and Cutting…………………………………………………. 19
Hot Coolant and Oils – Burn Prevention…………………………………. 20
Fire and Explosion Prevention…………………………………………. 21
Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)………………. 24
Electrical System and Electrical Shock…………………………………. 25
Rollover Protective Structure (ROPS)…………………………………… 25
Transportation………………………………………………………….. 29
Obey State and Local Over-the-Road Regulations………………………….. 29
Loading and Unloading………………………………………………… 29
Transporting Machine…………………………………………………. 30
Operation………………………………………………………………. 31
Before Engine Starting……………………………………………….. 31
Work Site…………………………………………………………… 32
Mounting/Dismounting…………………………………………………. 33
Cleaning……………………………………………………………. 34
Operator Station…………………………………………………….. 34
Seat Belt…………………………………………………………… 35
Visibility Information……………………………………………….. 36
Boost Starting or Charging Engine Batteries…………………………….. 37
Starting Engine……………………………………………………… 38
Swinging or Traveling………………………………………………… 39
Lifting and Digging………………………………………………….. 41
Operation on Slopes………………………………………………….. 42
Towing……………………………………………………………… 43
Attachment………………………………………………………….. 44
Equipment Lowering with Engine Stopped…………………………………. 44
Engine Stop…………………………………………………………. 44
Parking Machine……………………………………………………… 45
Preservation/Storing Machine………………………………………….. 46
Maintenance…………………………………………………………….. 48
Warning Tag…………………………………………………………. 51
Cleaning……………………………………………………………. 52
Proper Tools and Clothing…………………………………………….. 52
Disassembling Precautions…………………………………………….. 52
Use of Lighting……………………………………………………… 53
Fire and Explosion Prevention…………………………………………. 53
Burn Prevention……………………………………………………… 54
Rubber That Contains Fluorides………………………………………… 55
Rubber and Plastics………………………………………………….. 56
Welding Repairs……………………………………………………… 57
Warning for Counterweight and Front Attachment Removal…………………… 58
Lock Inspection Covers……………………………………………….. 59
Working on Machine…………………………………………………… 59
Accumulator…………………………………………………………. 60
Compressed Air………………………………………………………. 60
Track Tension Adjustments…………………………………………….. 61
Supports and Blocking for Work Equipment……………………………….. 61
High-pressure Lines, Tubes and Hoses…………………………………… 62
Battery…………………………………………………………….. 63
Environment and Circumstances…………………………………………….. 65
Work Site Areas Requiring Extra Caution………………………………… 65
High-voltage Cables………………………………………………….. 67
Underground Operation………………………………………………… 68
Working in Water…………………………………………………….. 68
Working in Contaminated Environment……………………………………. 68
Operation in Extreme Conditions……………………………………….. 69
Exhaust Ventilation………………………………………………….. 73
Asbestos Information…………………………………………………. 73
Silica Dust Information………………………………………………. 74
Disposal of Hazardous Materials……………………………………….. 74
Sound………………………………………………………………. 75
Vibration…………………………………………………………… 75
Specifications…………………………………………………………………. 77
Specifications for DX300LC-3 SP002323…………………………………………. 79
Safety Instructions……………………………………………………… 83
Applicable Models……………………………………………………….. 83
General Description……………………………………………………… 85
Component Locations……………………………………………………… 86
General Dimensions………………………………………………………. 88
One – Piece Boom…………………………………………………….. 88
Two – Piece Boom…………………………………………………….. 89
Working Range…………………………………………………………… 90
One – Piece Boom…………………………………………………….. 90
Two – Piece Boom…………………………………………………….. 92
General Specifications…………………………………………………… 94
Engine Performance Curves (Per KS-R1004 Standard)…………………………… 96
Approximate Weight of Workload Materials…………………………………… 98
Performance Tests………………………………………………………..100
Excavator Performance Measurements…………………………………………101
Test Conditions………………………………………………………101
Travel Speed and Travel Motor Balance (Steering Deviation) Tests…………..101
Swing Speed and Deceleration Force Test…………………………………103
Cylinder Performance Tests…………………………………………….105
General Maintenance……………………………………………………………..107
General Maintenance Instructions SP002454………………………………………109
Safety Instructions………………………………………………………113
Applicable Models………………………………………………………..113
Welding Precautions and Instructions……………………………………….114
Hydraulic System – General Precautions……………………………………..115
Maintenance Service and Repair Procedure……………………………………117
General Precautions…………………………………………………..117
Hydraulic System Cleanliness and Oil Leaks………………………………….118
Maintenance Precautions for Hydraulic System Service……………………..118
Oil Leakage Precautions……………………………………………….119
Cleaning and Inspection…………………………………………………..120
General Instructions………………………………………………….120
Bearing inspection……………………………………………………121
Standard Torques SP002404…………………………………………………….129
Safety Instructions………………………………………………………133
Applicable Models………………………………………………………..133
Torque Values for Standard Metric Fasteners…………………………………134
Torque Values for Standard U.S. Fasteners…………………………………..135
Type 8 Phosphate Coated Hardware…………………………………………..137
Torque Values for Hose Clamps……………………………………………..138
ORFS Swivel Nut Recommended Torque…………………………………………138
Torque Values for Split Flanges……………………………………………139
Torque Wrench Extension Tools……………………………………………..140
Torque Multiplication…………………………………………………140
Other Uses for Torque Wrench Extension Tools…………………………….141
Tightening Torque Specifications (Metric)……………………………….142
Upper Structure…………………………………………………………………145
Cabin SP002324………………………………………………………………147
Safety Instructions………………………………………………………151
Applicable Models………………………………………………………..151
Cabin Identification……………………………………………………..152
Rollover Protective Structure (ROPS)……………………………………152
Removal…………………………………………………………………154
Installation…………………………………………………………….158
Counterweight SP002325……………………………………………………….161
Safety Instructions………………………………………………………165
Applicable Models………………………………………………………..165
General…………………………………………………………………166
Warning for Counterweight and Front Attachment Removal……………………166
Removal…………………………………………………………………168
Installation…………………………………………………………….169
Fuel Tank SP002326…………………………………………………………..171
Safety Instructions………………………………………………………175
Applicable Models………………………………………………………..175
General Description………………………………………………………176
Parts List…………………………………………………………..176
Specifications……………………………………………………….177
Removal…………………………………………………………………178
Installation…………………………………………………………….183
Start-up Procedures………………………………………………………186
Fuel Transfer Pump (Option) SP002394…………………………………………..187
Safety Instructions………………………………………………………191
Applicable Models………………………………………………………..191
General Description………………………………………………………192
Theory of Operation…………………………………………………..192
Troubleshooting………………………………………………………….194
Replacement of Rotor and Vane……………………………………………..194
Replacement of Rear Cover…………………………………………………195
Replacement of Armature…………………………………………………..195
Swing Bearing SP002329……………………………………………………….197
Safety Instructions………………………………………………………201
Applicable Models………………………………………………………..201
Swing Bearing Maintenance…………………………………………………202
Operating Recommendation………………………………………………202
Measuring Swing Bearing Axial Play……………………………………..202
Measuring Bearing Lateral Play…………………………………………202
Swing Bearing Basic Operation………………………………………….203
Disassembly………………………………………………………….203
Assembly…………………………………………………………….205
Lower Structure and Chassis………………………………………………………207
Track Assembly SP002330………………………………………………………209
Safety Instructions………………………………………………………213
Applicable Models………………………………………………………..213
General Description………………………………………………………214
Track Tension……………………………………………………………215
Cleaning and Inspection (Wear Limits and Tolerances)…………………………217
Track Shoe…………………………………………………………..218
Lower Roller…………………………………………………………220
Upper Roller…………………………………………………………221
Front Idler………………………………………………………….222
Track Shoes and Links…………………………………………………….223
Track Removal………………………………………………………..223
Track Installation……………………………………………………224
Front Idler Roller……………………………………………………….226
Parts List…………………………………………………………..226
Front Idler Roller Disassembly…………………………………………227
Front Idler Roller Reassembly………………………………………….229
Lower Roller…………………………………………………………….230
Parts List…………………………………………………………..230
Lower Roller Removal………………………………………………….231
Lower Roller Disassembly………………………………………………231
Lower Roller Reassembly……………………………………………….232
Lower Roller Installation……………………………………………..233
Upper Roller…………………………………………………………….234
Parts List…………………………………………………………..234
Upper Roller Removal………………………………………………….235
Upper Roller Disassembly………………………………………………235
Upper Roller Reassembly……………………………………………….237
Track Spring and Track Adjusting Cylinder…………………………………..238
Parts List…………………………………………………………..238
Engine and Drivetrain……………………………………………………………241
Engine Coolant Heater (Option) SP002328………………………………………..243
Safety Instructions………………………………………………………247
Applicable Models………………………………………………………..247
Disassembly and Assembly………………………………………………….248
Changing the Circulating Pump………………………………………….248
Changing the Temperature Limiter……………………………………….250
Changing the Temperature Sensor………………………………………..251
Changing the Combustion Air Fan………………………………………..253
Changing the Burner, Flame Monitor and Glow Plug…………………………255
Changing the Burner Head………………………………………………257
Changing the Heat Exchanger……………………………………………259
Drive Coupling (Main Pump) SP002396……………………………………………261
Safety Instructions………………………………………………………265
Applicable Models………………………………………………………..265
Drive Coupling…………………………………………………………..266
Special Tools……………………………………………………………267
Drive Coupling Installation……………………………………………….268
Installation Procedure………………………………………………..270
Hydraulics……………………………………………………………………..271
Hydraulic System Troubleshooting, Testing and Adjustment SP002331…………………273
Safety Instructions………………………………………………………277
Applicable Models………………………………………………………..277
Hydraulic System – General Notes…………………………………………..278
Hydraulic Schematic………………………………………………………279
General Notes………………………………………………………..279
Operation of Working Components……………………………………………281
Boom Operating Circuit………………………………………………..281
Boom Up Circuit………………………………………………………281
Boom Down Circuit…………………………………………………….281
Arm Operating Circuit…………………………………………………282
Arm Crowd Circuit…………………………………………………….282
Arm Dump Circuit……………………………………………………..282
Bucket Operating Circuit………………………………………………283
Bucket Crowd Circuit………………………………………………….283
Bucket Dump Circuit…………………………………………………..283
Swing Operating Circuit……………………………………………….283
Right Swing Operating Circuit………………………………………….284
Left Swing Operating Circuit…………………………………………..284
Swing Relief Valve and Makeup Valve…………………………………….284
Travel Operating Circuit………………………………………………284
Forward Travel Circuit………………………………………………..285
Reverse Travel Circuit………………………………………………..285
Procedural Troubleshooting Baseline Recommendations………………………….286
Initial Checks and Tests to Establish Operating Condition of the Excavator….286
Pilot Pressure…………………………………………………………..288
Adjustment and Testing………………………………………………..288
Power Mode Valve…………………………………………………………289
Current Signal and Hydraulic Pressure Adjustments………………………..289
Pressure Up Valve………………………………………………………..290
Checks and Adjustments………………………………………………..290
Pump Input Power Control………………………………………………….292
Pump Regulator Adjustment……………………………………………..292
Flow Meter and Flow Meter Kit Installation and Testing……………………….295
Swing System Troubleshooting………………………………………………297
Precautions/Initial Checks…………………………………………….297
Swing Relief Valve Checking and Adjustment………………………………298
Troubleshooting – Swing Gearbox……………………………………………300
Troubleshooting – Hydraulic Problems……………………………………….301
Troubleshooting – Control Valve……………………………………………303
Troubleshooting – Travel Control Valve……………………………………..304
Troubleshooting – Joystick Control Valve……………………………………305
Accumulator SP002455…………………………………………………………307
Safety Instructions………………………………………………………311
Applicable Models………………………………………………………..311
General Description………………………………………………………312
Specifications……………………………………………………….314
Center Joint (Swivel) SP002456………………………………………………..315
Safety Instructions………………………………………………………319
Applicable Models………………………………………………………..319
General Description………………………………………………………321
Parts List…………………………………………………………..322
Troubleshooting, Testing and Adjustment…………………………………….323
Inspection…………………………………………………………..323
Testing……………………………………………………………..323
Disassembly……………………………………………………………..324
Reassembly………………………………………………………………327
Cylinders SP002332…………………………………………………………..329
Safety Instructions………………………………………………………333
Applicable Models………………………………………………………..333
General Description………………………………………………………334
Theory of Operation…………………………………………………..334
Parts List…………………………………………………………..336
Special Tools and Materials……………………………………………….342
Piston Nut…………………………………………………………..342
Piston Jig…………………………………………………………..344
Steel Bushing Jig…………………………………………………….347
Dust Wiper Jig……………………………………………………….350
Slipper Seal Jig……………………………………………………..353
Slipper Seal Straightening Jig…………………………………………356
Disassembly……………………………………………………………..359
Reassembly………………………………………………………………364
Swing Device SP002327………………………………………………………..369
Safety Instructions………………………………………………………373
Applicable Models………………………………………………………..373
Structure and Principle of Operation……………………………………374
Instructions before Operation………………………………………….385
Troubleshooting………………………………………………………389
Disassembly and Reassembly…………………………………………….393
Remove and Install Swing Device……………………………………………395
Removal……………………………………………………………..395
Installation…………………………………………………………398
Maintenance Instructions………………………………………………419
Travel Device SP002333……………………………………………………….421
Safety Instructions………………………………………………………425
Applicable Models………………………………………………………..425
Basic Structure and Drawings…………………………………………..427
Operation Principle…………………………………………………..432
Cautions for Operation………………………………………………..441
Troubleshooting………………………………………………………444
Maintenance Guidelines………………………………………………..446
Remove and Install Travel Device…………………………………………..449
Removal……………………………………………………………..449
Disassembly………………………………………………………….450
Assembly…………………………………………………………….460
Installation…………………………………………………………477
Matters to Check after Assembly………………………………………..478
Performance Test……………………………………………………..478
Main Pump SP002405…………………………………………………………..481
Safety Instructions………………………………………………………485
Applicable Models………………………………………………………..485
Axial Piston Pump………………………………………………………..486
General Description…………………………………………………..486
Special Tools and Materials……………………………………………491
Troubleshooting, Testing and Adjustment…………………………………493
Remove and Install Pump Device…………………………………………….495
Removal……………………………………………………………..495
Disassembly………………………………………………………….495
Cleaning and Inspection (Wear Limits and Tolerances)……………………..498
Reassembly…………………………………………………………..500
Installation…………………………………………………………502
Start-up Procedures…………………………………………………..504
Regulator for Axial Piston Pump……………………………………………505
General Description…………………………………………………..505
Special Tools and Materials……………………………………………516
Troubleshooting, Testing and Adjustment…………………………………516
Preparation for Disassembly……………………………………………519
Regulator Disassembly…………………………………………………520
Regulator Reassembly………………………………………………….523
Gear Pump (Option) SP002457…………………………………………………..527
Safety Instructions………………………………………………………531
Applicable Models………………………………………………………..531
Single Gear Pump…………………………………………………………532
Disassembly………………………………………………………….532
Reassembly…………………………………………………………..534
Double Gear Pump…………………………………………………………538
Disassembly………………………………………………………….538
Reassembly…………………………………………………………..540
Main Control Valve SP002403…………………………………………………..545
Safety Instructions………………………………………………………549
Applicable Models………………………………………………………..549
General Description………………………………………………………550
Theory of Operation…………………………………………………..550
Parts List…………………………………………………………..582
Specifications……………………………………………………….587
Troubleshooting, Testing and Adjustment…………………………………….588
Troubleshooting………………………………………………………588
Adjustment of Valves………………………………………………….589
Removal…………………………………………………………………591
Disassembly……………………………………………………………..592
Cleaning and Inspection (Wear Limits and Tolerances)…………………………601
Cleaning…………………………………………………………….601
Inspection…………………………………………………………..601
Reassembly………………………………………………………………602
Caution on Assembly…………………………………………………..602
Sequence of Subassembly……………………………………………….603
Maintenance of Relief Valves…………………………………………..609
Installation…………………………………………………………….612
Start-up Procedures………………………………………………………613
Remote Control Valve (Work Lever / Joystick) SP002395……………………………615
Safety Instructions………………………………………………………619
Applicable Models………………………………………………………..619
General Description………………………………………………………621
Theory of Operation…………………………………………………..621
Parts List…………………………………………………………..622
Specifications……………………………………………………….624
Torques……………………………………………………………..624
Tools and Materials………………………………………………………624
Disassembly……………………………………………………………..625
Reassembly………………………………………………………………628
Start-up Procedures………………………………………………………636
Travel Control Valve (with Damper) SP002381…………………………………….637
Safety Instructions………………………………………………………641
Applicable Models………………………………………………………..641
General Description………………………………………………………643
Theory of Operation…………………………………………………..643
Pressure Reducing Valve……………………………………………….644
Operating Theory of Damper Mechanism……………………………………645
Causes of Faults and Measures……………………………………………..647
Parts List…………………………………………………………..648
Specification………………………………………………………..650
Torques……………………………………………………………..650
Removal…………………………………………………………………651
Disassembly……………………………………………………………..654
Cleaning and Inspection (Wear Limits and Tolerances)…………………………656
Reassembly………………………………………………………………657
Installation…………………………………………………………….662
Start-up Procedures………………………………………………………665
Solenoid Valve Assembly SP002406………………………………………………667
Safety Instructions………………………………………………………671
Applicable Models………………………………………………………..671
5-Solenoid Valve…………………………………………………………672
Parts List…………………………………………………………..672
Functions of 5-Solenoid Valve Assembly………………………………….673
Assembly Diagram and Tools Required…………………………………….674
Cautions During Disassembly and Reassembly………………………………675
Solenoid Valve Diagram………………………………………………..676
Check Points and Solutions for Problems…………………………………677
Breaker EPPR Valve (Option) SP002458…………………………………………..679
Safety Instructions………………………………………………………683
Applicable Models………………………………………………………..683
Structure……………………………………………………………….684
Numbers and Names of Parts…………………………………………….684
Functions and Operation…………………………………………………..685
Cautions for Operation……………………………………………………685
Maintenance Instructions………………………………………………….686
Maintenance………………………………………………………….686
Disassembly………………………………………………………….687
Assembly…………………………………………………………….688
Hydraulic Schematic (DX300LC-3) SP002334……………………………………….691
Safety Instructions………………………………………………………695
Applicable Models………………………………………………………..695
Electrical System……………………………………………………………….699
Electrical System SP002337……………………………………………………701
Safety Instructions………………………………………………………707
Applicable Models………………………………………………………..707
Introduction…………………………………………………………….708
Electrical Supply System………………………………………………….710
Engine Starting Circuit…………………………………………………..712
Start Operation………………………………………………………712
After Start………………………………………………………….714
Engine Preheating System………………………………………………….716
Engine Stop……………………………………………………………..718
Charging System………………………………………………………….720
Monitoring System………………………………………………………..721
Instrument Panel……………………………………………………..722
Functional Check……………………………………………………..722
Monitoring System Schematic……………………………………………724
Operation……………………………………………………………….726
Instruments………………………………………………………….726
Warning and Indicator Lights………………………………………………728
Indication of Warning Lights…………………………………………..728
Indication of Multifunction Gauge………………………………………730
Initial Operation………………………………………………………..731
Graphic Information Area Display…………………………………………..732
Overview…………………………………………………………….732
Main Menus for the Graphic Display Area…………………………………732
Menu Selector Buttons…………………………………………………732
User Menu……………………………………………………………….733
User Menu – Access and Escape Methods…………………………………..733
Special Menu…………………………………………………………….765
Entering/Accessing and Exiting/Escaping Menus……………………………765
Special Menu Selections……………………………………………….766
Electronic Hydraulic Control System (e-EPOS)………………………………..792
Control System Schematic………………………………………………792
Power Plus Mode Control…………………………………………………..794
Operation……………………………………………………………796
Power Mode Control – Circuit Diagram……………………………………….798
Engine Control System…………………………………………………….800
Engine Control Dial………………………………………………………801
Engine Control Circuit Diagram…………………………………………….802
omatic Deceleration Control (Auto Idle Control)……………………………..804
Engine Overheat Protection System………………………………………….806
Power Boost Mode…………………………………………………………808
Operation……………………………………………………………808
Power Boost Control – Circuit Diagram…………………………………..810
Automatic Travel Speed Control…………………………………………….812
Automatic Travel Speed Control – Circuit Diagram…………………………814
Self-diagnostic Function………………………………………………….815
e-EPOS Controller…………………………………………………….815
Air Conditioner System……………………………………………………817
Outline……………………………………………………………..817
Internal and External Filters………………………………………….818
Air-Conditioning System Layout…………………………………………820
Air Conditioner/heater Circuit Diagram………………………………….821
Air Conditioner/heater Unit……………………………………………822
Ambient Air Temperature Sensor…………………………………………827
Sun Sensor…………………………………………………………..828
Control Panel………………………………………………………..828
Compressor…………………………………………………………..836
Receiver Dryer……………………………………………………….836
Troubleshooting………………………………………………………….837
Weight of R134a Gas Used In Machines……………………………………….839
Refrigerant System Repairs………………………………………………..840
Refrigerant Safe Handling Procedures……………………………………840
Repair and Replacement Procedure……………………………………….841
Refrigerant Recovery………………………………………………….843
Vacuuming Refrigerant System…………………………………………..843
Leakage Check………………………………………………………..845
Refrigerant Charging………………………………………………….845
Inspecting System For Leakage………………………………………….847
Wiper System…………………………………………………………….848
Wiper Circuit………………………………………………………..848
Wiper operation………………………………………………………849
Lighting System………………………………………………………….852
Lighting System Circuit Diagram………………………………………..852
Kind of Light………………………………………………………..853
Operation……………………………………………………………853
Overload Warning Device…………………………………………………..854
Overload Warning Device Circuit Diagram…………………………………854
Audio Controller…………………………………………………………855
Audio Controller Circuit Diagram……………………………………….855
Electrical Schematic (DX300LC-3) SP002376………………………………………857
Safety Instructions………………………………………………………861
Applicable Models………………………………………………………..861
Attachments…………………………………………………………………….865
Boom and Arm SP002335………………………………………………………..867
Safety Instructions………………………………………………………871
Applicable Models………………………………………………………..871
Front Attachment Pin Specifications………………………………………..872
DX300LC-3……………………………………………………………873
Front Attachment – Removal and Installation…………………………………874
Arm Removal Procedure…………………………………………………874
Boom Removal Procedure………………………………………………..876
Installation…………………………………………………………….877
Arm Installation Procedure…………………………………………….877
Boom Installation Procedure……………………………………………877
Start-up Procedures………………………………………………………878
Bucket SP002336……………………………………………………………..879
Safety Instructions………………………………………………………883
Applicable Models………………………………………………………..883
Bucket Tooth Inspection and Replacement…………………………………….884
Bucket O-ring Replacement…………………………………………………885
Bucket Shimming Procedures………………………………………………..887
New Bucket Installation……………………………………………….887
Attachments……………………………………………………………..889
Bucket Replacement and Reversal………………………………………..889
Replacement………………………………………………………….890
Reversal…………………………………………………………….891
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
R.D
Calvin Cyrus –
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