Doosan DX300LC-5 Install guide

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.

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
4Engine 1Engine
2 Engine Coolant Heater (Option)
5 Upper Structure 1Cabin
2 Counterweight
3 Oil Tank
4 Fuel Tank
5MainPump
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
2CenterJoint
3 Travel Device
4 Track Assembly

Table of Contents
Page II
7Front 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 1OneWay
2Two-way
3 Rotating
4 Quick Coupler
5TwoPump
11 Schematic 1 Hydraulic Schematic/Electrical Schematic

Track Excavator Maintenance Safety
1-1-1
DX300LC-5
Track Excavator
Maintenance
Safety
Edition 1

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.

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.

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

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

DX300LC-5Engine
4-1-1
Engine
Edition 1

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.

DX300LC-5Engine
4-1-8
OVERVIEW
EX1301800
FRONT
Figure 1

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

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

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

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