service repair manual

1. Original InstructionsCopyright DOOSAN 2012
Serial Number 1001 and Up
Serial Number 10001 and Up (Europe Only)
Shop Manual
DX340LC-3/DX350LC-3 Excavator
950106-00225E
February 2012
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
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
Hydraulic System Troubleshooting, Testing and Adjustment ............... SP002412
Accumulator.......................................................................................... SP002455
Center Joint (Swivel)............................................................................. SP002545
Cylinders............................................................................................... SP002422

3. Table of Contents
Page II
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. SP002322
Page 1
Track Excavator Maintenance Safety
SP002322
TRACK EXCAVATOR MAINTENANCE SAFETY
SP002322
Track Excavator
Maintenance
Safety
Edition 2

5. SP002322
Page 5
Track Excavator Maintenance Safety
SAFETY INSTRUCTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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.
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

6. SP002322Track Excavator Maintenance Safety
Page 6
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.
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.
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.
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.

7. SP002322
Page 7
Track Excavator Maintenance Safety
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.

8. SP002330
Page 1
Track Assembly
SP002330
TRACK ASSEMBLY SP002330
Track
Assembly
Edition 2

9. SP002330
Page 5
Track Assembly
SAFETY INSTRUCTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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.
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

10. SP002330Track Assembly
Page 6
GENERAL DESCRIPTION
The track assembly is composed of the following major
components:
1. Track
2. Front Idler Roller
3. Upper Roller
4. Lower Roller
5. Track Spring and Track Adjustment Cylinder

11. SP002330
Page 7
Track Assembly
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.
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.
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.
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.
FG018383
90 ~ 110
Figure 1
A
FG000223
Figure 2

12. SP002330Track Assembly
Page 8
4. The increased clearance recommended for muddy, sandy
or snowy ground conditions is between distance "C" in
below table.
5. 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.
6. 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).
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.
2
1
3
FG018365
Figure 3

13. SP002330
Page 9
Track Assembly
CLEANING AND INSPECTION
(WEAR LIMITS AND
TOLERANCES)
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.
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.

14. SP002330Track Assembly
Page 10
Track Shoe
8
7
2
7
2
10
119
FG018732
1
36
4 5
Figure 4

15. SP002330
Page 11
Track Assembly
No. Check Item Standard Dimension
Recommended Limit
for Maintenance
Limit for Use
(Repair - P or
Replace - R)
1 Link Pitch
216 mm
(8.504")
2
Bushing Outside
Diameter
66.5 mm
(2.618")
62.5 mm
(2.461")
59 mm (R)
(2.323")
3 Link Height
116 mm
(4.567")
108 mm
(4.252")
103 mm (P)
(4.055")
4 Length at Tip
22 mm
(0.866")
5 Length at Tip
16 mm
(0.630")
6 Height
30 mm
(1.181")
24 mm
(0.945")
20 mm
(0.787")
7
Interference between
bushing and link
Bushing Tolerance Link Tolerance
Standard
Interference
Repair
Limit
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
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
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
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
44.3 mm
(1.744")
±0.050
45.45 mm
(1.789")
+0.500
0.0
1.100 -
1.700

16. SP002330Track Assembly
Page 12
Lower Roller
5
6
2
1
3 4
FG018733
Figure 5
No. Check Item Standard Dimension
Recommended Limit for
Maintenance
Limit for Use
(Repair - P or
Replace - R)
1
Outside Diameter of
Flange
214 mm
(8.425")
2
Outside Diameter of
Tread
180 mm
(7.087")
168 mm
(6.614")
166 mm (P)
(6.535")
3 Width of Tread
51 mm
(2.008")
57 mm
(2.244")
60 mm (P)
(2.362")
4 Width of Flange
36 mm
(1.417")
5
Clearance between
shaft and bushing
Standard
Dimension
Tolerance Standard
Clearance
Repair
LimitShaft Hole
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 Standard
Interference
Repair
LimitShaft Hole
82 mm
(3.228")
+0.180
+0.130
+0.030
-0.020
0.100 - 0.200

17. SP002330
Page 13
Track Assembly
Upper Roller
FG019393
6
5
4 3
2
1
Figure 6
No. Check Item Standard Dimension
Recommended Limit for
Maintenance
Limit for Use
(Repair - P or
Replace - R)
1
Outside Diameter of
Flange
175 mm
(6.890")
2
Outside Diameter of
Tread
142 mm
(5.591")
135 mm
(5.315")
130 mm (P)
(5.118")
3 Width of Tread
45 mm
(1.772")
52 mm
(2.047")
54 mm (P)
(2.126")
4 Width of Flange
18.5 mm
(0.728")
5
Clearance between
shaft and bushing
Shaft Tolerance Bushing Tolerance
Standard
Clearance
Repair
Limit
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 Standard
Interference
Repair
LimitShaft Hole
61 mm
(2.402")
+0.120
+0.090
+0.040
-0.030
0.050 -
0.150

18. SP002330Track Assembly
Page 14
Front Idler
FG019394
6
7
2
4
3 5
1
Figure 7
No. Check Item Standard Dimension
Recommended Limit for
Maintenance
Limit for Use
(Repair - P or
Replace - R)
1
Outside Diameter of
Flange
630 mm
(24.803")
2
Outside Diameter of
Tread
580 mm
(22.835")
572 mm
(22.520")
568 mm (P)
(22.362")
3 Width of Protrusion
102 mm
(4.016")
4 Total Width
190 mm
(7.480")
5 Width of Tread
44 mm
(1.732")
47 mm
(1.850")
49 mm
(1.929")
6
Clearance between
shaft and bushing
Standard
Dimension
Tolerance Standard
Clearance
Repair
LimitShaft Hole
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 Standard
Interference
Repair
LimitShaft Hole
98 mm
(3.858")
+0.190
+0.155
+0.050
0.0
0.105 - 0.190

19. SP002330
Page 15
Track Assembly
TRACK SHOES AND LINKS
Track Removal
1. Position machine on a smooth level surface with adequate
room for forward and reverse travel.
2. Move machine until master link (4, Figure 9) is positioned
at approximately 4 o'clock from top position on front idle
roller.
3. Put a wooden block under track shoes, as shown.
4. Loosen grease valve (1, Figure 10) for track adjuster to
drain grease out. Use socket wrench 27 mm
5. Remove four nuts and bolts (1 and 2, Figure 9) holding
shoe to link. Remove enough shoes to make access to
master pin.
6. Remove master pin from master link by hammer or press.
Remove pin after detaching shoe.
FG019247
Figure 8
1
2
4
FG004355
Figure 9
Figure 10
1
FG004356
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.

20. SP002330Track Assembly
Page 16
7. Move unit forward until entire track is laying on ground.
NOTE: Do not drive unit off track.
8. Rotate upper structure to 90° from track. Use bucket and
boom to raise track frame off track.
9. Position blocking under frame.
Track Installation
1. Lay rebuilt or new track into position under track frame.
End of track should be positioned under drive sprocket.
2. With upper structure at 90° to track frame. Use bucket and
boom to raise track frame off blocking.
3. With blocking removed, lower track frame onto track. Make
sure all rollers are properly positioned on track.
4. Move unit forward while feeding track up over drive
sprocket. Continue to pull track back until it engages front
idle roller.
5. Align master links and install master pin.
6. Install four nuts and bolts (to fix track shoe).
7. Apply track tension. Refer to "“Track Tension” on page -7"
in this section for procedure.
FG003911
Figure 11
Figure 12
FG018383
90 ~ 110
FG018383
90 ~ 110
Figure 13
FG003912
Figure 14

21. SP002330Track Assembly
Page 18
FRONT IDLER ROLLER
Parts List
8
6
5
7
3
FG003913
4
2
1 9
9
4
7
8
3
6
Figure 15
Reference
Number
Description
1 Idler Assembly
2 Idler
3 Bearing
4 Shaft
5 Bushing
6 Pin
7 Floating Seal
8 O-ring
9 Plug
Reference
Number
Description

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23. SP002330
Page 19
Track Assembly
Front Idler Roller Disassembly
1. Remove plug (9, Figure 16) from idler assembly (1), and
drain oil into a suitable container.
2. Separate the pin (6, Figure 17) from the bearing (3).
3. Use a press to remove bearing from the axle (4). Separate
the O-ring (8, Figure 18) from the axle.
4. Detach the floating seal (7, Figure 19) from the idler (2)
and bearing (3).
FG003914
9
Figure 16
FG003915
6
3
Figure 17
3
FG001482
4
8
Figure 18
FG001483
3
3
7
7
2
Figure 19

24. SP002330Track Assembly
Page 20
5. Use a press to separate the axle (4, Figure 20), O-ring (8)
and bearing (3).
6. Remove bushing (5, Figure 21) with the press and special
tool (10, ST-1909).
FG001484
4
3
8
Figure 20
FG001485
10
5 2
Figure 21

25. SP002330
Page 21
Track Assembly
Front Idler Roller Reassembly
1. Degrease, clean and dry all parts before reassembly.
Insert bushing (5, Figure 21) into the idler (2).
2. Grease O-ring (8, Figure 22) and insert it into the axle.
3. Align the bearing (3, Figure 22) and axle (4) holes and pin
(6) them together.
4. Install floating seal (7, Figure 23) inside the idler (2) and
bearing (3).
NOTE: Apply clean engine oil to the joint side of the
floating seal. Apply grease to the floating seal
O-ring.
5. Install idler (2, Figure 24) on the axle.
6. 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).
7. Install plug (9, Figure 29) on the bearing.
FG001486
6
4
3
8
8
Figure 22
FG001483
3
3
7
7
2
Figure 23
FG001488
6
3
9
2
Figure 24