Daewoo doosan dx140 lcr excavator service repair manual (serial number 5001 and up)
- 1. K1049551E Shop Manual Copyright 2009 DOOSAN DOOSAN reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products. It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine's package. Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item. Shop Manual K1049551E Serial Number 5001 and Up DX140R DX140LCR
- 2. Table of Contents Page I 1Table of Contents Safety Track Excavator Safety......................................................................... SP001936 Specifications Specification for DX140LCR................................................................. SP001937 General Maintenance General Maintenance Procedures........................................................ SP000016 Standard Torques................................................................................. SP000813 Upper Structure Cabin .................................................................................................... SP001938 Counterweight....................................................................................... SP001939 Fuel Tank.............................................................................................. SP001940 Fuel Transfer Pump.............................................................................. SP000021 Swing Bearing....................................................................................... SP000022 Swing Reduction Gear.......................................................................... SP000921 Lower Structure and Chassis Track Assembly .................................................................................... SP001941 Engine and Drive Train QSB4.5 Engine..................................................................................... SP001671 Drive Coupling (Main Pump)................................................................. SP001326 Hydraulics Hydraulic System Troubleshooting, Testing and Adjustment ............... SP001942 Accumulator.......................................................................................... SP000028 Center Joint (Swivel)............................................................................. SP000029
- 3. Table of Contents Page II Cylinders............................................................................................... SP000030 Swing Motor.......................................................................................... SP001943 Travel Moter.......................................................................................... SP001346 Main Pump............................................................................................ SP001945 Main Control Valve ............................................................................... SP001029 Remote Control Valve (Work Lever / Joystick)..................................... SP000069 Travel Control Valve (with Damper)...................................................... SP000070 Solenoid Valve Assembly ..................................................................... SP001944 Breaker EPPR Valve (Opt) ................................................................... SP000192 Hydraulic Schematic (DX140LCR) ....................................................... SP001948 Electrical System Electrical System .................................................................................. SP001949 Electrical Schematic (DX140LCR)........................................................ SP001950 Attachments Boom and Arm...................................................................................... SP001331 Bucket................................................................................................... SP000939
- 4. SP001936 Page 1 Track Excavator Safety SP001936 TRACK EXCAVATOR SAFETYSP001936 Track Excavator Safety Edition 1
- 5. SP001936 Page 5 Track Excavator Safety SAFETY PRECAUTIONS APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. CAUTION Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that are in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. MODEL SERIAL NUMBER RANGE DX140LCR 5001 and Up
- 6. SP001936Track Excavator Safety Page 6 TO THE OPERATOR OF A EXCAVATOR Please respect the importance of taking responsibility for your own safety, and that of other people who may be affected by your actions. The safety information on the following pages is organized into the following sections: 1. “General Safety Essentials” on page 1-10 2. “Location of Safety Labels” on page 1-11 3. “Summary of Safety Precautions for Lifting in Digging Mode” on page 1-12 4. “Unauthorized Modifications” on page 1-13 5. “General Hazard Information” on page 1-13 6. “Before Starting Engine” on page 1-23 7. “Machine Operation” on page 1-27 8. “Maintenance” on page 1-34 9. “Battery” on page 1-43 10. “Towing” on page 1-45 11. “Shipping and Transportation” on page 1-46 12. “Lifting With Sling” on page 1-46 DANGER Unsafe use of the excavator could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
- 7. SP001936 Page 7 Track Excavator Safety WARNING Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. Operator and maintenance personnel should read this manual thoroughly before beginning operation or maintenance. Keep this manual in the storage compartment to the rear of the operator's seat, and have all personnel involved in working on the machine read the manual periodically. Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not done in a manner described in this manual. The procedures and precautions given in this manual apply only to intended uses of the machine. If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for any others. In no event should you or others engage in prohibited uses or actions as described in this manual. DOOSAN delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult DOOSAN or your DOOSAN distributor before operating the machine.
- 8. SP001936Track Excavator Safety Page 8 Learn the Signal Words Used with the Safety Alert Symbol The words "CAUTION," "WARNING," and "DANGER" used throughout this manual and on decals on the machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk indicate that safety is involved. Observe precautions indicated whenever you see the Safety Alert "Triangle," no matter which signal word appears next to the "Exclamation Point" symbol. SAFETY ALERT SYMBOL Be Prepared - Get to Know All Operating and Safety Instructions. This is the Safety Alert Symbol. Wherever it appears in this manual or on safety signs on the machine you should be alert to the potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures. CAUTION This word is used on safety messages and safety labels and indicates potential of a hazardous situation that, if not avoided, could result in minor or moderate injury. It may also be used to alert against a generally unsafe practice. WARNING This word is used on safety messages and safety labels and indicates potential of a hazardous situation that, if not avoided, could result in serious injury or death. It may also be used to alert against a highly unsafe practice. DANGER This word is used on safety messages and safety labels and indicates an imminent hazard of a situation that, if not avoided, is very likely to cause death or extremely serious injury. It may also be used to alert against equipment that may explode or detonate if handled or treated carelessly.
- 9. SP001936 Page 9 Track Excavator Safety Safety precautions are described in SAFETY from page -11 on. DOOSAN cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If you are unsure about the safety of some procedures, contact a DOOSAN distributor.
- 10. SP000921 Page 1 Swing Reduction Gear SP000921 SWING REDUCTION GEARSP000921 Swing Reduction Gear Edition 1
- 11. SP000921 Page 5 Swing Reduction Gear SAFETY PRECAUTIONS APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. CAUTION Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that are in good working order. Use lifting and hoisting equipment capable of safely handling the load. Remember, that ultimately safety is your own personal responsibility. MODEL SERIAL NUMBER RANGE DX140LC 5001 and Up DX140LCR 5001 and Up DX140W 5001 and Up DX160W 5001 and Up
- 12. SP000921 Page 7 Swing Reduction Gear GENERAL DESCRIPTION Theory of Operation The swing motor final drive is a two-stage planetary gearbox with two planet gears, two sun gears and two-stage output reduction. The planetary gear engages the ring gear. The pinion gear is connected to the output shaft and spline. The final drive reduces swing motor rpm to increase swing motor output torque. The available maximum swing speed provides a fast turning rate for efficient, rapid work cycling with more than adequate power for good acceleration.
- 13. SP000921Swing Reduction Gear Page 8 REASSEMBLY Parts List 2 6 5 4 1 27 17 7 8 10 20 26 19 29 25 23 22 22 21 18 14 12 12 12 12 13 13 11 15 9 28 24 24 3 16 FG005349 Figure 1
- 14. SP000921 Page 9 Swing Reduction Gear Reference Number Description 1 Casing 2 Driveshaft 3 Ring Gear 4 Planetary Gear 5 Sun Gear 2 6 Planetary Gear 7 Sun Gear 1 8 Carrier 2 9 Carrier 1 10 Pin Assembly 11 Pin Assembly 12 Adjustment Washer 13 Adjustment Washer 14 Level Bar 15 Level Gauge Piping 16 Pin 17 Roller Bearing 18 Roller Bearing 19 Socket Bolt 20 Oil Seal 21 Plug 22 Plug 23 Spring Pin 24 Retainer Ring 25 Retainer Ring 26 Ring 27 Spring Pin 28 Support Plate 29 Screw Bolt Reference Number Description
- 15. SP000921Swing Reduction Gear Page 10 SHRINKAGE FITTING OF SHAFT AND FLEXIBLE BEARING 1. Washing of shaft Remove fluids like anticorrosive fluid applied to the shaft and use an air conditioner to remove foreign substances. 2. Insert the support plate and the NILOS ring into the prepared shaft as shown in the figure and heat bearings (#22314, 2109-1041) on the heater. Figure 2 Figure 3
- 16. SP000921 Page 11 Swing Reduction Gear 3. When bearing is heated up to 90°C - 100°C, remove it from the heater, hold it with both hands, and insert it into the shaft evenly. To do so, slowly insert bearing 4-5 mm that it seats itself and then push it strongly to contact the NILOS ring. 4. After assembling the bearing, let it cooled fully in the air for 1 to 2 hours. Figure 4 Figure 5 Figure 6 CAUTION Do not heat bearing above 120°C.
- 17. SP000921Swing Reduction Gear Page 12 Figure 7
- 18. SP000921 Page 13 Swing Reduction Gear REASSEMBLY OF CARRIER SUB 1. Washing of carrier Put in a steam washer the carrier whose burr is removed completely with corner face-milling and place it on the assembly die after checking if there is not left any foreign substance in it. 2. Washing of planetary gear Check if planetary gear parts are washed or dented, and put them on the assembly die. 3. Reassembly of carrier #1 assembly A. Place the carrier #1 assembly on the assembly jig, insert the thrust washer in it, and fix it to the hole of carrier. B. Put a pressure jig on the pin and use a press to insert it. Figure 8 Figure 9 Figure 10
- 19. SP000921Swing Reduction Gear Page 14 C. Place the carrier with the pin being pressed in on the jig vertically, use a hammer to insert the spring pin (ø6 x 25 liter§), and drain valve it. Figure 11 Figure 12 Figure 13 Figure 14
- 20. SP000921 Page 15 Swing Reduction Gear D. Assemble 2 other parts in the same way. E. Put the thrust washer (B) in the middle of the carrier with all of pins being pressed in. F. Insert planetary gear #1 in 3 pins and put two thrust washers on them as shown in the figure. Figure 15 Figure 16 Figure 17 Figure 18
- 21. SP000921Swing Reduction Gear Page 16 G. Install a retaining ring (ø30, C type, and for shaft) on each and check if gear rotates smooth. Figure 19 Figure 20 Figure 21
- 22. SP000921 Page 17 Swing Reduction Gear 4. Reassembly of carrier #2 assembly A. Place the carrier #2 assembly on the assembly die, attach the thrust washer on a side of the planetary gear #2, and insert it in the carrier with the washer facing downward. B. Place the pin #2 assembly on the assembly die that the pinhole of the spring faces the same direction as the carrier shaft, and insert it by pressing with hands or gently knocking with hammer. Figure 22 CAUTION The calibers of gear and washer should be fit to holes of the carrier pins. Figure 23 Figure 24 Figure 25
- 23. SP000921Swing Reduction Gear Page 18 C. After inserting the pin assembly, set the carrier vertically as shown in the figure, insert the spring pin (ø6 x 25 mm) by gently knocking with hammer, and push it to the end with a jig. Figure 26 Figure 27 Figure 28 Figure 29
- 24. SP000921 Page 19 Swing Reduction Gear D. Use a punch to drain valve 2 or 3 places near hole where spring pin is inserted. E. Assemble other 3 parts and check if the gear runs smooth. Figure 30 Figure 31 Figure 32 Figure 33
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- 26. SP000921Swing Reduction Gear Page 20 ASSEMBLY OF THE MAIN 1. Washing of casing and other parts Wash casing and other parts with steam to remove remaining foreign substance after casting and machining. • Washing fluid: PK6540 (alkali) • Concentration : 3-5% • Temperature: 60 - 70°C 2. Assembly of shaft and bearing A. Fix the washed casing on the turnover machine and rotate the turnover machine that the press fitting side of the shaft looks upward. B. Place the driveshaft assembly where bearing (#22314) is assembled on the case assembly, put a press jig on it, and use press to insert it. Figure 34 Figure 35 Figure 36 CAUTION Make sure that bearing is not tilted for correct press fitting before using press.
- 27. SP000921 Page 21 Swing Reduction Gear C. Remove the bearing press jig, align the support plate with the bolt tap of the case, and install 6 Loctite (#262) applied flat head bolts (M8 x 15 mm) and tighten them with torque wrench (torque :320 kg•cm). Figure 37 Figure 38 Figure 39 Figure 40
- 28. SP000921Swing Reduction Gear Page 22 D. After installing the support plate, rotate the turnover machine that the case is situated as shown in the figure. Figure 41 Figure 42 Figure 43 Figure 44