Daewoo Doosan DX140LC-3 Excavator Service Repair Manual Instant Download

1
Shop Manual DX140LC-3 Excavator
Serial Number 1001 and Up Serial Number 50001 and
Up (Europe Only)
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.
950106-00388E April 2012
Original Instructions
Copyright DOOSAN 2012
2
Table of Contents
Safety Track Excavator Maintenance Safety
..................................................
. SP002322 Specifications Specifications for
DX140LC-3.........................................
...................... SP002509 General
Maintenance General Maintenance Instructions
..................................................
...... SP002454 Standard Torques
..................................................
............................... SP002404 Upper
Structure Cabin ..................................
..................................................
................ SP002324 Counterweight...........
..................................................
.......................... SP002510 Fuel
Tank..............................................
................................................
SP002511 Fuel Transfer Pump (Option)
..................................................
.............. SP002546 Swing Bearing.............
..................................................
........................ SP002329 Swing Reduction
Gear..............................................
............................ SP002526 Lower
Structure and Chassis Track Assembly
..................................................
..................................
SP002512 Engine and Drivetrain Engine Coolant
Heater (Option) ..................................
......................... SP002328 Drive Coupling
(Main Pump).......................................
.......................... SP002515 Hydraulics Hy
draulic System Troubleshooting, Testing and
Adjustment ............... SP002538
Accumulator.......................................
..................................................
. SP002455 Center Joint (Swivel)..................
..................................................
......... SP002456
3
Cylinders.........................................
..................................................
.... SP002539 Swing Motor.........................
..................................................
............... SP002527 Travel
Device............................................
............................................
SP002516 Main Pump................................
..................................................
.......... SP002517 Gear Pump ....................
..................................................
..................... SP002500 Main Control Valve
..................................................
............................. SP002528 Remote
Control Valve (Work Lever / Joystick)
..................................... SP002395
Travel Control Valve (with Damper)................
......................................
SP002381 Solenoid Valve Assembly
..................................................
................... SP002406 Breaker EPPR Valve
(Option) .........................................
..................... SP002458 Dozer Valve
..................................................
........................................ SP002529
Hydraulic Schematic (DX140LC-3)..................
.....................................
SP002518 Electrical System Electrical System
..................................................
................................
SP002337 Electrical Schematic ....................
..................................................
....... SP002508 Attachments Boom and
Arm...............................................
.......................................
SP002513 Bucket...................................
..................................................
.............. SP002506
4
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Track Excavator Maintenance
Safety
SP002322
Edition 3
Track Excavator Maintenance Safety
SP002322 Page 1
6
SAFETY INSTRUCTIONS
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.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
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
SP002322 Page 5
Track Excavator Maintenance Safety
7
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.
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 must be alert to the potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures.
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.
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.
Track Excavator Maintenance Safety Page 6
SP002322
8
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.
Other Signal Words In addition to safety signal
words, the following signal words are used to
indicate proper and effective use of machine.
IMPORTANT
This signal word identifies procedures which must be followed to avoid damage to machine.
The word "NOTE" identifies information for
effective use.
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.
SP002322 Page 7
Track Excavator Maintenance Safety
9
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 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.
• 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

Track Excavator Maintenance Safety Page 8
SP002322
10
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. 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.
FG018457
Figure 1
SP002322 Page 9
Track Excavator Maintenance Safety
11
SAFETY INSTRUCTIONS
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.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DX140LC-3 1001 and Up, 50001 and Up
SP002511 Page 5
Fuel Tank
12
GENERAL DESCRIPTION
WARNING
AVOID DEATH OR SERIOUS INJURY Diesel fuel is highly flammable and can be potentially explosive. To prevent fires or explosion, keep arcs, sparks or other ignition sources away from diesel fuel or fuel containers.
Parts List
11
10
1
17
12
16 15
9 13 7
8 13 7
14
2
3
5 4
6
FG022530
Figure 1
Fuel Tank Page 6
SP002511
13
Reference Number Description
1 Fuel Tank
2 O-ring
3 Fuel Tank Cover
4 Bolt
5 Washer
6 Drain Valve
7 Bolt
8 Shim
9 Shim
Reference Number Description
10 Fuel Strainer
11 Cap
12 Level Gauge
13 Spacer
14 Fuel Sensor
15 Bolt
16 Spring Washer
17 Fuel Float Switch
Specifications Fuel tank capacity is 267 liters
(70.5 U.S. gal).
SP002511 Page 7
Fuel Tank
14
REMOVAL
1. Look at fuel level display (Figure 2) on
instrument panel in operator's cabin to see what
it displays. The display is divided into ten
separated segments, each representing 10 percent
of total fuel supply. Also, look at level gauge
on side of tank to estimate volume of fuel left
in tank.
NOTE
If possible, operate excavator until available
fuel supply in tank has been run down as far as
possible.
E
F
FG018115
Figure 2 2. Park on firm and level ground and
swing upper structure to approximately a 90
with respect to tracks. See Figure 3.
FG022531
Figure 3

1. Lower bucket (or work tool) to ground.
2. Stop engine.
3. Set safety lever to "RELEASED" (UNLOCK) position.
4. Turn starter switch to "I" (ON) position.

O
I
WARNING
AVOID DEATH OR SERIOUS INJURY If engine must be running while performing maintenance, use extreme care. Always have one person in the cabin at all times. Never leave the cabin with the engine running.
WARNING
DO NOT OPERATE when performing inspection or
maintenance 190-00695A
OFF FG018470
ON
Figure 4

1. Fully stroke work levers (joysticks) in all
   directions to relieve any pressure from
   accumulators.
2. Set safety lever to "LOCK" position.
3. Turn key to "O" (OFF) position and remove from
   starter switch.
4. Attach maintenance warning tag on controls.
5. Turn battery disconnect switch to "OFF" position.

Fuel Tank Page 8
SP002511
15
12. Clean area around fuel tank fill cap (11,
Figure 5). Open fuel cap.
11
FG022532
Figure 5 13. Open drain valve (Figure 6) right
side door and drain. NOTE Fuel tank capacity is
267 liters (70.5 U.S. gal).
FG021690
Figure 6
14. Remove five bolts (23, Figure 7) and cover
(24) from fuel tank.
23
24
FG022535
Figure 7
SP002511 Page 9
Fuel Tank
16
15. Remove ten bolts (25 and 26, Figure 8) and
handrail (27) from fuel tank and frame. Remove
four bolts (28 and 29) and fuel tank cover (30)
from fuel tank. Remove two bolts (31) and bracket
(32) from tank. Remove four bolts (33) and
storage box (34) from frame.
26 27 28
32 31
29
30
33
34
25
FG022536
Figure 8 16. Remove four bolts (35 and 36,
Figure 9) and cover (37) from fuel tank and
support.
37
36
FG003878
35

• Figure 9
• Tag and disconnect fuel supply line (21, Figure
  10) and fuel return line (19) from fuel tank (1)
  and carefully drain remaining fuel from lines.
• Remove clamp (20, Figure 10) holding fuel return
  line (19) to tank (1).

1
19 20
21
FG022533
Figure 10
Fuel Tank Page 10
SP002511
17
19. If equipped, remove components from fuel
filler pump port (22, Figure 11) on side of fuel
tank (1).
1
22
FG022534
Figure 11
20. Tag and disconnect wires leading to fuel
sensor (14) and fuel float switch (17, Figure
12) on side of fuel tank (1).
1
17
14 Figure 12
FG022537

1. Install two 12 mm eyebolts in threaded holes (38
   and 39, Figure 13). Using a suitable lifting
   device, sling eyebolts.
2. Remove six bolts (7) and spacers (13, Figure 13)
   holding tank (1) to frame. Lift tank 25 mm (1")
   and make sure it is balanced. Make sure there
   are no other electrical wires or hoses connected
   to tank. Completely remove tank after inspection.

1
39
38
NOTE
The clear level gauge on the side of the tank is
easily damaged. Be careful of obstacles and wind
gusts.
23. Remove shims (9, Figure 13).
NOTE
If tank is to be reused note position and amount
of shims used for each mounting bolt location.
9 13 7 Figure 13
FG022538
SP002511 Page 11
Fuel Tank
18
INSTALLATION

1. Install two 12 mm eyebolts in threaded holes (38
   and 39, Figure 14). Using a suitable lifting
   device, sling eyebolts.
2. Set fuel tank (1, Figure 14) into position.
   Install six bolts (7) and spacers (13) finger
   tight, to secure tank to frame.

38
1 39
NOTE
The clear level gauge on the side of the tank is
easily damaged. Be careful of obstacles and wind
gusts.

• Install shims (9, Figure 14) as needed to prevent
  tank (1) from rocking or stress from mounting
  bolts (7).
• Tighten mounting bolts (7, Figure 14) after shims
  are installed.
• NOTE Bolt torque is 27 kgm (200 ft lb).

9 13 7
FG022495
Figure 14
5. Connect wires as tagged to fuel sensor (14)
and fuel float switch (17, Figure 15) on side of
fuel tank (1).
1
17
14 Figure 15
FG022537
6. If equipped, connect components to fuel filler
pump port (22, Figure 16) on side of fuel tank
(1).
1
22
FG022534
Figure 16
Fuel Tank Page 12
SP002511
19

1. Connect as tagged, fuel supply line (21, Figure
   17) and fuel return line (19) to fuel tank (1).
2. Install clamp (20, Figure 17) to hold fuel return
   line (19) to tank (1).

1
19 20
21
FG022533
Figure 17 9. Install four bolts (35 and 36,
Figure 18) and cover (37) on fuel tank and
support.
37
36
35
FG003878
Figure 18
10. Install four bolts (33, Figure 19) and
storage box (34) on frame. Install two bolts
(31) and bracket (32) on fuel tank. Install four
bolts (28 and 29) and fuel tank cover (30) on
fuel tank. Install ten bolts (25 and 26) and
handrail (27) on fuel tank and frame.
26 27
28
32 31
29
30
33
34
25
FG022536
Figure 19
SP002511 Page 13
Fuel Tank
20

1. Make sure fuel tank drain valve (Figure 20) right
   side door is closed.
2. Fill fuel tank and check for signs of leaks.
   Correct any problems found.
3. Turn disconnect switch to "ON" position.

FG021690
Figure 20
14. Install five bolts (23, Figure 21) and cover
(24) on fuel tank.
23
24
FG022535
Figure 21
Fuel Tank Page 14
SP002511
21

• START-UP PROCEDURES
• If engine does not start, the fuel system may
  need priming. Prime the fuel system using the
  following procedure
• Turn key to "OFF" position.
• Open right side door to access fuel filter.

FG022496
Figure 22

1. Loosen plug (1, Figure 23) on top of fuel filter
   head.
2. Pump hand-operated primer pump (2, Figure 23) by
   the fuel injection pump. Pump primer until fuel
   is present at plug hole in fuel filter head.
3. Tighten plug in fuel filter head.
4. Continue to pump primer pump until a strong
   resistance is felt.
5. Start engine and look for signs of leaks.

2
1
Repeat procedure if necessary.
FG020728
Figure 23
SP002511 Page 15
Fuel Tank
22
SHRINKAGE FITTING OF SHAFT AND FLEXIBLE BEARING

• Washing of shaft
• Remove fluids like anticorrosive fluid applied to
  the shaft and use an air conditioner to remove
  foreign substances.
• 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.

FG005350
Figure 2
FG005351
Figure 3
FG005352
Figure 4
FG005353
Figure 5
SP002526
Swing Reduction Gear Page 10
23
3. When bearing is heated up to 90C - 100C,
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.
CAUTION
AVOID INJURY Do not heat bearing above 120C.
FG005354
Figure 6 4. After assembling the bearing, let it
cooled fully in the air for 1 to 2 hours.
FG005355
Figure 7
SP002526 Page 11
Swing Reduction Gear
24
REASSEMBLY OF CARRIER SUB

• 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.
• Washing of planetary gear
• Check if planetary gear parts are washed or
  damaged, and put them on the assembly die.
• Reassembly of carrier 1 assembly
• Place the carrier 1 assembly on the assembly
  jig, insert the thrust washer in it, and install
  it to the hole of carrier.

FG005356
Figure 8
FG005357
Figure 9 B. Put a pressure jig on the pin and
use a press to insert it.
FG005358
Figure 10
SP002526
Swing Reduction Gear Page 12
25
FG005359
Figure 11 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.
FG005360
Figure 12
FG005361
Figure 13
FG005362
Figure 14
SP002526 Page 13
Swing Reduction Gear
26
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FG005363
Figure 15
D. Assemble 2 other parts in the same way.
FG005364
Figure 16 E. Put the thrust washer (B) in the
middle of the carrier with all of pins being
pressed in.
FG005365
Figure 17 F. Insert planetary gear 1 in 3 pins
and put two thrust washers on them as shown in
the figure.
FG005366
Figure 18
SP002526
Swing Reduction Gear Page 14
28
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