Daewoo Doosan DX160LC-3 Excavator Service Repair Manual Instant Download

1
Shop Manual DX160LC-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.
950106-01172E April 2014
Original Instructions
Copyright DOOSAN 2014
2
Table of Contents
Safety Track Excavator Maintenance Safety
..................................................
. SP002322 Specifications Specifications for
DX160LC-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
..................................................
..................................
SP002524 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............................................
............................................
SP002514 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 (DX160LC-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
DX160LC-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
Track Excavator Maintenance Safety
SP002322 Page 5
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.
Track Excavator Maintenance Safety
SP002322 Page 7
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
Track Excavator Maintenance Safety
SP002322 Page 9
11
Swing Reduction Gear
SP002526
Edition 1
Swing Reduction Gear
SP002526 Page 1
12
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
DX160LC-3 1001 and Up, 50001 and Up
Swing Reduction Gear
SP002526 Page 5
13
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.
Swing Reduction Gear
SP002526 Page 7
14
REASSEMBLY Parts List
19
24 12 12 11 6 12
3
24 7 13
14
13
9
5
23
15
10
8
4 12
25
18
27
20
16
22
1
21 22
17 28 29 2 26
FG005349
Figure 1
Swing Reduction Gear Page 8
SP002526
15
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
Reference Number Description
16 Pin
17 Roller Bearing
18 Roller Bearing
19 Socket Bolt
20 Oil Seal
21 Plug
22 Plug
23 Spring Pin
24 Retaining Ring
25 Retaining Ring
26 Ring
27 Spring Pin
28 Support Plate
29 Screw Bolt
Swing Reduction Gear
SP002526 Page 9
16
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
Swing Reduction Gear Page 10
SP002526
17
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
Swing Reduction Gear
SP002526 Page 11
18
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
Swing Reduction Gear Page 12
SP002526
19
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
Swing Reduction Gear
SP002526 Page 13
20
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
Swing Reduction Gear Page 14
SP002526
21
FG005367
Figure 19 G. Install a retaining ring (ø30, C
type, and for shaft) on each and check if gear
rotates smooth.
FG005368
Figure 20
FG005369
Figure 21
Swing Reduction Gear
SP002526 Page 15
22

• Reassembly of carrier 2 assembly
• 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.

CAUTION
AVOID INJURY The calibers of gear and washer must
be fit to holes of the carrier pins.
FG005370
Figure 22
FG005371
Figure 23
FG005372
Figure 24 B. Place the pin 2 assembly on the
assembly die that pinhole of the spring faces
the same direction as the carrier shaft, and
insert it by pressing with hands or gently
tapping with hammer.
FG005373
Figure 25
Swing Reduction Gear Page 16
SP002526
23
FG005374
Figure 26
FG005375
Figure 27 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 tapping with hammer, and push it to the
end with a jig.
FG005376
Figure 28
FG005377
FG005375
Figure 29
Swing Reduction Gear
SP002526 Page 17
24
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FG005378
Figure 30 D. Use a punch to drain valve 2 or 3
places near hole where spring pin is inserted.
FG005379
Figure 31
FG005380
Figure 32 E. Assemble other 3 parts and check if
the gear runs smooth.
FG005381
Figure 33
SP002526
Swing Reduction Gear Page 18
26
ASSEMBLY OF THE MAIN

• 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 - 70C
• Assembly of shaft and bearing
• A. Attach the washed casing on the turnover
  machine and rotate the turnover machine so that
  press fitting side of the shaft looks upward.

FG005382
Figure 34
FG005383
Figure 35 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.
CAUTION
AVOID INJURY Make sure that bearing is not tilted
for correct press fitting before using press.
FG005384
Figure 36
SP002526 Page 19
Swing Reduction Gear
27
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