Daewoo Doosan DX140LCR-3 Excavator Service Repair Manual Instant Download (Serial Number 1001 and Up)

1
Shop Manual DX140LCR-3 Excavator
Serial Number 1001 and Up
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.
950106-01021E December 2012
Original Instructions
Copyright DOOSAN 2012
2
Table of Contents
Safety Track Excavator Maintenance Safety
..................................................
. SP002907 Specifications Specifications for
DX140LCR-3 .......................................
..................... SP002908 General
Maintenance General Maintenance Instructions
..................................................
...... SP002454 Standard Torques
..................................................
............................... SP002404 Upper
Structure Cabin ..................................
..................................................
................ SP002909 Counterweight...........
..................................................
.......................... SP002910 Fuel
Tank..............................................
................................................
SP002911 Fuel Transfer Pump (Option)
..................................................
.............. SP002912 Swing Bearing.............
..................................................
........................ SP002913 Swing Reduction
Gear..............................................
............................ SP002526 Lower
Structure and Chassis Track Assembly
..................................................
..................................
SP002914 Engine and Drivetrain QSB4.5 Engine
..................................................
...................................
SP002915 Drive Coupling (Main Pump)...............
..................................................
SP002931 Hydraulics Hydraulic System
Troubleshooting, Testing and Adjustment
............... SP002916 Accumulator..............
..................................................
.......................... SP002455 Center Joint
(Swivel)..........................................
................................... SP002917
3
Cylinders.........................................
..................................................
.... SP002918 Swing Motor.........................
..................................................
............... SP002919 Travel
Device............................................
............................................
SP002920 Main Pump................................
..................................................
.......... SP002930 Gear Pump ....................
..................................................
..................... SP002500 Main Control Valve
..................................................
............................. SP002528 Remote
Control Valve (Work Lever / Joystick)
..................................... SP002921
Travel Control Valve (with Damper)................
......................................
SP002922 Solenoid Valve Assembly
..................................................
................... SP002923 Breaker EPPR Valve
(Option) .........................................
..................... SP002458 Hydraulic
Schematic (DX140LCR-3) ...........................
......................... SP002924 Electrical
System Electrical System .........................
..................................................
....... SP002925 Electrical Schematic
..................................................
........................... SP002926 Attachments
Boom and Arm......................................
................................................
SP002927 Bucket...................................
..................................................
.............. SP002506
4
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.ebo
oklibonline.com
5
Track Excavator Maintenance
Safety
SP002907
Edition 1
Track Excavator Maintenance Safety
SP002907 Page 1
6
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.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DX140LCR-3 1001 and Up
SP002907 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
SP002907
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 Maintenance Manual, and parts manual
for your unit. Always replace damaged or faded
decals.
SP002907 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.

Track Excavator Maintenance Safety Page 8
SP002907
10
Swing Reduction Gear
SP002526
Edition 2
Swing Reduction Gear
SP002526 Page 1
11
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.
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
DX140LCR-3 1001 and Up
SP002526 Page 5
Swing Reduction Gear
12
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.
SP002526 Page 7
Swing Reduction Gear
13
REASSEMBLY Parts List
19
24 12 12 11 6 12
3
24 7 13 13
14
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
14
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
SP002526 Page 9
Swing Reduction Gear
15
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
16
3. When bearing is heated up to 90C - 100C
(194F - 212F), 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.
IMPORTANT
Do not heat bearing above 120C (248F).
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
17
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
18
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
19
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
20
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
SP002526 Page 15
Swing Reduction Gear
21

• 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.

IMPORTANT
The calibers of gear and washer must be assembled in the 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
22
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
SP002526 Page 17
Swing Reduction Gear
23
Suggest If the above button click is invalid.
Please download this document first, and then
click the above link to download the complete
manual. Thank you so much for reading
24
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
25
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 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.
IMPORTANT
Before using a press to insert bearing, make sure bearing is not tilted and is properly aligned.
FG005384
Figure 36
SP002526 Page 19
Swing Reduction Gear
26
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.ebo
oklibonline.com