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K1016585E Shop Manual
Copyright 2006 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
K1016585E
Serial Number 5001 and Up
DX255LC
Table of Contents
Page I
1Table of Contents
Safety
Track Excavator Safety......................................................................... SP000014
Specifications
Specification for DX255LC.................................................................... SP001009
General Maintenance
General Maintenance Procedures........................................................ SP000016
Standard Torques................................................................................. SP000813
Upper Structure
Cabin .................................................................................................... SP000943
Counterweight....................................................................................... SP000940
Fuel Tank.............................................................................................. SP001012
Fuel Transfer Pump.............................................................................. SP000021
Swing Bearing....................................................................................... SP001068
Swing Reduction Gear.......................................................................... SP001015
Lower Structure and Chassis
Track Assembly .................................................................................... SP001016
Engine and Drive Train
Drive Coupling (Main Pump)................................................................. SP001069
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ............... SP001017
Accumulator.......................................................................................... SP000028
Center Joint (Swivel)............................................................................. SP000029
Cylinders............................................................................................... SP000030
Table of Contents
Page II
Swing Motor.......................................................................................... SP001020
Travel Motor.......................................................................................... SP001021
Gear Pump ........................................................................................... SP000931
Main Control Valve ............................................................................... SP000034
Axial Piston Pump................................................................................. SP001022
PTO Server........................................................................................... SP000933
Remote Control Valve (Work Lever / Joystick)..................................... SP000069
Travel Control Valve (with Damper)...................................................... SP000070
Solenoid Valve Assembly ..................................................................... SP000445
Breaker EPPR Valve (Opt) ................................................................... SP000192
Hydraulic Schematic (DX255LC).......................................................... SP001023
Electrical System
Electrical System .................................................................................. SP001025
Electrical Schematic (DX180LC/DX225LC/225NLC/255LC)................ SP000936
Attachments
Boom and Arm...................................................................................... SP001026
Bucket................................................................................................... SP000939
SP001020Swing Motor
Page 24
REASSEMBLY
General Cautions
1. Wash and clean each part. Then dry them with
compressed air. The friction plate, however, should not be
washed with treated oil.
2. Each connecting parts should be tightened according to its
assigned torque.
3. Only use a plastic soft-faced hammer.
Assembly
1. Put roll bearing (3) and bushing (39) on a heater and apply
heat to their inner race (inlet temperature: 290°C for 2
minutes).
!'
!
FG001328
Bushing X 1ea
(SUJ)
Roll Bearing X 1ea
(NUP2209)
Figure 40
FG000715
Figure 41
SP001020
Page 25
Swing Motor
2. Assemble heated roll bearing (3) and bushing (39). Use
retaining ring pliers to assemble install retaining ring (7).
3. Put body (1) on assembly jig and secure it so it cannot
move.
4. Assemble oil seal (2) in body (1) using bar hammer.
FG000716
Figure 42
FG000717
Figure 43
FG000718
Figure 44
FG000719
Figure 45
SP001020Swing Motor
Page 26
5. Install shaft in body (1) using bar hammer.
6. Secure shaft with retaining ring (4) using retaining ring
pliers.
FG000720
Figure 46
FG000717
Figure 47
FG000721
Figure 48
FG000722
Figure 49
SP001020
Page 27
Swing Motor
7. Coat shoe plate (8) with grease, and assemble it into body.
Assembly of Cylinder Block Assembly
Subassembly
8. Insert nine sets of springs (1 thru 9) in cylinder block (9).
FG000723
Figure 50
FG000724
Figure 51
FG000725
Figure 52
FG000726
Figure 53
SP001020Swing Motor
Page 28
9. Insert ball guide (1-B-11) in cylinder block (9).
10. Assemble friction plate (14) and plate (15) into cylinder
block (9)
FG000727
Figure 54
FG000728
Figure 55
FG000729
Figure 56
FG000759
Figure 57
SP001020
Page 29
Swing Motor
11. Insert piston assembly (1-C-13) in set plate (1-B-12) and
assemble it into cylinder block (9).
NOTE: Coat piston with clean hydraulic oil.
FG000730
Figure 58
FG000731
Figure 59
FG000696
Figure 60
FG000732
Figure 61
SP001020Swing Motor
Page 30
12. Assemble cylinder block into body (1).
13. Insert O-ring (38) in body (1).
14. Assemble O-ring (17) into brake piston (16).
FG000733
Figure 62
FG000734
Figure 63
FG000704
Figure 64
FG000687
Figure 65
SP001020
Page 31
Swing Motor
15. Insert brake piston assembly in body and secure it using
jig.
16. Insert eighteen springs (18) into brake piston (16).
Assembly of Rear Cover Assembly
Subassembly
1. Insert pins (6 and 21) in rear cover (19) with bar hammer
and assemble needle bearing (20) using jig.
FG000735
Figure 66
FG000736
Figure 67
FG000737
Figure 68
FG000738
Figure 69
SP001020Swing Motor
Page 32
2. Assemble O-ring (17) into rear cover (19).
3. Assemble check valve. Install O-ring (27) using jig.
FG000739
Figure 70
FG000740
Figure 71
FG000741
Figure 72
FG000742
Figure 73
SP001020
Page 33
Swing Motor
4. Insert poppet (24), spring (25), and plug (26) in rear cover
(19). Tighten plug with L wrench. (Left and right
symmetrically.)
5. Assemble anti-inversion valve. Assemble body, spring
seat, spring, poppet, poppet seat, stopper, and spring.
Then assemble O-ring (31), backup ring (32), and O-ring
(30).
FG000743
Figure 74
FG000708
Figure 75
FG000744
Figure 76
FG000745
Figure 77
SP001020Swing Motor
Page 34
6. Assemble anti-inversion valve set. Assemble anti-inversion
valve set and plug assembly (29) into rear cover (19) and
tighten them with L wrench.
7. Assemble plug assembly (36) into rear cover (19) with L
wrench.
FG000711
Figure 78
FG000710
Figure 79
FG000746
Figure 80
FG000747
Figure 81
SP001020
Page 35
Swing Motor
8. Assemble two relief valve assemblies into rear cover (19)
with torque wrench. (Left and right symmetrically.)
9. Coat valve plate (1-A-22) with grease and attach it to rear
cover (19).
FG000748
Figure 82
FG000706
Figure 83
FG000749
Figure 84
FG000701
Figure 85
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SP001020Swing Motor
Page 36
10. Position rear cover assembly on body (1) and tighten hex
socket head bolt (23).
11. Install time delay valve assembly onto rear cover (19) with
hex socket head bolts (35).
FG000750
Figure 86
FG000751
Figure 87
FG000752
Figure 88
FG000682
Figure 89
SP001020
Page 37
Swing Motor
Air Pressure Test
Apply air pressure into assembled motor, dip it in treated oil for
one minute and check any leakage from it.
Oil Leakage Check
Wash motor with Color Check No.1, spray No.3, and check for
any oil leakage.
FG000753
Figure 90
FG000754
Figure 91
FG000755
Figure 92
SP001020Swing Motor
Page 38
FG000756
Figure 93
FG000757
Figure 94

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Daewoo doosan dx255 lc excavator service repair manual

  • 1. K1016585E Shop Manual Copyright 2006 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 K1016585E Serial Number 5001 and Up DX255LC
  • 2. Table of Contents Page I 1Table of Contents Safety Track Excavator Safety......................................................................... SP000014 Specifications Specification for DX255LC.................................................................... SP001009 General Maintenance General Maintenance Procedures........................................................ SP000016 Standard Torques................................................................................. SP000813 Upper Structure Cabin .................................................................................................... SP000943 Counterweight....................................................................................... SP000940 Fuel Tank.............................................................................................. SP001012 Fuel Transfer Pump.............................................................................. SP000021 Swing Bearing....................................................................................... SP001068 Swing Reduction Gear.......................................................................... SP001015 Lower Structure and Chassis Track Assembly .................................................................................... SP001016 Engine and Drive Train Drive Coupling (Main Pump)................................................................. SP001069 Hydraulics Hydraulic System Troubleshooting, Testing and Adjustment ............... SP001017 Accumulator.......................................................................................... SP000028 Center Joint (Swivel)............................................................................. SP000029 Cylinders............................................................................................... SP000030
  • 3. Table of Contents Page II Swing Motor.......................................................................................... SP001020 Travel Motor.......................................................................................... SP001021 Gear Pump ........................................................................................... SP000931 Main Control Valve ............................................................................... SP000034 Axial Piston Pump................................................................................. SP001022 PTO Server........................................................................................... SP000933 Remote Control Valve (Work Lever / Joystick)..................................... SP000069 Travel Control Valve (with Damper)...................................................... SP000070 Solenoid Valve Assembly ..................................................................... SP000445 Breaker EPPR Valve (Opt) ................................................................... SP000192 Hydraulic Schematic (DX255LC).......................................................... SP001023 Electrical System Electrical System .................................................................................. SP001025 Electrical Schematic (DX180LC/DX225LC/225NLC/255LC)................ SP000936 Attachments Boom and Arm...................................................................................... SP001026 Bucket................................................................................................... SP000939
  • 4. SP001020Swing Motor Page 24 REASSEMBLY General Cautions 1. Wash and clean each part. Then dry them with compressed air. The friction plate, however, should not be washed with treated oil. 2. Each connecting parts should be tightened according to its assigned torque. 3. Only use a plastic soft-faced hammer. Assembly 1. Put roll bearing (3) and bushing (39) on a heater and apply heat to their inner race (inlet temperature: 290°C for 2 minutes). !' ! FG001328 Bushing X 1ea (SUJ) Roll Bearing X 1ea (NUP2209) Figure 40 FG000715 Figure 41
  • 5. SP001020 Page 25 Swing Motor 2. Assemble heated roll bearing (3) and bushing (39). Use retaining ring pliers to assemble install retaining ring (7). 3. Put body (1) on assembly jig and secure it so it cannot move. 4. Assemble oil seal (2) in body (1) using bar hammer. FG000716 Figure 42 FG000717 Figure 43 FG000718 Figure 44 FG000719 Figure 45
  • 6. SP001020Swing Motor Page 26 5. Install shaft in body (1) using bar hammer. 6. Secure shaft with retaining ring (4) using retaining ring pliers. FG000720 Figure 46 FG000717 Figure 47 FG000721 Figure 48 FG000722 Figure 49
  • 7. SP001020 Page 27 Swing Motor 7. Coat shoe plate (8) with grease, and assemble it into body. Assembly of Cylinder Block Assembly Subassembly 8. Insert nine sets of springs (1 thru 9) in cylinder block (9). FG000723 Figure 50 FG000724 Figure 51 FG000725 Figure 52 FG000726 Figure 53
  • 8. SP001020Swing Motor Page 28 9. Insert ball guide (1-B-11) in cylinder block (9). 10. Assemble friction plate (14) and plate (15) into cylinder block (9) FG000727 Figure 54 FG000728 Figure 55 FG000729 Figure 56 FG000759 Figure 57
  • 9. SP001020 Page 29 Swing Motor 11. Insert piston assembly (1-C-13) in set plate (1-B-12) and assemble it into cylinder block (9). NOTE: Coat piston with clean hydraulic oil. FG000730 Figure 58 FG000731 Figure 59 FG000696 Figure 60 FG000732 Figure 61
  • 10. SP001020Swing Motor Page 30 12. Assemble cylinder block into body (1). 13. Insert O-ring (38) in body (1). 14. Assemble O-ring (17) into brake piston (16). FG000733 Figure 62 FG000734 Figure 63 FG000704 Figure 64 FG000687 Figure 65
  • 11. SP001020 Page 31 Swing Motor 15. Insert brake piston assembly in body and secure it using jig. 16. Insert eighteen springs (18) into brake piston (16). Assembly of Rear Cover Assembly Subassembly 1. Insert pins (6 and 21) in rear cover (19) with bar hammer and assemble needle bearing (20) using jig. FG000735 Figure 66 FG000736 Figure 67 FG000737 Figure 68 FG000738 Figure 69
  • 12. SP001020Swing Motor Page 32 2. Assemble O-ring (17) into rear cover (19). 3. Assemble check valve. Install O-ring (27) using jig. FG000739 Figure 70 FG000740 Figure 71 FG000741 Figure 72 FG000742 Figure 73
  • 13. SP001020 Page 33 Swing Motor 4. Insert poppet (24), spring (25), and plug (26) in rear cover (19). Tighten plug with L wrench. (Left and right symmetrically.) 5. Assemble anti-inversion valve. Assemble body, spring seat, spring, poppet, poppet seat, stopper, and spring. Then assemble O-ring (31), backup ring (32), and O-ring (30). FG000743 Figure 74 FG000708 Figure 75 FG000744 Figure 76 FG000745 Figure 77
  • 14. SP001020Swing Motor Page 34 6. Assemble anti-inversion valve set. Assemble anti-inversion valve set and plug assembly (29) into rear cover (19) and tighten them with L wrench. 7. Assemble plug assembly (36) into rear cover (19) with L wrench. FG000711 Figure 78 FG000710 Figure 79 FG000746 Figure 80 FG000747 Figure 81
  • 15. SP001020 Page 35 Swing Motor 8. Assemble two relief valve assemblies into rear cover (19) with torque wrench. (Left and right symmetrically.) 9. Coat valve plate (1-A-22) with grease and attach it to rear cover (19). FG000748 Figure 82 FG000706 Figure 83 FG000749 Figure 84 FG000701 Figure 85
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  • 17. SP001020Swing Motor Page 36 10. Position rear cover assembly on body (1) and tighten hex socket head bolt (23). 11. Install time delay valve assembly onto rear cover (19) with hex socket head bolts (35). FG000750 Figure 86 FG000751 Figure 87 FG000752 Figure 88 FG000682 Figure 89
  • 18. SP001020 Page 37 Swing Motor Air Pressure Test Apply air pressure into assembled motor, dip it in treated oil for one minute and check any leakage from it. Oil Leakage Check Wash motor with Color Check No.1, spray No.3, and check for any oil leakage. FG000753 Figure 90 FG000754 Figure 91 FG000755 Figure 92