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Daewoo doosan dx140 lc excavator service repair manual (serial number 5001 and up)
1. K1034080E Shop Manual
Copyright 2007 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
K1034080E
Serial Number 5001 and Up
DX140LC
2. Table of Contents
Page I
1Table of Contents
Safety
Track Excavator Safety......................................................................... SP000014
Specifications
Specification for DX140LC.................................................................... SP001313
General Maintenance
General Maintenance Procedures........................................................ SP000016
Standard Torques................................................................................. SP000813
Upper Structure
Cabin .................................................................................................... SP000943
Counterweight....................................................................................... SP000940
Fuel Tank.............................................................................................. SP001320
Fuel Transfer Pump.............................................................................. SP000021
Swing Bearing....................................................................................... SP000022
Swing Reduction Gear.......................................................................... SP000921
Lower Structure and Chassis
Track Assembly .................................................................................... SP001321
Engine and Drive Train
Drive Coupling (Main Pump)................................................................. SP001326
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ............... SP001327
Accumulator.......................................................................................... SP000028
Center Joint (Swivel)............................................................................. SP000029
Cylinders............................................................................................... SP000030
3. Table of Contents
Page II
Swing Motor.......................................................................................... SP000985
Travel Moter.......................................................................................... SP001346
Main Pump............................................................................................ SP001329
Main Control Valve ............................................................................... SP001029
Remote Control Valve (Work Lever / Joystick)..................................... SP000069
Travel Control Valve (with Damper)...................................................... SP000070
Solenoid Valve Assembly ..................................................................... SP000445
Breaker EPPR Valve (Opt) ................................................................... SP000192
Hydraulic Schematic (DX140LC).......................................................... SP001330
Electrical System
Electrical System .................................................................................. SP001038
Electrical Schematic (DX140LC) .......................................................... SP001357
Attachments
Boom and Arm...................................................................................... SP001331
Bucket................................................................................................... SP000939
5. SP000014
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
DX140LC 5001 and Up
DX180LC 5001 and Up
DX225LC 5001 and Up
DX225NLC 5001 and Up
DX255LC 5001 and Up
DX300LC 5001 and Up
DX340LC 5001 and Up
6. SP000014Track 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. SP000014
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. SP000014Track 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. SP000014
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.
11. 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. 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
14. 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
15. 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. 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
18. 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
19. 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
20. 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
21. 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
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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
25. 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.
