Daewoo Doosan DX18 MINI CRAWLER EXCAVATOR Service Repair Manual (Serial Number 40001 and Up)

Jun 26, 2020 | Publisher: b3i4tz1 | Category: Other |   | Views: 1 | Likes: 1

K1043970AE Shop Manual Copyright 2008 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 K1043970AE Serial Number 40001 and Up DX15 / DX18 Table of Contents Page I 1Table of Contents Safety Track Excavator Safety......................................................................... SP001521 Specifications Specification for DX15/DX18 ................................................................ SP001522 General Maintenance General Maintenance Procedures ........................................................ SP000016 Standard Torques................................................................................. SP000813 Upper Structure Lower Structure and Chassis Track Assembly .................................................................................... SP001523 Engine and Drive Train Engine................................................................................................... SP001524 Hydraulics Center Joint (Swivel)............................................................................. SP001525 Cylinders............................................................................................... SP001526 Swing Motor.......................................................................................... SP001527 Travel Motor (With Gear Box)............................................................... SP001528 Pilot Control Valve (Work Lever / Joystick)........................................... SP001529 Main Pump............................................................................................ SP001530 Main Control Valve ............................................................................... SP001531 Solenoid Valve...................................................................................... SP001532 Hydraulic Schematic (DX15/DX18)....................................................... SP001681 Table of Contents Page II Electrical System Electrical System .................................................................................. SP001534 Electrical Schematic (DX15/DX18) ....................................................... SP001535 Attachments Boom and Arm...................................................................................... SP001536 Bucket................................................................................................... SP001550 SP001521 Page 1 Track Excavator Safety SP001521 TRACK EXCAVATOR SAFETYSP001521 Track Excavator Safety Edition 1 SP001521 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 DX15 40001 and Up DX18 40001 and Up SP001521 Track Excavator Safety Page 6 TO THE OPERATOR OF A DOOSAN 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 1-8 2. “Location of Safety Labels” on page 1-8 3. “Work Site Precautions” on page 1-9 4. “Operation” on page 1-13 5. “Equipment” on page 1-19 6. “Maintenance” on page 1-24 7. “Shipping and Transportation” on page 1-28 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. SP001521 Page 7 Track Excavator Safety 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 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 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 Indicates 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. SP001521 Track Excavator Safety Page 8 GENERAL SAFETY ESSENTIALS Accessory Applications The excavator has been primarily designed for moving earth with a bucket. Use of an accessory hydraulic hammer (breaker), work in rough terrain, demolition applications or other hazardous operation may require installation of additional protective structures to safeguard the operator. Never use machine for lifting. The excavator is designed for excavating and loading only. The excavator is not equipped for lifting and does not have safety devices for lifting. LOCATION OF SAFETY LABELS 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. UNAUTHORIZED MODIFICATIONS Any modification made without authorization or written approval from DOOSAN can create a safety hazard, for which the machine owner must be held responsible. For safety's sake, replace all OEM parts with the correct authorized or genuine DOOSAN part. For example, not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a condition in which the safety of critical assemblies is dangerously compromised. HKA1013L Figure 1 SP001523 Page 1 Track Assembly SP001523 TRACK ASSEMBLY SP001523 Track Assembly Edition 1 SP001523 Page 5 Track Assembly 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 DX15 40001 and Up DX18 40001 and Up SP001523 Track Assembly Page 6 GENERAL DESCRIPTION The track assembly is composed of the following major components: 1. Track 2. Front Idler Roller 3. Upper Roller 4. Lower Roller 5. Track Spring and Track Adjustment Cylinder TRACK TENSION Track shoe link pins and bushings wear with normal usage, reducing track tension. Periodic adjustment is necessary to compensate for wear and it may also be required by working conditions. 1. Track tension is checked by jacking up one side of the excavator. See Figure 1. Place blocking under frame while taking measurement. WARNING Safely measuring track tension requires two people. One person must be in the operator's seat, running the controls to keep one side frame in the air, while the other person makes dimensional checks. Take all necessary precautions to make sure the machine won't move or shift position during service. Warm up the engine to prevent stalls, travel the excavator to an area that provides level, uniform ground support and/or use support blocks when necessary. The track adjusting mechanism is under very high-pressure. NEVER release pressure too suddenly. The grease cylinder valve should never be backed off more than 1 complete turn from the fully tightened down position. Bleed off pressure slowly and keep your body away from the valve at all times. HKA1304L Figure 1 SP001523 Page 7 Track Assembly 2. Measure the distance (A, Figure 2) between the rolling surface of the track roller and the contact surface of the crawler. NOTE: This measurement can be thrown off if there is too much mud or dirt or other material in the track assembly. Clean off the tracks before checking clearance. A. For rubber crawlers It is accepted if the distance between the rolling surface of the track roller and the contact surface of the crawler is 10 - 15 mm (0.39 - 0.59 in). 3. Too little sag in the crawler track can cause excessive component wear. The recommended adjustment can also be too tight causing accelerated stress and wear if ground conditions are wet, marshy or muddy, or if the ground is hard and full of rocks or gravel. 4. Track tension adjustments are made through the grease fitting (1, Figure 4) in the middle of each side frame. Adding grease increases the length of the adjustment cylinder. The longer the adjustment cylinder, the greater the pressure on the tension spring pushing the track idler wheel outward. 5. If there isn't enough slack or clearance in the tracks and the adjustment is too tight, the idler wheel and adjusting cylinder can be retracted by bleeding off grease thru hole in adjustment cylinder. 6. After completing the tension adjustment, tighten the valve securely. NOTE: Cartridge tightening torque: 6 - 9 kg• m (43 - 65 ft lb). Figure 2 Figure 3 WARNING The track adjusting mechanism is under very high-pressure. NEVER release pressure too suddenly. The grease cylinder valve should never be backed off more than 1 complete turn from the fully tightened down position. Bleed off pressure slowly and keep your body away from the valve at all times. Figure 4 SP001523 Track Assembly Page 8 CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) The tables that follow provide factory specified dimensional limits (as new condition, recommended service and replacement limit) for lower travel frame components. Recommended maintenance to renew most listed components requires welding on additional material and grinding off excess. Some components must be replaced before the service limit is exceeded. No maintenance or renewal is possible. Compare the values in the tables with dimensions and profiles shown in the following figures. Rubber Tracks The amount of friction on the rubber track shoes determines the limit of use. However, it is subject to change depending upon the work condition and environment. CAUTION Refer to the "Welding Precautions and Guidelines" information in "General Maintenance Procedures" section for general recommendations and specific safety precautions, before starting any lower travel frame component rebuilding procedure. 2 0 1 5 1 0 5 0 500 1000 1500 2000 2500 3000 HKA1313L A B C Wear Amount (mm)Operating Hours Figure 5 Reference Number Description A Concrete Surface B Normal Use C Dirt SP001523 Page 9 Track Assembly A B C D E F HBOH840L Figure 6 Reference Number Description A 25.0 mm (0.98 in) B 26.0 mm (1.02 in) C 25.0 mm (0.98 in) D 23.5 mm (0.93 in) E 22.0 mm (0.87 in) F 230.0 mm (9.06 in) Reference Number Description A HKA1315L Figure 7 Reference Number Description A Pitch 96.0 mm (3.78 in) Item DX15/DX18 Distance Between Centers of Shoes 4,410 ±12 mm (173.62 ±0.47 in) Scale Cord Rigid 800 kg (1,764 lb) No. of Coils 40 ±4 Coils Operating Temperature Range -25°C - 55°C (-13°F - 131°F) Width x Pitch 230 x 96 mm (9.06 x 3.78 in) SP001523 Track Assembly Page 10 Track Frame Spring HKA1312L Figure 8 Item Limit Remarks Deformed Frame Bending 5.0 mm (0.20 in) (Overall length of track frame) Bent Distorted 10.0 mm (0.39 in) (Distortion between left and right crawler frames) Widened Idler 5.0 mm (0.20 in) Item Normal (New) Dimension Recommended Limit for Maintenance Remarks Gap between upper and lower sides of idler guide Track Frame 51.0 mm (2.01 in) 56.0 mm (2.20 in) Rebuild or Replace Idler Frame 50.0 mm (1.97 in) 45.0 mm (1.77 in) Rebuild or Replace Gap between left and right of idler guide Track Frame 153.0 mm (6.02 in) 158.0 mm (6.22 in) Rebuild or Replace Idler Support 150.0 ±1.0 mm (5.91 ±0.04 in) 145.0 mm (5.71 in) Rebuild or Replace Item Free Length Mounted Length Remarks Track Spring 261.0 mm (10.28 in) 223.0 mm (8.78 in) Replace SP001523 Page 11 Track Assembly Idler (For Steel Shoes) A B C D HKA1402L Figure 9 No. Item Unit Standard Limits Remarks A Outside Diameter mm (in) ø292.0 (11.49) ø288.0 (11.34) Rebuild or Replace B PCD mm (in) ø277.18 (10.91) - Rebuild or Replace C Dedendum Diameter mm (in) ø253.0 (9.96) - Rebuild or Replace D Face Width mm (in) 22.0 (0.87) - Rebuild or Replace SP001523 Track Assembly Page 12 Track Roller A B C D E F G HKA1602L Figure 10 No Item Unit Standard Limits Remarks A Outside Diameter mm (in) ø100.0 (3.94) – Rebuild or Replace B Contact Surface Diameter mm (in) ø80.0 (3.15) ø78.0 (3.07) Rebuild or Replace C Tab Width mm (in) 22.0 (0.87) 17.0 (0.67) Rebuild or Replace D Overall Width mm (in) 80.0 (3.15) – Rebuild or Replace E Contact Width mm (in) 29.0 (1.15) – Rebuild or Replace F Side Clearance mm (in) 0.2 ±0.1 (0.008 ±0.004) 1.5 (0.059) Replace Bushing G Tightening Torque kg•m (ft lb) 21 kg•m (152 ft lb) SP001523 Page 13 Track Assembly Track Spring d L L0 L O.DP.C.DI.D1 HKA1503L Figure 11 Designation Units Dimensions No. of Active Coils ea. 7.5 Total No. of Coils ea. 9 Spring Constant kg/mm (lb/0.0394 in) 23.03 (50.77) Set Load kg (lb) 875 (1929) Compressive Load kg (lb) 4650 (10,250) Minimum Closed Length (L) mm (in) 195.1 (7.68) Free Length (L0) mm (in) 261 (10.28) Set Length (L1) mm (in) 233.5 (9.19) Outside Diameter mm (in) 78 (3.07) Mean Diameter mm (in) 63 (2.48) Inside Diameter mm (in) 48 (1.89) Wire Diameter (D) mm (in) 15 (0.59) SP001523 Track Assembly Page 14 Sprocket A BC D EHKA1702L Figure 12 No Item Unit Standard Limits Remarks A Sprocket Tooth Width mm (in) 22.0 (0.87) 16.0 (0.63) Rebuild or Replace B Sprocket Deddendum Diameter mm (in) ø253.0 (9.96) ø240.0 (9.45) Rebuild or Replace C Mounting Bolt Tightening Torque kg•m (ft lb) 6.5 (47) M10 D Motor Mounting Bolt Tightening Torque kg•m (ft lb) 6.5 (47) M10 x 1.5 E Travel Motor Mounting Hole mm (in) ø140.0 mm (5.51 in) - SP001523 Page 15 Track Assembly TRACK SHOES AND LINKS Track Removal 1. Position machine on a smooth level surface with adequate room for forward and reverse travel. 2. Relieve track tension. Refer to "Track Tension" in this section for procedure. 3. Swing the front attachment to the side being serviced. Lift the side by lowering the boom to the ground. Install jack stands to support the weight of the equipment. Rubber Shoes 1. Loosen track tension cylinder nut and relieve all pressure and be certain that the cylinder is completed retracted. 2. Use a steel bar for leverage and slide the rubber track assembly over the idler assembly. HKA1304L Figure 13 Figure 14 SP001523 Track Assembly Page 16 Track Installation Rubber Shoes 1. With upper structure at 90° to track frame. Use bucket and boom to raise track frame off blocking. 2. Place rubber track assembly over idler and rollers. 3. Use a steel bar for leverage and slide the rubber track assembly over the idler assembly. 4. Apply track tension. Refer to "Track Tension" in this section for procedure. HKA1304L Figure 15 Figure 16 Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it. SP001523 Page 17 Track Assembly INTERCHANGING SHOE TYPES The steel and rubber track assemblies can be interchanged as necessary depending on the application. Changing to Rubber Track Assembly 1. Refer to "Track Removal" section to remove the track assembly before proceeding to the following steps. 2. Remove steel track idler. 3. Remove steel track rollers. 4. Install rubber track rollers and tighten to specified torque. NOTE: Steel tracks use a washer (1, Figure 18). 5. Install rubber track idler. NOTE: Nut tightening torque: 21 kg•m (152 ft lb) 6. Refer to "Track Installation" section for track assembly installation procedures. Changing to Steel Track Assembly 1. Refer to "Track Removal" section to remove the track assembly before proceeding to the following steps. 2. Remove rubber track idler. 3. Remove rubber track rollers. 4. Install steel track rollers and tighten to specified torque. 5. Install steel track idler. NOTE: Nut tightening torque: 21 kg•m (152 ft lb) 6. Refer to "Track Installation" section for track assembly installation procedures. Figure 17 HKA1802S 1 Figure 18 SP001523 Track Assembly Page 18 FRONT IDLER ROLLER Parts List 7 7 6 6 5 5 4 4 2 1 3 8 8 HKA1401L Figure 19 Reference Number Description 1 Front Idler Assembly 2 Idler 3 Shaft 4 Bearing (BL-207) 5 Retaining Ring 6 Oil Seal 7 Spring Pin 8 Guide Reference Number Description SP001523 Page 19 Track Assembly Removal and Disassembly 1. Refer to "Track Removal" section to remove the track assembly before proceeding to the following steps. 2. Remove spring pin (7, Figure 20) from guide (8). 3. Remove guide (8, Figure 20) from shaft (3). 4. Remove oil seal (6, Figure 20) using a screw driver. NOTE: Once removed, the oil seal should not be reused. 5. Remove retaining ring (5, Figure 20), bearing (4), and shaft (3). 6. Repeat steps 2 - 5 for other side. Reassembly and Installation 1. Degrease, clean and dry all parts before reassembly. 2. Insert shaft (3, Figure 20) into idler gear (2). 3. Assemble bearing (4, Figure 20) onto shaft (3) and install retaining ring (5) 4. Install new grease seal (6, Figure 20). 5. Install Shaft guide (8, Figure 20) and spring pin (7). 6. Repeat steps 1 - 5 for other side. 7. Refer to "Track Installation" section for track assembly installation procedures. 7 6 5 4 2 3 8 HBOH850L Figure 20

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