Doosan DX140R - Shop Manual

Table of Contents13

Applicable Models15

Safety Precautions15

To the Operator of a Excavator16

General Safety Essentials19

Location of Safety Labels20

Summary of Safety Precautions for Lifting in Digging Mode21

General Hazard Information22

Unauthorized Modifications22

Before Starting Engine32

Shipping and Transportation56

Specification for DX140LCR63

Applicable Models89

General Maintenance Procedures89

Safety Precautions89

Welding Precautions and Guidelines90

Hydraulic System - General Precautions91

Maintenance Service and Repair Procedure93

General Precautions93

Hydraulic System Cleanliness and Oil Leaks94

Cleaning and Inspection96

Applicable Models109

Safety Precautions109

Standard Torques109

Fasteners110

Torque Values for Standard Metric110

Torque Values for Standard U.S. Fasteners111

Type 8 Phosphate Coated Hardware113

Torque Values for Hose Clamps114

Torque Values for Split Flanges115

Torque Wrench Extension Tools116

Applicable Models127

Safety Precautions127

Cab Identification128

Roll over Protective Structure (ROPS) When Required by Local Regulations128

Removal130

Installation134

Applicable Models141

Safety Precautions141

General142

Warning for Counterweight and Front Attachment Removal142

Removal154

Installation158

Applicable Models167

Fuel Transfer Pump167

Safety Precautions167

General Description168

Theory of Operation168

Replacement of Rotor and Vane169

Troubleshooting169

Replacement of Armature170

Replacement of Rear Cover170

Applicable Models175

Safety Precautions175

Swing Bearing175

Swing Bearing Maintenance176

Applicable Models185

Safety Precautions185

Swing Reduction Gear185

General Description187

Theory of Operation187

Reassembly188

Parts List188

Shrinkage Fitting of Shaft and Flexible Bearing190

Reassembly of Carrier Sub193

Assembly of the Main200

Test212

Reassembly of Motor215

Applicable Models229

Safety Precautions229

Track Assembly229

General Description230

Track Tension230

Cleaning and Inspection233

Track Shoes and Links239

Front Idler241

Lower Roller245

Upper Roller249

Track Spring and Track Adjusting Cylinder253

Parts List253

Applicable Models263

Safety Precautions263

QSB4.5 Engine264

Important Reference Numbers265

General Information266

Engine Identification282

Operating Instructions304

Maintenance Guidelines315

Maintenance Procedures at Daily Interval318

Maintenance Procedures at 500 Hours or 6 Months328

Maintenance Procedures at 1,000 Hours or 1 Year338

Maintenance Procedures at 2,000 Hours or 2 Years340

System Diagrams379

Service Literature392

Service Assistance398

Troubleshooting Symptoms451

Applicable Models549

Hydraulic System Troubleshooting, Testing and Adjustment549

Safety Precautions549

Hydraulic System - General Notes550

Hydraulic Schematic551

General Notes551

Operation of Working Components553

Procedural Troubleshooting Baseline Recommendations558

Initial Checks and Tests to Establish Operating Condition of the Excavator558

Pilot Pressure560

Adjustment and Testing560

Power Mode Valve561

Current Signal and Hydraulic Pressure Adjustments561

Swing Priority Valve562

Control Valve Pressure and Current Adjustments562

Pressure up Valve563

Checks and Adjustments563

Pump Input Power Control565

Pump Regulator Adjustment565

Flow Meter and Flow Meter Kit Installation and Testing569

Swing System Troubleshooting571

Troubleshooting - Swing Gearbox574

Troubleshooting - Hydraulic Problems575

Troubleshooting - Control Valve577

Troubleshooting - Travel Control Valve578

Troubleshooting - Joystick Control Valve579

Applicable Models585

Safety Precautions585

General Description586

Specifications588

Applicable Models593

Center Joint (Swivel)593

Safety Precautions593

General Description594

Parts List595

Troubleshooting, Testing and Adjustment596

Disassembly597

Reassembly598

Applicable Models603

Safety Precautions603

General Description604

Special Tools and Materials608

Safety Precautions633

Instruction Manual634

Maintenance Manual650

Disassembling and Assembling650

Applicable Models669

Safety Precautions669

Product Overview670

External Dimensions671

General Description672

Operating Description675

Maintenance and Inspection686

Seals Table689

Troubleshooting690

Outline of Maintenance692

Disassembling698

Maintenance Standards716

Assembling718

Applicable Models741

Main Pump741

Safety Precautions741

Disassembling and Reassembling Procedures742

Pump Maintenance Criteria751

Worn Part Replacement Criteria751

Applicable Models759

Safety Precautions759

General Description760

Control Valve Specification802

Troubleshooting803

Tools and Materials814

Disassembly815

Cleaning and Inspection818

Reassembly819

Start-Up Procedures825

Removal841

Disassembly842

Cleaning and Inspection844

Reassembly845

Installation850

Start-Up Procedures851

Applicable Models857

Safety Precautions857

Solenoid Valve Assembly857

Parts List858

Functions of 5-Solenoid Valve Assembly Package859

Applicable Models871

Safety Precautions871

Structure872

Numbers and Names of Parts872

Cautions for Operation873

Functions and Operation873

Maintenance Instructions874

Applicable Models893

Safety Precautions893

Introduction894

Electrical Supply System895

Engine Starting Circuit897

Engine Preheating System901

Warning and Indicator Lights913

Initial Operation916

Mode Selector Switch916

Graphic Information Area Display917

Main Menu919

Special Menu923

Electronic Hydraulic Control System (E-EPOS)941

Power Mode Control943

Power / Economy Mode Control - Circuit Diagram949

Engine Control Dial950

Air Conditioner System968

Troubleshooting981

Weight of R134A Gas Used in Machines983

Refrigerant System Repairs984

Wiper System992

Lighting System995

Overload Warning Device997

Audio Controller998

Doosan DX140R - Shop Manual

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