Daewoo doosan dx140 lc 3 excavator service repair manual serial number 50001 and up (europe only)

Original InstructionsCopyright DOOSAN 2012
Serial Number 1001 and Up
Serial Number 50001 and Up (Europe Only)
Shop Manual
DX140LC-3 Excavator
950106-00388E
April 2012
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.

Table of Contents
Page I
1Table of Contents
Safety
Track Excavator Maintenance Safety................................................... SP002322
Specifications
Specifications for DX140LC-3............................................................... SP002509
General Maintenance
General Maintenance Instructions........................................................ SP002454
Standard Torques................................................................................. SP002404
Upper Structure
Cabin .................................................................................................... SP002324
Counterweight....................................................................................... SP002510
Fuel Tank.............................................................................................. SP002511
Fuel Transfer Pump (Option)................................................................ SP002546
Swing Bearing....................................................................................... SP002329
Swing Reduction Gear.......................................................................... SP002526
Lower Structure and Chassis
Track Assembly .................................................................................... SP002512
Engine and Drivetrain
Engine Coolant Heater (Option) ........................................................... SP002328
Drive Coupling (Main Pump)................................................................. SP002515
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ............... SP002538
Accumulator.......................................................................................... SP002455
Center Joint (Swivel)............................................................................. SP002456

Table of Contents
Page II
Cylinders............................................................................................... SP002539
Swing Motor.......................................................................................... SP002527
Travel Device........................................................................................ SP002516
Main Pump............................................................................................ SP002517
Gear Pump ........................................................................................... SP002500
Main Control Valve ............................................................................... SP002528
Remote Control Valve (Work Lever / Joystick)..................................... SP002395
Travel Control Valve (with Damper)...................................................... SP002381
Solenoid Valve Assembly ..................................................................... SP002406
Breaker EPPR Valve (Option) .............................................................. SP002458
Dozer Valve .......................................................................................... SP002529
Hydraulic Schematic (DX140LC-3)....................................................... SP002518
Electrical System
Electrical System .................................................................................. SP002337
Electrical Schematic ............................................................................. SP002508
Attachments
Boom and Arm...................................................................................... SP002513
Bucket................................................................................................... SP002506

SP002322
Page 1
Track Excavator Maintenance Safety
SP002322
TRACK EXCAVATOR MAINTENANCE SAFETY
SP002322
Track Excavator
Maintenance
Safety
Edition 3

SP002322
Page 5
SAFETY INSTRUCTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation and
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.
MODEL SERIAL NUMBER RANGE
DX140LC-3 1001 and Up, 50001 and Up
DX380LC-3 10001 and Up

SP002322Track Excavator Maintenance Safety
Page 6
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.
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.
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.
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.

SP002322
Page 7
Other Signal Words
In addition to safety signal words, the following signal words are
used to indicate proper and effective use of 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 and Maintenance Manual, and
parts manual for your unit.
Always replace damaged or faded decals.
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.
IMPORTANT
This signal word identifies procedures which must be
followed to avoid damage to machine.

SP002322Track Excavator Maintenance Safety
Page 8
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.
Proper Work Tools and Attachments
Only use work tools and attachments that are recommended by
DOOSAN for use on DOOSAN machines. When installing and
using optional attachments, read instruction manual for
attachment, and general information related to attachments in
this manual. Because DOOSAN cannot anticipate, identify or
test all attachments that owners may want to install on their
machines, contact DOOSAN for written authorization and

SP002322
Page 9
approval of attachments, and their compatibility with optional
kits.
Attachments and attachment control systems that are
compatible with the machine are required for safe and reliable
machine operation. Do not exceed maximum operating weight
(machine weight plus attachment) that is listed on ROPS
certification plate.
Make sure that all guards and shields are in place on machine
and on work tool. Depending on type or combination of work
equipment, there is a potential that work equipment could
interfere with the cabin or other parts of machine. Before using
unfamiliar work equipment, check if there is any potential of
interference, and operate with caution.
While you are performing any maintenance, testing, or
adjustments to attachments, stay clear of the following areas:
cutting edges, pinch points, and crushing surfaces.
Never use attachment as a work platform or manlift.
Contact your DOOSAN distributor about auxiliary hydraulic kits
for attachments installation. If you are in doubt about
compatibility of a particular attachment with a machine, consult
your DOOSAN distributor.
Pressurized Fluids
Pressurized air or fluids can cause debris and/or fluids to be
blown out. This could result in death or serious injury.
Immediately after operations are stopped, coolant, engine oil,
and hydraulic oil are at their highest temperatures and the
radiator and hydraulic tank are still under pressure. Always wait
for temperature to cool down. Follow specified procedures when
attempting to remove caps, drain oil or coolant, or replacing
filters. Always wait for temperature to cool down, and follow
specified procedures when performing these operations. Failure
to do so can result in death or serious injury.
When pressurized air and/or pressurized water is used for cleaning,
wear protective clothing, protective shoes, and eye protection. Eye
protection includes goggles or a protective face shield.
Pressure can be trapped in a hydraulic system and must be
relieved before maintenance is started.
Releasing trapped pressure can cause sudden machine
movement or attachment movement. Use caution if you
disconnect hydraulic lines or fittings.
High-pressure oil that is released can cause a hose to whip or oil
to spray. Fluid penetration can result in death or serious injury. If
fluid enters skin or eyes, get immediate medical attention from a
physician familiar with this injury.
Obey all local laws and regulations for disposal of liquids.
To prevent hot coolant from spraying out, stop engine and wait for
coolant to cool. Using gloves, slowly loosen cap to relieve pressure.
FG018457
Figure 1

SP002511
Page 5
Fuel Tank
SAFETY INSTRUCTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
WARNING
Instructions are necessary before operating or servicing
machine. Read and understand the Operation and
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.
MODEL SERIAL NUMBER RANGE

SP002511Fuel Tank
Page 6
GENERAL DESCRIPTION
Parts List
WARNING
Diesel fuel is highly flammable and can be potentially
explosive. To prevent fires or explosion, keep arcs, sparks or
other ignition sources away from diesel fuel or fuel
containers.
11
10
1
8
13
72
3
9
13
7
5
4 6
12
15
14
16
17
FG022530
Figure 1

SP002511
Page 7
Fuel Tank
Specifications
Fuel tank capacity is 267 liters (70.5 U.S. gal).
Reference
Number
Description
1 Fuel Tank
2 O-ring
3 Fuel Tank Cover
4 Bolt
5 Washer
6 Drain Valve
7 Bolt
8 Shim
9 Shim
10 Fuel Strainer
11 Cap
12 Level Gauge
13 Spacer
14 Fuel Sensor
15 Bolt
16 Spring Washer
17 Fuel Float Switch
Reference
Number
Description

SP002511Fuel Tank
Page 8
REMOVAL
1. Look at fuel level display (Figure 2) on instrument panel in
operator's cabin to see what it displays. The display is
divided into ten separated segments, each representing 10
percent of total fuel supply. Also, look at level gauge on
side of tank to estimate volume of fuel left in tank.
NOTE: If possible, operate excavator until available fuel
supply in tank has been run down as far as
possible.
2. Park on firm and level ground and swing upper structure to
approximately a 90° with respect to tracks. See Figure 3.
3. Lower bucket (or work tool) to ground.
4. Stop engine.
5. Set safety lever to "RELEASED" (UNLOCK) position.
6. Turn starter switch to "I" (ON) position.
7. Fully stroke work levers (joysticks) in all directions to
relieve any pressure from accumulators.
8. Set safety lever to "LOCK" position.
9. Turn key to "O" (OFF) position and remove from starter
switch.
10. Attach maintenance warning tag on controls.
11. Turn battery disconnect switch to "OFF" position.
E F
FG018115
Figure 2
FG022531
Figure 3
FG018470
DO NOT OPERATE
when performing inspection
WARNING
190-00695A
or maintenance
ON OFF
O I
Figure 4
WARNING
If engine must be running while performing
maintenance, use extreme care. Always have one
person in the cabin at all times. Never leave the cabin
with the engine running.

SP002511
Page 9
Fuel Tank
12. Clean area around fuel tank fill cap (11, Figure 5). Open
fuel cap.
13. Open drain valve (Figure 6) right side door and drain.
NOTE: Fuel tank capacity is 267 liters (70.5 U.S. gal).
14. Remove five bolts (23, Figure 7) and cover (24) from fuel
tank.
FG022532
11
Figure 5
FG021690
Figure 6
23
24
FG022535
Figure 7

SP002511Fuel Tank
Page 10
15. Remove ten bolts (25 and 26, Figure 8) and handrail (27)
from fuel tank and frame.
Remove four bolts (28 and 29) and fuel tank cover (30)
from fuel tank.
Remove two bolts (31) and bracket (32) from tank.
Remove four bolts (33) and storage box (34) from frame.
16. Remove four bolts (35 and 36, Figure 9) and cover (37)
from fuel tank and support.
17. Tag and disconnect fuel supply line (21, Figure 10) and
fuel return line (19) from fuel tank (1) and carefully drain
remaining fuel from lines.
18. Remove clamp (20, Figure 10) holding fuel return line (19)
to tank (1).
FG022536
27
29
33
26
32
31
30
34
25
28
Figure 8
36
FG003878
37
35
Figure 9
FG022533
1
19
20
21
Figure 10

SP002511
Page 11
Fuel Tank
19. If equipped, remove components from fuel filler pump port
(22, Figure 11) on side of fuel tank (1).
20. Tag and disconnect wires leading to fuel sensor (14) and
fuel float switch (17, Figure 12) on side of fuel tank (1).
21. Install two 12 mm eyebolts in threaded holes (38 and 39,
Figure 13). Using a suitable lifting device, sling eyebolts.
22. Remove six bolts (7) and spacers (13, Figure 13) holding
tank (1) to frame. Lift tank 25 mm (1") and make sure it is
balanced. Make sure there are no other electrical wires or
hoses connected to tank. Completely remove tank after
inspection.
NOTE: The clear level gauge on the side of the tank is
easily damaged. Be careful of obstacles and
wind gusts.
23. Remove shims (9, Figure 13).
NOTE: If tank is to be reused note position and amount
of shims used for each mounting bolt location.
FG022534
1
22
Figure 11
1
14
17
FG022537
Figure 12
1
39
9
38
13
7 FG022538
Figure 13

SP002511Fuel Tank
Page 12
INSTALLATION
1. Install two 12 mm eyebolts in threaded holes (38 and 39,
Figure 14). Using a suitable lifting device, sling eyebolts.
2. Set fuel tank (1, Figure 14) into position. Install six bolts (7)
and spacers (13) finger tight, to secure tank to frame.
NOTE: The clear level gauge on the side of the tank is
easily damaged. Be careful of obstacles and
wind gusts.
3. Install shims (9, Figure 14) as needed to prevent tank (1)
from rocking or stress from mounting bolts (7).
4. Tighten mounting bolts (7, Figure 14) after shims are
installed.
NOTE: Bolt torque is 27 kg•m (200 ft lb).
5. Connect wires as tagged to fuel sensor (14) and fuel float
switch (17, Figure 15) on side of fuel tank (1).
6. If equipped, connect components to fuel filler pump port
(22, Figure 16) on side of fuel tank (1).
Figure 14
1
3938
9
13
7 FG022495
1
14
17
FG022537
Figure 15
Figure 16
FG022534
1
22

SP002511
Page 13
Fuel Tank
7. Connect as tagged, fuel supply line (21, Figure 17) and fuel
return line (19) to fuel tank (1).
8. Install clamp (20, Figure 17) to hold fuel return line (19) to
tank (1).
9. Install four bolts (35 and 36, Figure 18) and cover (37) on
fuel tank and support.
10. Install four bolts (33, Figure 19) and storage box (34) on
frame.
Install two bolts (31) and bracket (32) on fuel tank.
Install four bolts (28 and 29) and fuel tank cover (30) on
fuel tank.
Install ten bolts (25 and 26) and handrail (27) on fuel tank
and frame.
Figure 17
FG022533
1
19
20
21
36
FG003878
37
35
Figure 18
Figure 19
FG022536
27
29
33
26
32
31
30
34
25
28

SP002511Fuel Tank
Page 14
11. Make sure fuel tank drain valve (Figure 20) right side door
is closed.
12. Fill fuel tank and check for signs of leaks. Correct any
problems found.
13. Turn disconnect switch to "ON" position.
14. Install five bolts (23, Figure 21) and cover (24) on fuel tank.
Figure 20
FG021690
Figure 21
23
24
FG022535

SP002511
Page 15
Fuel Tank
START-UP PROCEDURES
If engine does not start, the fuel system may need priming.
Prime the fuel system using the following procedure:
1. Turn key to "OFF" position.
2. Open right side door to access fuel filter.
3. Loosen plug (1, Figure 23) on top of fuel filter head.
4. Pump hand-operated primer pump (2, Figure 23) by the
fuel injection pump. Pump primer until fuel is present at
plug hole in fuel filter head.
5. Tighten plug in fuel filter head.
6. Continue to pump primer pump until a strong resistance is
felt.
7. Start engine and look for signs of leaks.
Repeat procedure if necessary.
Figure 22
FG022496
Figure 23
2
1
FG020728

SP002526Swing 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. FG005350
Figure 2
FG005351
Figure 3
FG005352
Figure 4
FG005353
Figure 5

SP002526
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.
FG005354
Figure 6
CAUTION
AVOID INJURY
Do not heat bearing above 120°C.
FG005355
Figure 7

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Page 12
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 damaged, 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 install it to the hole
of carrier.
B. Put a pressure jig on the pin and use a press to insert
it.
FG005356
Figure 8
FG005357
Figure 9
FG005358
Figure 10

SP002526
Page 13
Swing Reduction Gear
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.
FG005359
Figure 11
FG005360
Figure 12
FG005361
Figure 13
FG005362
Figure 14

Page 14
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.
FG005363
Figure 15
Figure 16
FG005364
Figure 17
FG005365
Figure 18
FG005366

Daewoo doosan dx140 lc 3 excavator service repair manual serial number 50001 and up (europe only)

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