service repair manual

1. Original InstructionsCopyright DOOSAN 2012
Serial Number 1001 and Up
Shop Manual
DX140LCR-3 Excavator
950106-01021E
December 2012
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.

2. Table of Contents
Page I
1Table of Contents
Safety
Track Excavator Maintenance Safety................................................... SP002907
Specifications
Specifications for DX140LCR-3............................................................ SP002908
General Maintenance
General Maintenance Instructions........................................................ SP002454
Standard Torques................................................................................. SP002404
Upper Structure
Cabin .................................................................................................... SP002909
Counterweight....................................................................................... SP002910
Fuel Tank.............................................................................................. SP002911
Fuel Transfer Pump (Option)................................................................ SP002912
Swing Bearing....................................................................................... SP002913
Swing Reduction Gear.......................................................................... SP002526
Lower Structure and Chassis
Track Assembly .................................................................................... SP002914
Engine and Drivetrain
QSB4.5 Engine..................................................................................... SP002915
Drive Coupling (Main Pump)................................................................. SP002931
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ............... SP002916
Accumulator.......................................................................................... SP002455
Center Joint (Swivel)............................................................................. SP002917

3. Table of Contents
Page II
Cylinders............................................................................................... SP002918
Swing Motor.......................................................................................... SP002919
Travel Device........................................................................................ SP002920
Main Pump............................................................................................ SP002930
Gear Pump ........................................................................................... SP002500
Main Control Valve ............................................................................... SP002528
Remote Control Valve (Work Lever / Joystick)..................................... SP002921
Travel Control Valve (with Damper)...................................................... SP002922
Solenoid Valve Assembly ..................................................................... SP002923
Breaker EPPR Valve (Option) .............................................................. SP002458
Hydraulic Schematic (DX140LCR-3) .................................................... SP002924
Electrical System
Electrical System .................................................................................. SP002925
Electrical Schematic ............................................................................. SP002926
Attachments
Boom and Arm...................................................................................... SP002927
Bucket................................................................................................... SP002506

4. SP002907
Page 1
Track Excavator Maintenance Safety
SP002907
TRACK EXCAVATOR MAINTENANCE SAFETY
SP002907
Track Excavator
Maintenance
Safety
Edition 1

5. SP002907
Page 5
Track Excavator Maintenance Safety
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 &
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
DX140LCR-3 1001 and Up

6. SP002907Track 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.

7. SP002907
Page 7
Track Excavator Maintenance Safety
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 & 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.

8. SP002907Track 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.

9. SP002526
Page 1
Swing Reduction Gear
SP002526
SWING REDUCTION GEARSP002526
Swing
Reduction Gear
Edition 2

10. SP002526
Page 5
Swing Reduction Gear
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 &
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
DX140LCR-3 1001 and Up

11. SP002526
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.

12. SP002526Swing Reduction Gear
Page 8
REASSEMBLY
Parts List
2
6
5
4
1
27
17
7
8
10
20
26
19
29
25
23
22
22
21
18
14
12
12
12
12
13
13
11
15
9
28
24
24
3
16
FG005349
Figure 1

13. SP002526
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 Retaining Ring
25 Retaining Ring
26 Ring
27 Spring Pin
28 Support Plate
29 Screw Bolt
Reference
Number
Description

14. 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

15. SP002526
Page 11
Swing Reduction Gear
3. When bearing is heated up to 90°C - 100°C (194°F -
212°F), 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
IMPORTANT
Do not heat bearing above 120°C (248°F).
FG005355
Figure 7

16. SP002526Swing Reduction Gear
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

17. 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

18. SP002526Swing Reduction Gear
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

19. SP002526
Page 15
Swing Reduction Gear
G. Install a retaining ring (ø30, C type, and for shaft) on
each and check if gear rotates smooth.
Figure 19
FG005367
Figure 20
FG005368
FG005369
Figure 21

20. SP002526Swing Reduction Gear
Page 16
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
pinhole of the spring faces the same direction as the
carrier shaft, and insert it by pressing with hands or
gently tapping with hammer.
Figure 22
FG005370
IMPORTANT
The calibers of gear and washer must be
assembled in the holes of the carrier pins.
Figure 23
FG005371
Figure 24
FG005372
Figure 25
FG005373

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22. SP002526
Page 17
Swing Reduction Gear
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 tapping with hammer, and
push it to the end with a jig.
Figure 26
FG005374
Figure 27
FG005375
Figure 28
FG005376
Figure 29
FG005375FG005377

23. SP002526Swing Reduction Gear
Page 18
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
FG005378
Figure 31
FG005379
Figure 32
FG005380
Figure 33
FG005381

24. SP002526
Page 19
Swing Reduction Gear
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. Attach the washed casing on the turnover machine
and rotate the turnover machine so 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
FG005382
Figure 35
FG005383
Figure 36
FG005384
IMPORTANT
Before using a press to insert bearing, make sure
bearing is not tilted and is properly aligned.