The document provides instructions for reassembling and repairing components of a swing reduction gear used in excavators, including: 1) Reassembling the carrier sub-assembly by pressing pins into carriers and installing planetary gears, thrust washers, and retaining rings. 2) Assembling the main part by press-fitting a driveshaft and bearing into the casing, installing a support plate, and torquing bolts. 3) Procedures for shrink-fitting a shaft and flexible bearing, including heating the bearing and allowing it to cool before insertion. 4) Parts lists and diagrams to support the reassembly and repair instructions. Safety precautions are provided at the beginning.

1. K1049551E Shop Manual
Copyright 2009 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
K1049551E
Serial Number 5001 and Up
DX140R
DX140LCR

2. Table of Contents
Page I
1Table of Contents
Safety
Track Excavator Safety......................................................................... SP001936
Specifications
Specification for DX140LCR................................................................. SP001937
General Maintenance
General Maintenance Procedures........................................................ SP000016
Standard Torques................................................................................. SP000813
Upper Structure
Cabin .................................................................................................... SP001938
Counterweight....................................................................................... SP001939
Fuel Tank.............................................................................................. SP001940
Fuel Transfer Pump.............................................................................. SP000021
Swing Bearing....................................................................................... SP000022
Swing Reduction Gear.......................................................................... SP000921
Lower Structure and Chassis
Track Assembly .................................................................................... SP001941
Engine and Drive Train
QSB4.5 Engine..................................................................................... SP001671
Drive Coupling (Main Pump)................................................................. SP001326
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ............... SP001942
Accumulator.......................................................................................... SP000028
Center Joint (Swivel)............................................................................. SP000029

3. Table of Contents
Page II
Cylinders............................................................................................... SP000030
Swing Motor.......................................................................................... SP001943
Travel Moter.......................................................................................... SP001346
Main Pump............................................................................................ SP001945
Main Control Valve ............................................................................... SP001029
Remote Control Valve (Work Lever / Joystick)..................................... SP000069
Travel Control Valve (with Damper)...................................................... SP000070
Solenoid Valve Assembly ..................................................................... SP001944
Breaker EPPR Valve (Opt) ................................................................... SP000192
Hydraulic Schematic (DX140LCR) ....................................................... SP001948
Electrical System
Electrical System .................................................................................. SP001949
Electrical Schematic (DX140LCR)........................................................ SP001950
Attachments
Boom and Arm...................................................................................... SP001331
Bucket................................................................................................... SP000939

4. SP001936
Page 1
Track Excavator Safety
SP001936
TRACK EXCAVATOR SAFETYSP001936
Track
Excavator
Safety
Edition 1

5. SP001936
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
DX140LCR 5001 and Up

6. SP001936Track 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. SP001936
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. SP001936Track 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. SP001936
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.

10. SP000921
Page 1
Swing Reduction Gear
SP000921
SWING REDUCTION GEARSP000921
Swing
Reduction Gear
Edition 1

11. SP000921
Page 5
Swing Reduction Gear
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 the load.
Remember, that ultimately safety is your own personal
responsibility.
MODEL SERIAL NUMBER RANGE
DX140LC 5001 and Up
DX140LCR 5001 and Up
DX140W 5001 and Up
DX160W 5001 and Up

12. 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. SP000921Swing 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

14. 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

15. 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

16. 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. SP000921Swing Reduction Gear
Page 12
Figure 7

18. 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

19. 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

20. 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

21. 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

22. 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

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

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26. 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.

27. SP000921
Page 21
Swing Reduction Gear
C. Remove the bearing press jig, align the support plate
with the bolt tap of the case, and install 6 Loctite
(#262) applied flat head bolts (M8 x 15 mm) and
tighten them with torque wrench (torque :320 kg•cm).
Figure 37
Figure 38
Figure 39
Figure 40

28. SP000921Swing Reduction Gear
Page 22
D. After installing the support plate, rotate the turnover
machine that the case is situated as shown in the
figure.
Figure 41
Figure 42
Figure 43
Figure 44