Doosan DX140LCR Manuals

Manuals and User Guides for Doosan DX140LCR. We have 2 Doosan DX140LCR manuals available for free PDF download: Shop Manual, Operation & Maintenance Manual

Doosan DX140LCR Shop Manual

Doosan DX140LCR Shop Manual (1032 pages)

Brand: Doosan | Category: Excavators | Size: 31.73 MB

Table of Contents

English

13
- Table of Contents
  13
- Applicable Models
  15
- Safety Precautions
  15
- To the Operator of a Excavator
  16
- General Safety Essentials
  19
- Location of Safety Labels
  20
- Summary of Safety Precautions for Lifting in Digging Mode
  21
- General Hazard Information
  22
- Unauthorized Modifications
  22
- Before Starting Engine
  32
- Machine Operation
  36
- Maintenance
  44
- Battery
  53
- Towing
  55
- Lifting with Sling
  56
- Shipping and Transportation
  56
- Specification for DX140LCR
  63
  - Safety Precautions
    63
  - Applicable Models
    63
  - General Description
    64
  - Component Locations
    64
  - General Dimensions
    66
    
    One - Piece Boom
    66
    
    Two - Piece Boom
    67
  - Working Range
    68
    
    One - Piece Boom
    68
    
    Two - Piece Boom
    69
  - General Specifications
    70
  - Engine Performance Curves (Per DIN 6270 Standard)
    72
  - Approximate Weight of Workload Materials
    74
  - Performance Tests
    76
  - Excavator Performance Standards
    77
    
    Test Conditions
    77
    
    Travel Speed and Travel Motor Balance (Steering Deviation) Tests
    77
    
    Swing Speed and Deceleration Force Test
    79
    
    Cylinder Performance Tests
    81
- Applicable Models
  89
- General Maintenance Procedures
  89
- Safety Precautions
  89
- Welding Precautions and Guidelines
  90
- Hydraulic System - General Precautions
  91
- Maintenance Service and Repair Procedure
  93
  - General Precautions
    93
- Hydraulic System Cleanliness and Oil Leaks
  94
  - Maintenance Precautions for Hydraulic System Service10
    94
  - Oil Leakage Precautions
    95
- Cleaning and Inspection
  96
  - General Guidelines
    96
  - Bearing Inspection
    97
- Applicable Models
  109
- Safety Precautions
  109
- Standard Torques
  109
- Fasteners
  110
- Torque Values for Standard Metric
  110
- Torque Values for Standard U.S. Fasteners
  111
- Type 8 Phosphate Coated Hardware
  113
- Torque Values for Hose Clamps
  114
- Torque Values for Split Flanges
  115
- Torque Wrench Extension Tools
  116
- Applicable Models
  127
- Safety Precautions
  127
- Cab Identification
  128
  - Roll over Protective Structure (ROPS) When Required by Local Regulations
    128
- Removal
  130
- Installation
  134
- Applicable Models
  141
- Safety Precautions
  141
- General
  142
  - Warning for Counterweight and Front Attachment Removal
    142
- Removal
  154
- Installation
  158
- Applicable Models
  167
- Fuel Transfer Pump
  167
- Safety Precautions
  167
- General Description
  168
- Theory of Operation
  168
- Replacement of Rotor and Vane
  169
- Troubleshooting
  169
- Replacement of Armature
  170
- Replacement of Rear Cover
  170
- Applicable Models
  175
- Safety Precautions
  175
- Swing Bearing
  175
- Swing Bearing Maintenance
  176
  - Operating Recommendation
    176
  - Measuring Swing Bearing Axial Play
    176
  - Measuring Bearing Lateral Play
    176
  - Swing Bearing Basic Operation
    177
  - Disassembly
    177
  - Assembly
    179
- Applicable Models
  185
- Safety Precautions
  185
- Swing Reduction Gear
  185
- General Description
  187
  - Theory of Operation
    187
- Reassembly
  188
  - Parts List
    188
- Shrinkage Fitting of Shaft and Flexible Bearing
  190
- Reassembly of Carrier Sub
  193
- Assembly of the Main
  200
- Test
  212
- Reassembly of Motor
  215
- Applicable Models
  229
- Safety Precautions
  229
- Track Assembly
  229
- General Description
  230
- Track Tension
  230
- Cleaning and Inspection
  233
  - Track Shoe
    234
  - Lower Roller
    236
  - Upper Roller
    237
  - Front Idler
    238
- Track Shoes and Links
  239
  - Track Removal
    239
  - Track Installation
    240
- Front Idler
  241
  - Parts List
    241
  - Disassembly of Front Idler
    242
  - Reassembly of Front Idler
    243
- Lower Roller
  245
  - Parts List
    245
  - Lower Roller Removal
    246
  - Lower Roller Disassembly
    246
  - Lower Roller Reassembly
    247
  - Lower Roller Installation
    248
- Upper Roller
  249
  - Parts List
    249
  - Upper Roller Removal
    250
  - Upper Roller Disassembly
    250
  - Upper Roller Reassembly
    252
- Track Spring and Track Adjusting Cylinder
  253
  - Parts List
    253
- Applicable Models
  263
- Safety Precautions
  263
- QSB4.5 Engine
  264
  - Important Reference Numbers
    265
- General Information
  266
  - To the Owner and Operator
    266
  - About the Manual
    266
  - General Safety Instructions
    268
  - General Repair Instructions
    271
  - General Cleaning Instructions
    273
  - Fuel System
    280
  - Acronyms and Abbreviations
    281
- Engine Identification
  282
  - Engine Data Plate
    282
  - Cummins Engine Nomenclature
    284
  - Fuel Injection Pump Dataplate
    284
  - ECM Data Plate
    284
  - Air Compressor (Not Used)
    285
  - Engine Diagrams
    286
  - Fan Control
    291
  - Water-In-Fuel Sensor
    292
  - Idle Shutdown
    293
  - Accelerator Optionals
    295
  - Intermediate Speed Control (ISC)
    296
  - Alternate Droop
    298
  - Switchable (Alternate) Torque
    299
  - Multiple Unit Synchronization
    300
  - Hot Shutdown Monitor
    301
  - Automatic Boost Power
    302
  - Fuel Consumption Rate Logger
    303
- Operating Instructions
  304
  - Operating Instructions -Overview
    304
  - General Information
    304
  - Normal Starting Procedure
    306
  - Jump Starting
    308
  - Cold Weather Starting
    309
  - Starting Procedure after Extended Shutdown or Oil Change
    309
  - Operating the Engine
    309
  - Engine Operating Range
    312
  - Engine Shutdown
    313
  - Electromagnetic Interference (EMI)
    313
- Maintenance Guidelines
  315
  - Maintenance Guidelines -Overview
    315
  - Tool Requirements
    315
  - Maintenance Schedule
    316
  - Oil Drain Intervals
    317
- Maintenance Procedures at Daily Interval
  318
  - Daily Maintenance Procedures - Overview
    318
  - Air Tanks and Reservoirs
    319
  - Crankcase Breather Tube
    319
  - Fuel-Water Separator
    320
  - Lubricating Oil Level
    321
  - Drive Belts
    321
  - Air Cleaner Restriction
    323
  - Air Compressor (Not Used)
    324
  - Charge-Air Cooler
    324
  - Charge-Air Piping
    324
  - Radiator Hoses
    325
  - Air Intake Piping
    325
  - Fan, Cooling
    326
  - Coolant Level
    327
- Maintenance Procedures at 500 Hours or 6 Months
  328
  - Maintenance Procedures - Overview
    328
  - Cooling System
    328
  - Fuel Filter (Spin-On Type)
    333
  - Lubricating Oil and Filters
    335
- Maintenance Procedures at 1,000 Hours or 1 Year
  338
  - Maintenance Procedures - Overview
    338
  - Fan Hub, Belt Driven
    339
- Maintenance Procedures at 2,000 Hours or 2 Years
  340
  - Air Compressor Discharge Lines (Not Used)
    340
  - Cooling System
    342
  - Vibration Damper, Rubber
    347
  - Vibration Damper, Viscous
    347
  - Overhead Set
    348
  - Alternator
    354
  - Charge-Air Cooler
    360
  - Coolant Thermostat
    365
  - Cooling Fan Belt Tensioner
    370
  - Drive Belt, Cooling Fan
    371
  - Fan Spacer and Pulley
    372
  - Starting Motor
    374
- System Diagrams
  379
  - General Information
    379
  - Fuel System
    380
  - Lubricating Oil System
    382
  - Cooling System
    387
  - Air Intake System
    388
  - Exhaust System
    389
  - Compressed Air System
    391
- Service Literature
  392
- Service Assistance
  398
- Troubleshooting Symptoms
  451
  - Troubleshooting Procedures and Techniques
    451
  - Troubleshooting Symptoms Charts
    451
- Applicable Models
  549
- Hydraulic System Troubleshooting, Testing and Adjustment
  549
- Safety Precautions
  549
- Hydraulic System - General Notes
  550
- Hydraulic Schematic
  551
  - General Notes
    551
- Operation of Working Components
  553
  - Boom Operating Circuit
    553
  - Boom up Circuit
    553
  - Boom down Circuit
    553
  - Arm Operating Circuit
    554
  - Arm Crowd Circuit
    554
  - Arm Dump Circuit
    554
  - Bucket Operating Circuit
    555
  - Bucket Crowd Circuit
    555
  - Bucket Dump Circuit
    555
  - Swing Operating Circuit
    555
  - Right Swing Operating Circuit
    556
  - Left Swing Operating Circuit
    556
  - Swing Relief Valve and Makeup Valve
    556
  - Travel Operating Circuit
    556
  - Forward Travel Circuit
    557
  - Reverse Travel Circuit
    557
- Procedural Troubleshooting Baseline Recommendations
  558
  - Initial Checks and Tests to Establish Operating Condition of the Excavator
    558
- Pilot Pressure
  560
  - Adjustment and Testing
    560
- Power Mode Valve
  561
  - Current Signal and Hydraulic Pressure Adjustments
    561
- Swing Priority Valve
  562
  - Control Valve Pressure and Current Adjustments
    562
- Pressure up Valve
  563
  - Checks and Adjustments
    563
- Pump Input Power Control
  565
  - Pump Regulator Adjustment
    565
- Flow Meter and Flow Meter Kit Installation and Testing
  569
- Swing System Troubleshooting
  571
  - Precautions/Initial Checks
    571
  - Swing Relief Valve Checking and Adjustment
    572
- Troubleshooting - Swing Gearbox
  574
- Troubleshooting - Hydraulic Problems
  575
- Troubleshooting - Control Valve
  577
- Troubleshooting - Travel Control Valve
  578
- Troubleshooting - Joystick Control Valve
  579
- Applicable Models
  585
- Safety Precautions
  585
- General Description
  586
  - Specifications
    588
- Applicable Models
  593
- Center Joint (Swivel)
  593
- Safety Precautions
  593
- General Description
  594
  - Parts List
    595
- Troubleshooting, Testing and Adjustment
  596
  - Inspection
    596
  - Testing
    596
- Disassembly
  597
- Reassembly
  598
- Applicable Models
  603
- Safety Precautions
  603
- General Description
  604
  - Theory of Operation
    604
  - Parts List
    606
- Special Tools and Materials
  608
  - Piston Nut
    608
  - Piston Jig
    610
  - Steel Bushing Jig
    612
  - Dust Wiper Jig
    614
  - Slipper Seal Jig
    616
  - Slipper Seal Straightening Jig
    618
- Disassembly
  620
- Reassembly
  625
- Swing Motor
  632
- Applicable Models
  633
- Safety Precautions
  633
- Instruction Manual
  634
  - Construction and Principles of Working
    636
  - Precaution in Use
    643
  - Troubleshooting
    647
- Maintenance Manual
  650
  - Disassembling and Assembling
    650
- Applicable Models
  669
- Safety Precautions
  669
- Product Overview
  670
- External Dimensions
  671
- General Description
  672
- Operating Description
  675
  - Reduction Gear
    675
  - Hydraulic Drives
    676
  - Tubing
    685
  - Fluid Selection
    685
- Maintenance and Inspection
  686
  - Daily Inspection
    686
  - Changing Fluid
    687
  - Changing Lubrication
    687
- Seals Table
  689
- Troubleshooting
  690
- Outline of Maintenance
  692
  - Tools
    692
  - Bolts
    692
  - Equipments
    693
  - Fabricated Tools
    693
  - Torque
    697
  - Weight Table
    697
- Disassembling
  698
  - Work Preparation
    698
  - General Precautions for Work
    698
  - Disassembling Order
    699
- Maintenance Standards
  716
  - Seals
    716
  - Maintenance Standards for Wearable Parts
    716
- Assembling
  718
  - Preparation
    718
  - General Precautions for Assembling Work
    718
  - Order of Assembling
    719
- Applicable Models
  741
- Main Pump
  741
- Safety Precautions
  741
- Disassembling and Reassembling Procedures
  742
  - Tool
    742
  - Disassembling Procedures
    743
  - Reassembling Procedures
    747
- Pump Maintenance Criteria
  751
  - Worn Part Replacement Criteria
    751
- Applicable Models
  759
- Safety Precautions
  759
- General Description
  760
  - Theory of Operation
    761
  - Composite Operation
    772
  - Anti-Drift Valve
    773
- Disassembly
  775
  - Precautions for Disassembly
    775
  - Disassembling Procedures
    775
- Inspection
  781
- Washing
  781
- Assembling
  782
  - Sub-Assembly
    782
  - Assembling Control Valve
    785
- Relief Valve
  791
  - Main Relief Valve
    791
  - Overload Relief Valve
    795
  - Negacon Relief Valve
    798
  - Adjusting Relief Valve
    800
- Installation
  801
- Operation
  801
- Control Valve Specification
  802
- Troubleshooting
  803
  - Control Valve: Overall
    803
  - Hydraulic System: Overall
    804
  - Torques
    814
- Tools and Materials
  814
- Disassembly
  815
- Cleaning and Inspection
  818
- Reassembly
  819
- Start-Up Procedures
  825
  - Specification
    840
  - Torques
    840
- Removal
  841
- Disassembly
  842
- Cleaning and Inspection
  844
- Reassembly
  845
- Installation
  850
- Start-Up Procedures
  851
- Applicable Models
  857
- Safety Precautions
  857
- Solenoid Valve Assembly
  857
- Parts List
  858
- Functions of 5-Solenoid Valve Assembly Package
  859
- Applicable Models
  871
- Safety Precautions
  871
- Structure
  872
  - Numbers and Names of Parts
    872
- Cautions for Operation
  873
- Functions and Operation
  873
- Maintenance Instructions
  874
  - Maintenance
    874
  - Disassembly
    875
  - Assembly
    876
- Applicable Models
  893
- Safety Precautions
  893
- Introduction
  894
- Electrical Supply System
  895
- Engine Starting Circuit
  897
- Engine Preheating System
  901
- Engine Stop
  903
- Charging System
  905
- Monitoring System
  906
- Operation
  911
- Warning and Indicator Lights
  913
- Initial Operation
  916
- Mode Selector Switch
  916
- Graphic Information Area Display
  917
- Main Menu
  919
- Special Menu
  923
- Electronic Hydraulic Control System (E-EPOS)
  941
- Power Mode Control
  943
- Power / Economy Mode Control - Circuit Diagram
  949
- Engine Control Dial
  950
- Air Conditioner System
  968
- Troubleshooting
  981
- Weight of R134A Gas Used in Machines
  983
- Refrigerant System Repairs
  984
- Wiper System
  992
- Lighting System
  995
- Overload Warning Device
  997
- Audio Controller
  998
Unknown

1002
- Table of Contents
  1002
- Applicable Models
  1013
- Boom and Arm
  1013
- Safety Precautions
  1013
- Front Attachment Pin Specifications
  1014
  - One-Piece Boom
    1014
  - Two-Piece Boom
    1015
- Front Attachment - Removal and Installation
  1016
  - Arm Removal Procedure
    1016
  - Boom Removal Procedure
    1018
- Installation
  1019
  - Arm Installation Procedure
    1019
  - Boom Installation Procedure
    1019
- Start-Up Procedures
  1019
- Applicable Models
  1025
- Bucket
  1025
- Safety Precautions
  1025
- Bucket Tooth Inspection and Replacement
  1026
- Bucket O-Ring Replacement
  1027
- Bucket Attachment, Removal and Reversal
  1029
  - Detaching the Bucket
    1029
  - Attaching the Bucket
    1029
  - Reversing the Bucket
    1030

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Doosan DX140LCR Operation & Maintenance Manual

Doosan DX140LCR Operation & Maintenance Manual (314 pages)

Brand: Doosan | Category: Excavators | Size: 35.61 MB

Table of Contents

Table of Contents
5
EC Declaration of Conformity
9
To the Operator of Adoosan Excavator
11
Safety Decals
14
Visibility Information
29
Summary of Safety Precautions for Lifting in Digging Mode
31
Unauthorized Modifications
32
General Hazard Information
32
Before Starting Engine
41
Machine Operation
46
Maintenance
55
Battery
64
Towing
66
Shipping and Transportation
67
Excavator Rated Lift Capacity Tables
68
Operating Controls

89
- Component Locations
  90
- Operator's Area
  92
- Operational Controls and Panels
  94
- Instrument Panel
  107
- Multifunction Gauge and Graphic Information
  113
- Mode Selector Buttons
  119
- Setting Main Menu
  121
- Flow Control
  131
- Operation Selection Display
  133
- Heater and Air Conditioner Control Panel
  136
- Stereo
  141
- Miscellaneous Electrical Devices
  142
- Seat Adjustment
  144
- Ceiling Cover
  148
- Front Windows
  149
- Door Side Latch
  151
- Cabin Storage Compartments
  152
- Ashtray
  152
- Sun Visor
  153
- Hanger
  153
- Cup Holder
  153
- Emergency Glass Breaking Tool
  154
- Miscellaneous Access Covers and Doors
  155
Operation

157
- To Handle a New Excavator
  157
- Starting and Stopping the Engine
  158
- Safety Lever
  168
- Travel
  169
- Operating Instructions
  175
- Operating Precautions
  182
- Parking Excavator
  187
- Towing Procedure
  188
- Hydraulic Attachments (Optional)
  189
- Adjusting the Pump Flow
  194
- Lifting Objects
  197
- Operation under Unusual Conditions
  199
- Road Liners (Machine Equipped with Road Liner)
  203
- Operation
  204
Inspection, Maintenance and Adjustment

207
Transportation

291
- Loading and Unloading
  291
- Lifting Machine
  296
Specification

297
- Standard Specification
  297
- Overall Dimensions
  298
- Working Range
  300
- Approximate Weight of Workload Materials
  304
Index

307

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