Part of the Doosan Repair Manuals.
Within the hour you could have a gauge on the DX140LCR-3's hydraulics, checking main relief against 330 kg/cm2 (4,689 psi) instead of guessing. This Doosan shop manual, publication 950106-01021E from December 2012, covers serial number 1001 and up.
It covers the cabin and counterweight, the swing bearing and swing reduction gear, and the undercarriage from track tension to the idler and rollers. The hydraulics section takes in the main pump, travel device, swing motor and cylinders, and the electrical section covers the EPOS-controlled machine. A full Cummins QSB4.5 engine service section is bound in, along with fold-out hydraulic and electrical schematics.
Every hour the excavator sits, an operator and a truck are waiting on you. Find the fault, set it to spec and get the bucket back in the dirt.
What's Inside This Doosan DX140LCR-3 Manual
| System | Pages | Key Topics |
|---|---|---|
| Cover & Table of Contents | 1-4 | Cover, Publication 950106-01021E, Table of Contents |
| Safety | 5-74 | Track Excavator Maintenance Safety, Safety Messages, Safety Decals, General, Transportation, Operation, Maintenance, Environment and Circumstances |
| Specifications | 75-104 | Specifications for DX140LCR-3, Component Locations, General Dimensions, Working Range, General Specifications, Engine Performance Curves (per DIN 6271 Standard), Approximate Weight of Workload Materials, Performance Tests |
| General Maintenance | 105-142 | General Maintenance Instructions, Standard Torques, Welding Precautions and Instructions, Hydraulic System - General Precautions, Maintenance Service and Repair Procedure, Hydraulic System Cleanliness and Oil Leaks, Cleaning and Inspection, Torque Values for Standard Metric Fasteners |
| Upper Structure | 143-242 | Cabin, Counterweight, Fuel Tank, Fuel Transfer Pump (Option), Swing Bearing, Swing Reduction Gear, Cabin Identification, General |
| Lower Structure and Chassis | 243-274 | Track Assembly, Track Tension, Track Shoes and Links, Front Idler Roller, Lower Roller, Upper Roller, Track Spring and Track Adjusting Cylinder |
| QSB4.5 Engine (Cummins Service Section) | 275-572 | QSB4.5 Engine, General Information, Engine Identification, Operating Instructions, Maintenance Guidelines, Maintenance Procedures at Daily Interval, Maintenance Procedures at 250 Hours or 3 Months, Maintenance Procedures at 500 Hours or 6 Months |
| Drive Coupling (Main Pump) | 573-582 | Drive Coupling, Installation of Drive Coupling |
| Hydraulics | 583-946 | Hydraulic System Troubleshooting, Testing and Adjustment, Accumulator, Center Joint (Swivel), Cylinders, Swing Motor, Travel Device, Main Pump, Gear Pump |
| Hydraulic Schematic | 947-954 | Hydraulic Schematic (DX140LCR-3) |
| Electrical System | 955-1076 | Introduction, Electrical Supply System, Engine Starting Circuit, Engine Preheating System, Engine Stop, Charging System, Monitoring System, Operation |
| Electrical Schematic | 1077-1084 | Fold-Out Electrical Schematic (DX140LCR-3) |
| Attachments | 1085-1114 | Boom and Arm, Bucket, Front Attachment Pin Specifications, Front Attachment - Removal and Installation, Start-Up Procedures, Bucket Tooth Inspection and Replacement, Bucket O-Ring Replacement |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine model | QSB4.5 | p. 95 |
| Engine power (DIN 6271) | 110 ps @ 2,200 rpm (81 kW @ 2,200 rpm) | p. 95 |
| Engine max. torque | 489 Nm @ 1,500 rpm (49.8 kg•m @ 1,500 rpm) | p. 95 |
| Fuel consumption (rated) | 165 g/kw•hr | p. 95 |
| Alternator | 24V x 70A | p. 95 |
| Shipping weight | 15.1 tons (33,289 lb) | p. 92 |
| Counterweight | 3,500 kg (7,716 lb) | p. 92 |
| Fuel tank capacity | 220 liters (58 U.S. gal) | p. 92 |
| Hydraulic system capacity | Full: 131 liters (34.6 U.S. gal), System: 161 liters (42.5 U.S. gal) | p. 92 |
| Hydraulic reservoir capacity | 85 liters (22.4 U.S. gal) | p. 92 |
| Main relief pressure | 330 kg/cm2 (4,689 psi) normal operation; 350 kg/cm2 (4,970 psi) with "Pressure Up" | p. 98 |
| Travel speed 20 m (66 ft), Standard Mode | High 16.0 ±1.0 sec; Low 25.0 ±1.5 sec | p. 98 |
| Swing (3 revolutions), Standard Mode | 17.6 ±1.5 sec | p. 98 |
| Swing relief valve | 270 kg/cm2 (3,840 psi) | p. 596 |
Doosan DX140LCR-3 Common Problems This Manual Covers
Boom, arm, bucket, swing and travel all dead, with loud noise coming from the main pump
Start with the hydraulic oil level, then check the main pump inlet piping and supply hose for damage. If oil and inlet are good, the pump itself is suspect. The Hydraulic System Troubleshooting chart covers each cause, and the Main Pump pages cover repair or replacement.
Manual Section: Hydraulics - Hydraulic System Troubleshooting / Main PumpEvery hydraulic function is slow, including attachment, swing and travel
Check oil level and pull the reservoir intake strainer for cleaning. Tighten the pump inlet connections, because one loose fitting lets air into the whole system. Then gauge main relief and readjust it. If pressure still will not come up, the troubleshooting chart points to worn main pumps.
Manual Section: Hydraulics - Hydraulic System Troubleshooting, Testing and AdjustmentQSB4.5 coolant temperature creeping above normal and slowly overheating
Follow the step-by-step cause and correction chart in the Cummins section. Check for blocked radiator and charge-air cooler fins, then coolant level and antifreeze mix. Next look at fan shroud and baffle damage, fan drive belt condition, collapsed hoses, and whether the temperature gauge is reading true.
Manual Section: QSB4.5 Engine (Cummins service section) - troubleshooting p. 504Swing is weak or sluggish while the rest of the machine works normally
Check the swing motor brake piston and friction plate for sticking, then test makeup valve pressure for cavitation. If the pressures check out, the troubleshooting chart sends you to the joystick, the electrical control circuit and the EPOS circuit. Run the self-diagnostic test to check those.
Manual Section: Hydraulics - Hydraulic System Troubleshooting / Swing MotorFrequently Asked Questions
What should main relief pressure be on the DX140LCR-3, and what about swing relief?
The spec table lists 330 kg/cm2 (4,689 psi) for normal operation and 350 kg/cm2 (4,970 psi) with "Pressure Up" engaged. Swing relief is 270 kg/cm2 (3,840 psi). The Testing and Adjustment pages in the Hydraulics section show how to check these before you blame the pump. p. 98
What do error codes V000201 and V000202 mean on the instrument panel?
The Communication Monitor table lists V000201 as a communication error in the instrument panel and V000202 as a communication error in the engine controller. Trace the circuit with the Electrical System section and the fold-out electrical schematic before you order a controller. p. 1044
Does it cover the Cummins QSB4.5 engine, or just the machine?
The engine is covered too. A full QSB4.5 service section is bound in, with daily, 250 hour/3 month and 500 hour/6 month procedures plus an overheating cause and correction chart. Rated output is 110 ps @ 2,200 rpm (81 kW @ 2,200 rpm) and max torque is 489 Nm @ 1,500 rpm. p. 95
How do I tell if travel and swing speeds are where they should be?
Use the Performance Tests in the Specifications section. In Standard Mode, 20 m (66 ft) of travel should take 16.0 ±1.0 sec in high and 25.0 ±1.5 sec in low. Three swing revolutions should take 17.6 ±1.5 sec. Running those tests on a used machine before you buy it is the best reason to own the book. p. 98
How much hydraulic oil and fuel does it hold?
The hydraulic reservoir is 85 liters (22.4 U.S. gal). The spec table lists system capacity as Full: 131 liters (34.6 U.S. gal), System: 161 liters (42.5 U.S. gal). The fuel tank holds 220 liters (58 U.S. gal). Shipping weight is 15.1 tons (33,289 lb), including a 3,500 kg (7,716 lb) counterweight. p. 92
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