Part of the Doosan Repair Manuals.
This is the factory shop manual for the 2009 Doosan DX140R and DX140LCR reduced tail swing crawler excavators, publication K1049551E. The whole Cummins QSB4.5 engine service book is bound in (pages 251 to 524), so you get engine troubleshooting symptom charts, maintenance intervals out to 2,000 hours, and specifications alongside the machine side: swing reduction gear, travel and swing motors, main pump teardown, main control valve, track assembly wear limits, and cabin-to-swing-bearing removal. Fault code tables with E-codes and V-codes plus FMI numbers are printed on page 928. Full hydraulic schematic (SP001948, page 879) and electrical schematic (SP001950, page 1000) are included. The R and LCR carry separate dimension tables, and this book covers both.
What's Inside This Doosan DX140R, DX140LCR Manual
| System | Pages | Key Topics |
|---|---|---|
| Track Excavator Safety | 9-56 | Safety Precautions, To the Operator of a Excavator, Learn the Signal Words Used with the Safety Alert Symbol, General Safety Essentials, Accessory Applications, Lifting Capacity Rating Configuration |
| Specification for DX140LCR | 57-82 | Safety Precautions, General Description, Component Locations, General Dimensions, One - Piece Boom, Two - Piece Boom |
| General Maintenance Procedures and Standard Torques | 83-120 | Safety Precautions, Welding Precautions and Guidelines, Hydraulic System - General Precautions, Maintenance Service and Repair Procedure, General Precautions, Hydraulic System Cleanliness and Oil Leaks |
| Cabin to Swing Bearing | 121-174 | Safety Precautions, Removal, Installation, Warning for Counterweight and Front Attachment Removal, General Description, Parts List |
| Swing Reduction Gear | 175-218 | Safety Precautions, General Description, Theory of Operation, Reassembly, Parts List, Shrinkage Fitting of Shaft and Flexible Bearing |
| Track Assembly | 219-250 | Safety Precautions, General Description, Track Tension, Cleaning and Inspection (Wear Limits and Tolerances), Track Shoe, Lower Roller |
| QSB4.5 Engine - Safety Precautions to Engine Identification | 251-297 | Safety Precautions, QSB4.5 Engine, Important Reference Numbers, General Information, To the Owner and Operator, About the Manual |
| QSB4.5 Engine - Operating Instructions to Maintenance Procedures at 1,000 Hours or 1 Year | 298-333 | Operating Instructions, Operating Instructions -Overview, General Information, Normal Starting Procedure, Jump Starting, Cold Weather Starting |
| QSB4.5 Engine - Maintenance Procedures at 2,000 Hours or 2 Years to Service Literature | 334-391 | Maintenance Procedures at 2, 000 Hours or 2 Years, Air Compressor Discharge Lines (Not Used), Cooling System, Vibration Damper, Rubber, Viscous, Overhead Set |
| QSB4.5 Engine - Service Assistance | 392-444 | Service Assistance, Routine Service and Parts, Emergency and Technical Service, Problem Solving, Division and Regional Offices Locations, Distributors and Branches United States |
| QSB4.5 Engine - Troubleshooting Symptoms | 445-494 | Troubleshooting Symptoms, Troubleshooting Procedures and Techniques, Troubleshooting Symptoms Charts |
| QSB4.5 Engine - Maintenance Specifications and Warranty | 495-524 | Maintenance Specifications, General Engine, Fuel System, Lubricating Oil System, Cooling System, Air Intake System |
| Drive Coupling (Main Pump) and Hydraulic System Troubleshooting, Testing and Adjustment | 525-574 | Safety Precautions, Drive Coupling, Special Tools, Installation of Drive Coupling, Installation Procedure, Hydraulic System - General Notes |
| Accumulator to Cylinders | 575-622 | Safety Precautions, General Description, Specifications, Parts List, Troubleshooting, Testing and Adjustment, Inspection |
| Swing Motor | 623-658 | Safety Precautions, Instruction Manual, Indication of Type, Specifications, Construction and Principles of Working, Construction |
| Travel Moter | 659-730 | Safety Precautions, Product Overview, General Specifications, External Dimensions, General Description, Operating Description |
| Main Pump | 731-748 | Safety Precautions, Disassembling and Reassembling Procedures, Tool, Disassembling Procedures, Reassembling Procedures, Pump Maintenance Criteria |
| Main Control Valve | 749-798 | Safety Precautions, General Description, Theory of Operation, Service Spool Movement, Swing Spool Movement, Bucket Spool Movement |
| Remote Control Valve (Work Lever / Joystick) and Travel Control Valve (with Damper) | 799-846 | Safety Precautions, General Description, Theory of Operation, Structure, Function, Parts List |
| Solenoid Valve Assembly to Hydraulic Schematic (DX140LCR) | 847-881 | Safety Precautions, Parts List, Functions of 5-Solenoid Valve Assembly Package, Functions of Solenoid Valve Assembly Package, This Solenoid Valve Assembly Package Have the Following Functions., Functions and Operations of Solenoid Valves |
| Electrical System | 882-993 | Safety Precautions, Electrical Supply System, Engine Starting Circuit, Start Operation, After Start, Engine Preheating System |
| Electrical Schematic (DX140LCR) to Bucket | 994-1024 | Safety Precautions, DX140LCR, Front Attachment Pin Specifications, One-Piece Boom, Two-Piece Boom, Front Attachment - Removal and Installation |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine model (DX140LCR) | Cummins QSB4.5, rated to DIN 6270 | p. 71 |
| Rated power (DX140LCR) | 100 ps (98.5 hp) @ 1,800 rpm | p. 71 |
| Fuel tank capacity (DX140LCR) | 235 liters (62.3 U.S. gal) | p. 68 |
| Hydraulic system capacity (DX140LCR) | 131 liters (34.6 U.S. gal) | p. 68 |
| Hydraulic reservoir capacity (DX140LCR) | 93.5 liters (24.7 U.S. gal) | p. 68 |
| Main relief pressure (DX140LCR) | 330 kg/cm² (normal operation) | p. 74 |
| Main control valve sub spool plug torque | 103 - 113 N·m | p. 783 |
| Main control valve cap bolt torque | 20 - 25 N·m | p. 783 |
| Main control valve plug assembly torque range | 19 - 227 N·m depending on the plug | p. 783 |
Doosan DX140R, DX140LCR Common Problems This Manual Covers
Engine stalls, refuses to start, or loses power under load, usually traced to fuel restriction, a clogged fuel prefilter, or a fuel pressure fault.
Work the Troubleshooting Symptoms charts in the QSB4.5 engine section. They walk cause by cause through fuel supply restriction, filter condition, and pressure faults so you replace the part that actually failed, not the first sensor you can reach.
Manual Section: QSB4.5 Engine - Troubleshooting Symptoms p. 539No hydraulic pressure or very weak digging and boom movement, often a worn or sheared pump drive coupling rather than the pump itself.
The Drive Coupling and Hydraulic System Troubleshooting, Testing and Adjustment section covers coupling inspection and the installation procedure with special tools, then gives the test and adjustment steps to verify pressure against the 330 kg/cm2 main relief figure on page 74.
Manual Section: Drive Coupling (Main Pump) and Hydraulic System Troubleshooting, Testing and Adjustment p. 623Overheating or gradual cooling performance decline from a plugged dust net, oil cooler, or intercooler.
Follow the cooling system maintenance procedures in the QSB4.5 engine section, which schedule cooling system service through the 2,000 hour / 2 year interval and include the vibration damper checks done at the same teardown, so you clean the coolers before a head gasket pays the price.
Manual Section: QSB4.5 Engine - Maintenance Procedures at 2,000 Hours or 2 Years to Service Literature p. 659Weak swing or a noisy, grinding swing reduction gear, common on machines that spend their lives trenching in one arc.
The Swing Reduction Gear chapter gives the general description, theory of operation, full reassembly procedure, and parts list, including the shrinkage fitting procedure for the shaft and flexible bearing, which is the step that gets botched when this unit is rebuilt without the book.
Manual Section: Swing Reduction Gear p. 219Frequently Asked Questions
A warning light came on and the machine tells me to stop. How do I find out what the fault is?
The manual's approach is to stop the machine and read the fault from the main screen, then look it up in the code table on page 928. Codes in this book are four-digit E-codes like E0322, E0323, E0324, and V-codes such as V201, V202, V204 and V228 through V232, each listed with an FMI number and an 'Operation when failure occurs' column so you know what the machine limits while the fault is active. There is no P-code or flash code system on this machine, so if a chart you found online uses those, it is for a different model. p. 928
Does this manual actually cover the Cummins QSB4.5 engine, or do I need a separate engine book?
The complete QSB4.5 service section is bound into this manual, pages 251 to 524. That covers engine identification, starting procedures including jump starting and cold weather starting, every maintenance interval up to 2,000 hours or 2 years, troubleshooting symptom charts, and full maintenance specifications for the fuel, lubricating oil, cooling, and air intake systems. The engine is rated to DIN 6270 at 100 ps (98.5 hp) at 1,800 rpm. You do not need to buy the Cummins book separately. p. 251
The excavator digs weak or the boom barely moves. Will this manual get me to the cause?
Yes, and it starts where a mechanic would: the Drive Coupling and Hydraulic System Troubleshooting, Testing and Adjustment section. The pump drive coupling is a known failure point on these machines, and the manual covers its inspection and installation procedure with special tools. Main relief pressure for normal operation is 330 kg/cm2, printed on page 74, so you can put a gauge on it and compare against a real number instead of guessing. Low oil level and leaks are covered under the hydraulic system general precautions and cleanliness procedures. p. 539
I have a DX140R, not the LCR. Is this the right book?
Yes. The Specification chapter carries separate dimension tables for the DX140R and the DX140LCR, because the two machines differ dimensionally. The service procedures for the engine, pump, motors, valves, and undercarriage apply to both. Note that the printed hydraulic schematic (page 879) and electrical schematic (page 1000) are labeled for the DX140LCR. p. 60
Are full wiring and hydraulic schematics included, or just partial circuit snippets?
Both full schematics are in the book. The complete hydraulic schematic is SP001948 on page 879, and the complete electrical schematic is SP001950 on page 1000. The Electrical System chapter also walks through the supply system, engine starting circuit, and preheating system as separate explained circuits, which is what you want when chasing a no-crank or charging problem instead of staring at one giant foldout. p. 879
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