Doosan DX140LCR-3 Excavator Shop Manual Sn 1001 and up – PDF DOWNLOAD
DESCRIPTION:
Doosan DX140LCR-3 Excavator Shop Manual Sn 1001 and up – PDF DOWNLOAD
Serial Number 1001 and Up
950106-01021E
GENERAL:
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.
Proper Work Tools and Attachments:
.Only use work tools and attachments that are recommended by DOOSAN for use on DOOSAN machines. When installing and using optional attachments, read instruction manual for attachment, and general information related to attachments in this manual.
- Because DOOSAN cannot anticipate, identify or test all attachments that owners may want to install on their machines, contact DOOSAN for written authorization and approval of attachments, and their compatibility with optional kits. Attachments and attachment control systems that are compatible with the machine are required for safe and reliable machine operation.
- Do not exceed maximum operating weight (machine weight plus attachment) that is listed on ROPS certification plate. Make sure that all guards and shields are in place on machine and on work tool. Depending on type or combination of work equipment, there is a potential that work equipment could interfere with the cabin or other parts of machine.
- Before using unfamiliar work equipment, check if there is any potential of interference, and operate with caution. While you are performing any maintenance, testing, or adjustments to attachments, stay clear of the following areas: cutting edges, pinch points, and crushing surfaces.
- Never use attachment as a work platform or manlift. Contact your DOOSAN distributor about auxiliary hydraulic kits for attachments installation. If you are in doubt about compatibility of a particular attachment with a machine, consult your DOOSAN distributor
.
Doosan DX140LCR-3 Excavator Shop Manual Sn 1001 and up – PDF DOWNLOAD
DX140LCR-3………………………………………………………………………………….. 5
Table of Contents………………………………………………………………………… 7
Safety………………………………………………………………………………….. 9
Track Excavator Maintenance Safety SP002907……………………………………………… 11
Safety Instructions……………………………………………………………….. 15
Applicable Models…………………………………………………………………. 15
Safety Messages…………………………………………………………………… 16
Signal Words………………………………………………………………….. 16
Other Signal Words…………………………………………………………….. 17
Safety Decals…………………………………………………………………….. 17
General………………………………………………………………………….. 18
Safe Operation is Operator’s Responsibility………………………………………. 18
Know Your Machine……………………………………………………………… 18
Proper Work Tools and Attachments……………………………………………….. 19
Pressurized Fluids…………………………………………………………….. 19
Flying or Falling Objects………………………………………………………. 20
Personal Protective Equipment (PPE)……………………………………………… 21
Correction of Machine Problems………………………………………………….. 21
Crushing and Cutting…………………………………………………………… 21
Hot Coolant and Oils – Burn Prevention…………………………………………… 22
Fire and Explosion Prevention…………………………………………………… 23
Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)………………………… 26
Electrical System and Electrical Shock…………………………………………… 27
Rollover Protective Structure (ROPS)…………………………………………….. 27
Transportation……………………………………………………………………. 31
Obey State and Local Over-the-Road Regulations……………………………………. 31
Loading and Unloading………………………………………………………….. 31
Transporting Machine…………………………………………………………… 32
Operation………………………………………………………………………… 33
Before Engine Starting…………………………………………………………. 33
Work Site…………………………………………………………………….. 34
Mounting/Dismounting…………………………………………………………… 35
Cleaning……………………………………………………………………… 36
Operator Station………………………………………………………………. 36
Seat Belt…………………………………………………………………….. 37
Visibility Information…………………………………………………………. 38
Boost Starting or Charging Engine Batteries………………………………………. 39
Starting Engine……………………………………………………………….. 40
Swinging or Traveling………………………………………………………….. 41
Lifting and Digging……………………………………………………………. 43
Operation on Slopes……………………………………………………………. 44
Towing……………………………………………………………………….. 45
Attachment……………………………………………………………………. 46
Equipment Lowering with Engine Stopped…………………………………………… 46
Engine Stop…………………………………………………………………… 46
Parking Machine……………………………………………………………….. 47
Preservation/Storing Machine……………………………………………………. 48
Maintenance………………………………………………………………………. 50
Warning Tag…………………………………………………………………… 53
Cleaning……………………………………………………………………… 54
Proper Tools and Clothing………………………………………………………. 54
Disassembling Precautions………………………………………………………. 54
Use of Lighting……………………………………………………………….. 55
Fire and Explosion Prevention…………………………………………………… 55
Burn Prevention……………………………………………………………….. 56
Rubber That Contains Fluorides………………………………………………….. 57
Rubber and Plastics……………………………………………………………. 58
Welding Repairs……………………………………………………………….. 59
Warning for Counterweight and Front Attachment Removal…………………………….. 60
Lock Inspection Covers…………………………………………………………. 61
Working on Machine…………………………………………………………….. 61
Accumulator…………………………………………………………………… 62
Compressed Air………………………………………………………………… 62
Track Tension Adjustments………………………………………………………. 63
Supports and Blocking for Work Equipment…………………………………………. 63
High-pressure Lines, Tubes and Hoses…………………………………………….. 64
Battery………………………………………………………………………. 65
Environment and Circumstances………………………………………………………. 67
Work Site Areas Requiring Extra Caution………………………………………….. 67
High-voltage Cables……………………………………………………………. 69
Underground Operation………………………………………………………….. 70
Working in Water………………………………………………………………. 70
Working in Contaminated Environment……………………………………………… 70
Operation in Extreme Conditions…………………………………………………. 71
Exhaust Ventilation……………………………………………………………. 75
Asbestos Information…………………………………………………………… 75
Silica Dust Information………………………………………………………… 76
Disposal of Hazardous Materials…………………………………………………. 76
Sound………………………………………………………………………… 77
Vibration…………………………………………………………………….. 77
Specifications…………………………………………………………………………… 79
Specifications for DX140LCR-3 SP002908………………………………………………….. 81
Safety Instructions……………………………………………………………….. 85
Applicable Models…………………………………………………………………. 85
General Description……………………………………………………………….. 87
Component Locations……………………………………………………………….. 88
General Dimensions………………………………………………………………… 90
One – Piece Boom………………………………………………………………. 90
Two – Piece Boom………………………………………………………………. 91
Working Range…………………………………………………………………….. 92
One – Piece Boom………………………………………………………………. 92
Two – Piece Boom………………………………………………………………. 94
General Specifications…………………………………………………………….. 96
Engine Performance Curves (Per DIN 6271 Standard)…………………………………….. 98
Approximate Weight of Workload Materials…………………………………………….. 100
Performance Tests…………………………………………………………………. 102
Excavator Performance Measurements………………………………………………….. 103
Test Conditions……………………………………………………………….. 103
Travel Speed and Travel Motor Balance (Steering Deviation) Tests……………………. 103
Swing Speed and Deceleration Force Test………………………………………….. 105
Cylinder Performance Tests……………………………………………………… 107
General Maintenance………………………………………………………………………. 109
General Maintenance Instructions SP002454……………………………………………….. 111
Safety Instructions……………………………………………………………….. 115
Applicable Models…………………………………………………………………. 115
Welding Precautions and Instructions………………………………………………… 116
Hydraulic System – General Precautions………………………………………………. 117
Maintenance Service and Repair Procedure…………………………………………….. 119
General Precautions……………………………………………………………. 119
Hydraulic System Cleanliness and Oil Leaks…………………………………………… 120
Maintenance Precautions for Hydraulic System Service………………………………. 120
Oil Leakage Precautions………………………………………………………… 121
Cleaning and Inspection……………………………………………………………. 122
General Instructions…………………………………………………………… 122
Bearing Inspection…………………………………………………………….. 123
Standard Torques SP002404……………………………………………………………… 131
Safety Instructions……………………………………………………………….. 135
Applicable Models…………………………………………………………………. 135
Torque Values for Standard Metric Fasteners………………………………………….. 136
Torque Values for Standard U.S. Fasteners……………………………………………. 137
Type 8 Phosphate Coated Hardware……………………………………………………. 139
Torque Values for Hose Clamps………………………………………………………. 140
ORFS Swivel Nut Recommended Torque………………………………………………….. 140
Torque Values for Split Flanges…………………………………………………….. 141
Torque Wrench Extension Tools………………………………………………………. 142
Torque Multiplication………………………………………………………….. 142
Other Uses for Torque Wrench Extension Tools……………………………………… 143
Tightening Torque Specifications (Metric)………………………………………… 144
Upper Structure………………………………………………………………………….. 147
Cabin SP002909……………………………………………………………………….. 149
Safety Instructions……………………………………………………………….. 153
Applicable Models…………………………………………………………………. 153
Cabin Identification………………………………………………………………. 154
Rollover Protective Structure (ROPS)…………………………………………….. 154
Removal………………………………………………………………………….. 156
Installation……………………………………………………………………… 160
Counterweight SP002910………………………………………………………………… 163
Safety Instructions……………………………………………………………….. 167
Applicable Models…………………………………………………………………. 167
General………………………………………………………………………….. 168
Warning for Counterweight and Front Attachment Removal…………………………….. 168
Removal………………………………………………………………………….. 170
Installation……………………………………………………………………… 171
Fuel Tank SP002911……………………………………………………………………. 173
Safety Instructions……………………………………………………………….. 177
Applicable Models…………………………………………………………………. 177
General Description……………………………………………………………….. 178
Parts List……………………………………………………………………. 178
Specifications………………………………………………………………… 179
Removal………………………………………………………………………….. 180
Installation……………………………………………………………………… 184
Start-up Procedures……………………………………………………………….. 187
Fuel Transfer Pump (Option) SP002912……………………………………………………. 189
Safety Instructions……………………………………………………………….. 193
Applicable Models…………………………………………………………………. 193
General Description……………………………………………………………….. 194
Theory of Operation……………………………………………………………. 194
Troubleshooting…………………………………………………………………… 195
Replacement of Rotor and Vane………………………………………………………. 195
Replacement of Rear Cover………………………………………………………….. 196
Replacement of Armature……………………………………………………………. 196
Swing Bearing SP002913………………………………………………………………… 197
Safety Instructions……………………………………………………………….. 201
Applicable Models…………………………………………………………………. 201
Swing Bearing Maintenance………………………………………………………….. 202
Operating Recommendation……………………………………………………….. 202
Measuring Swing Bearing Axial Play………………………………………………. 202
Measuring Bearing Lateral Play………………………………………………….. 202
Swing Bearing Basic Operation…………………………………………………… 203
Disassembly…………………………………………………………………… 203
Assembly……………………………………………………………………… 205
Swing Reduction Gear SP002526………………………………………………………….. 207
Safety Instructions……………………………………………………………….. 211
Applicable Models…………………………………………………………………. 211
General Description……………………………………………………………….. 213
Theory of Operation……………………………………………………………. 213
Reassembly……………………………………………………………………….. 214
Parts List……………………………………………………………………. 214
Shrinkage Fitting of Shaft and Flexible Bearing………………………………………. 216
Reassembly of Carrier Sub………………………………………………………….. 218
Assembly of the Main………………………………………………………………. 225
Test…………………………………………………………………………….. 237
Reassembly of Motor……………………………………………………………….. 240
Lower Structure and Chassis……………………………………………………………….. 247
Track Assembly SP002914……………………………………………………………….. 249
Safety Instructions……………………………………………………………….. 253
Applicable Models…………………………………………………………………. 253
General Description……………………………………………………………….. 254
Track Tension…………………………………………………………………….. 255
Cleaning and Inspection (Wear Limits and Tolerances)………………………………….. 257
Track Shoe……………………………………………………………………. 258
Lower Roller………………………………………………………………….. 260
Upper Roller………………………………………………………………….. 261
Front Idler…………………………………………………………………… 262
Track Shoes and Links……………………………………………………………… 263
Track Removal…………………………………………………………………. 263
Track Installation…………………………………………………………….. 264
Front Idler Roller………………………………………………………………… 265
Parts List……………………………………………………………………. 265
Front Idler Roller Disassembly………………………………………………….. 266
Front Idler Roller Reassembly…………………………………………………… 267
Lower Roller……………………………………………………………………… 269
Parts List……………………………………………………………………. 269
Lower Roller Removal…………………………………………………………… 270
Lower Roller Disassembly……………………………………………………….. 270
Lower Roller Reassembly………………………………………………………… 271
Lower Roller Installation………………………………………………………. 272
Upper Roller……………………………………………………………………… 273
Parts List……………………………………………………………………. 273
Upper Roller Removal…………………………………………………………… 274
Upper Roller Disassembly……………………………………………………….. 274
Upper Roller Reassembly………………………………………………………… 276
Track Spring and Track Adjusting Cylinder……………………………………………. 277
Parts List……………………………………………………………………. 277
Engine and Drivetrain…………………………………………………………………….. 279
QSB4.5 Engine SP002915………………………………………………………………… 281
Safety Instructions……………………………………………………………….. 287
Applicable Models…………………………………………………………………. 287
General Information……………………………………………………………….. 288
Foreword……………………………………………………………………… 288
About the Manual………………………………………………………………. 289
How to Use the Manual………………………………………………………….. 289
Symbols………………………………………………………………………. 290
Illustrations…………………………………………………………………. 291
General Safety Instructions…………………………………………………….. 292
Important Safety Notice…………………………………………………….. 292
General Repair Instructions…………………………………………………….. 295
Welding on a Vehicle with an Electronic Controlled Fuel System………………….. 296
General Cleaning Instructions…………………………………………………… 297
Definition of Clean………………………………………………………… 297
Abrasive Pads and Abrasive Paper…………………………………………….. 298
Gasket Surfaces……………………………………………………………. 300
Solvent and Acid Cleaning…………………………………………………… 300
Steam Cleaning…………………………………………………………….. 301
Plastic Bead Cleaning………………………………………………………. 302
Fuel System……………………………………………………………….. 304
Acronyms and Abbreviations……………………………………………………… 306
Engine Identification……………………………………………………………… 308
Engine Data Plate……………………………………………………………… 308
Cummins® Engine Nomenclature……………………………………………………. 310
Fuel Injection Pump Data Plate………………………………………………….. 310
ECM Data Plate………………………………………………………………… 311
Air Compressor………………………………………………………………… 312
Turbocharger Data Plate………………………………………………………… 312
Exhaust System………………………………………………………………… 313
Engine Diagrams……………………………………………………………….. 314
Engine Views………………………………………………………………. 314
Operating Instructions…………………………………………………………….. 319
Operating Instructions – Overview……………………………………………….. 319
General Information………………………………………………………… 319
Normal Starting Procedure………………………………………………………. 320
Starting………………………………………………………………….. 320
Jump-starting……………………………………………………………… 323
Cold Weather Starting………………………………………………………….. 324
General Information………………………………………………………… 324
Using Starting Aids………………………………………………………… 324
Starting Procedure After Extended Shutdown or Oil Change…………………………… 324
General Information………………………………………………………… 324
Operating the Engine…………………………………………………………… 325
Normal……………………………………………………………………. 325
Cold Weather………………………………………………………………. 326
Winterfronts and Shutters…………………………………………………… 326
Engine Operating Range…………………………………………………………. 326
General Information………………………………………………………… 326
Engine Shutdown……………………………………………………………….. 327
General Information………………………………………………………… 327
Electromagnetic Interference (EMI)………………………………………………. 328
General Information………………………………………………………… 328
System EMI Susceptibility…………………………………………………… 328
System EMI Radiation Levels…………………………………………………. 328
Turbocharger, Variable Flow…………………………………………………….. 329
Initial Check……………………………………………………………… 329
Leak Test…………………………………………………………………. 331
Preparatory Steps………………………………………………………….. 334
Remove……………………………………………………………………. 335
Clean and Inspect for Reuse…………………………………………………. 335
Install…………………………………………………………………… 336
Prime…………………………………………………………………….. 337
Finishing Steps……………………………………………………………. 338
Maintenance Guidelines…………………………………………………………….. 339
Maintenance Guidelines – Overview……………………………………………….. 339
General Information………………………………………………………… 339
Tool Requirements……………………………………………………………… 340
General Information………………………………………………………… 340
Maintenance Schedule…………………………………………………………… 340
General Information………………………………………………………… 340
Oil Drain Intervals………………………………………………………… 342
Maintenance Procedures at Daily Interval…………………………………………….. 343
Daily Maintenance Procedures – Overview………………………………………….. 343
General Information………………………………………………………… 343
Unusual System Noise……………………………………………………….. 344
Air Tanks and Reservoirs……………………………………………………….. 344
Drain…………………………………………………………………….. 344
Crankcase Breather Tube………………………………………………………… 344
Maintenance Check………………………………………………………….. 344
Fuel-Water Separator…………………………………………………………… 346
Drain…………………………………………………………………….. 346
Canister Type……………………………………………………………… 346
Spin-on Type………………………………………………………………. 346
Lubricating Oil Level………………………………………………………….. 347
Maintenance Check………………………………………………………….. 347
Cooling Fan…………………………………………………………………… 347
Inspect for Reuse………………………………………………………….. 347
Coolant Level…………………………………………………………………. 348
Maintenance Check………………………………………………………….. 348
Air Intake Piping……………………………………………………………… 349
Maintenance Check………………………………………………………….. 349
Maintenance Procedures at 250 Hours or 3 Months………………………………………. 350
Maintenance Procedures – Overview……………………………………………….. 350
General Information………………………………………………………… 350
Radiator Hoses………………………………………………………………… 350
Maintenance Check………………………………………………………….. 350
Air Intake Piping……………………………………………………………… 350
Maintenance Check………………………………………………………….. 350
Radiator……………………………………………………………………… 351
General Information………………………………………………………… 351
Initial Check……………………………………………………………… 351
Charge-Air Cooler……………………………………………………………… 352
Initial Check……………………………………………………………… 352
Leak Test…………………………………………………………………. 353
Pressure Test……………………………………………………………… 355
Temperature Differential Test……………………………………………….. 356
Preparatory Steps………………………………………………………….. 357
Remove……………………………………………………………………. 357
Clean…………………………………………………………………….. 357
Install…………………………………………………………………… 359
Finishing Steps……………………………………………………………. 359
Charge-Air Piping……………………………………………………………… 359
Maintenance Check………………………………………………………….. 359
Maintenance Procedures at 500 Hours or 6 Months………………………………………. 360
Maintenance Procedures – Overview……………………………………………….. 360
General Information………………………………………………………… 360
Fuel Filter (Spin-on Type)……………………………………………………… 360
General Information………………………………………………………… 360
Preparatory Steps………………………………………………………….. 361
Remove……………………………………………………………………. 362
Install…………………………………………………………………… 362
Finishing Steps……………………………………………………………. 363
Prime…………………………………………………………………….. 363
Lubricating Oil and Filters…………………………………………………….. 365
Drain…………………………………………………………………….. 365
Remove……………………………………………………………………. 365
Install…………………………………………………………………… 366
Fill……………………………………………………………………… 367
Engine Coolant Antifreeze………………………………………………………. 369
Maintenance Check………………………………………………………….. 369
Batteries…………………………………………………………………….. 369
Inspect…………………………………………………………………… 369
Battery Cables and Connections………………………………………………….. 370
Initial Check……………………………………………………………… 370
Radiator Pressure Cap………………………………………………………….. 372
General Information………………………………………………………… 372
Inspect for Reuse………………………………………………………….. 373
Pressure Test……………………………………………………………… 373
Maintenance Procedures at 1,000 Hours or 1 Year………………………………………. 374
Maintenance Procedures – Overview……………………………………………….. 374
General Information………………………………………………………… 374
Cooling Fan Belt Tensioner……………………………………………………… 374
Initial Check……………………………………………………………… 374
Preparatory Steps………………………………………………………….. 376
Remove……………………………………………………………………. 376
Clean and Inspect for Reuse…………………………………………………. 376
Install…………………………………………………………………… 377
Finishing Steps……………………………………………………………. 378
Drive Belt, Cooling Fan………………………………………………………… 378
General Information………………………………………………………… 378
Troubleshooting……………………………………………………………. 379
Preparatory Steps………………………………………………………….. 381
Remove……………………………………………………………………. 382
Clean and Inspect for Reuse…………………………………………………. 383
Install…………………………………………………………………… 384
Finishing Steps……………………………………………………………. 384
Air Compressor Discharge Lines………………………………………………….. 385
General Information………………………………………………………… 385
Maintenance Check………………………………………………………….. 385
Fan Hub, Belt Driven…………………………………………………………… 386
Maintenance Check………………………………………………………….. 386
Maintenance Procedures at 2,000 Hours or 2 Years……………………………………… 387
Maintenance Procedures – Overview……………………………………………….. 387
General Information………………………………………………………… 387
Vibration Damper, Viscous………………………………………………………. 387
Inspect…………………………………………………………………… 387
Vibration Damper, Rubber……………………………………………………….. 388
Inspect…………………………………………………………………… 388
Engine Steam Cleaning………………………………………………………….. 388
Clean…………………………………………………………………….. 388
Crankcase Breather (External)…………………………………………………… 389
General Information………………………………………………………… 389
Preparatory Steps………………………………………………………….. 389
Remove……………………………………………………………………. 390
Disassemble……………………………………………………………….. 390
Clean and Inspect for Reuse…………………………………………………. 391
Assemble………………………………………………………………….. 392
Install…………………………………………………………………… 392
Finishing Steps……………………………………………………………. 393
Cooling System………………………………………………………………… 394
Preparatory Steps………………………………………………………….. 394
Drain…………………………………………………………………….. 395
Flush…………………………………………………………………….. 395
Fill……………………………………………………………………… 397
Maintenance Procedures at 2,000 Hours……………………………………………….. 399
Maintenance Procedures – Overview……………………………………………….. 399
General Information………………………………………………………… 399
Crankcase Ventilation Filter……………………………………………………. 399
General Information………………………………………………………… 399
Preparatory Steps………………………………………………………….. 400
Remove……………………………………………………………………. 400
Clean and Inspect for Reuse…………………………………………………. 401
Install…………………………………………………………………… 402
Finishing Steps……………………………………………………………. 402
Maintenance Procedures at 5,000 Hours or 4 Years……………………………………… 403
Maintenance Procedures – Overview……………………………………………….. 403
General Information………………………………………………………… 403
Overhead Set………………………………………………………………….. 403
Preparatory Steps………………………………………………………….. 403
Adjust……………………………………………………………………. 403
Finishing Steps……………………………………………………………. 405
Adjustment, Repair, and Replacement…………………………………………………. 406
Alternator……………………………………………………………………. 406
Initial Check……………………………………………………………… 406
Test……………………………………………………………………… 406
Preparatory Steps………………………………………………………….. 409
Remove……………………………………………………………………. 409
Install…………………………………………………………………… 410
Finishing Steps……………………………………………………………. 410
Lubricating Oil Dipstick……………………………………………………….. 411
Calibrate…………………………………………………………………. 411
Rocker Lever Cover…………………………………………………………….. 412
General Information………………………………………………………… 412
Preparatory Steps………………………………………………………….. 412
Remove……………………………………………………………………. 413
Install…………………………………………………………………… 413
Finishing Steps……………………………………………………………. 414
Coolant Thermostat…………………………………………………………….. 414
General Information………………………………………………………… 414
Preparatory Steps………………………………………………………….. 415
Remove……………………………………………………………………. 416
Clean and Inspect for Reuse…………………………………………………. 417
Measure…………………………………………………………………… 417
Install…………………………………………………………………… 418
Finishing Steps……………………………………………………………. 418
Fan Spacer and Pulley………………………………………………………….. 419
Preparatory Steps………………………………………………………….. 419
Remove……………………………………………………………………. 419
Clean and Inspect for Reuse…………………………………………………. 420
Install…………………………………………………………………… 420
Finishing Steps……………………………………………………………. 421
Starting Motor………………………………………………………………… 422
Initial Check……………………………………………………………… 422
Remove……………………………………………………………………. 424
Install…………………………………………………………………… 424
Finishing Steps……………………………………………………………. 424
EGR Connection Tubes…………………………………………………………… 425
General Information………………………………………………………… 425
Preparatory Steps………………………………………………………….. 425
Remove……………………………………………………………………. 425
Clean and Inspect for Reuse…………………………………………………. 427
Install…………………………………………………………………… 428
Finishing Steps……………………………………………………………. 429
System Diagrams…………………………………………………………………… 430
System Diagrams – Overview……………………………………………………… 430
General Information………………………………………………………… 430
Fuel System…………………………………………………………………… 431
Lubricating Oil System…………………………………………………………. 432
Cooling System………………………………………………………………… 437
Air Intake System……………………………………………………………… 439
Exhaust System………………………………………………………………… 440
Compressed Air System………………………………………………………….. 442
Service Literature………………………………………………………………… 443
Additional Service Literature…………………………………………………… 443
General Information………………………………………………………… 443
Service Literature Ordering Location…………………………………………….. 443
Contact Information………………………………………………………… 443
Cummins Customized Parts Catalog………………………………………………… 444
General Information………………………………………………………… 444
Ordering the Customized Parts Catalog………………………………………… 444
Service Assistance………………………………………………………………… 446
Routine Service and Parts………………………………………………………. 446
General Information………………………………………………………… 446
Emergency and Technical Service…………………………………………………. 446
General Information………………………………………………………… 446
Problem Solving……………………………………………………………….. 446
General Information………………………………………………………… 446
Division and Regional Offices…………………………………………………… 448
Locations…………………………………………………………………. 448
Distributors and Branches………………………………………………………. 450
United States……………………………………………………………… 450
Canada……………………………………………………………………. 465
China, People’s Republic……………………………………………………. 467
Australia…………………………………………………………………. 468
New Zealand……………………………………………………………….. 473
Regional Offices – International………………………………………………… 474
Locations…………………………………………………………………. 474
Distributors – International……………………………………………………. 479
Locations…………………………………………………………………. 479
Troubleshooting Symptoms…………………………………………………………… 500
Troubleshooting Procedures and Techniques………………………………………… 500
General Information………………………………………………………… 500
Troubleshooting Symptoms Charts…………………………………………………. 501
General Information………………………………………………………… 501
Air Compressor Air Pressure Rises Slowly……………………………………… 501
Air Compressor Cycles Frequently…………………………………………….. 502
Air Compressor Noise is Excessive……………………………………………. 502
Air Compressor Pumping Excess Lubricating Oil into the Air System……………….. 503
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)…. 503
Air Compressor Will Not Stop Pumping…………………………………………. 504
Alternator Not Charging or Insufficient Charging………………………………. 504
Alternator Overcharging…………………………………………………….. 505
Coolant Contamination………………………………………………………. 506
Coolant Loss – External…………………………………………………….. 507
Coolant Temperature Above Normal – Gradual Overheat……………………………. 508
Coolant Temperature Above Normal – Sudden Overheat…………………………….. 510
Coolant Temperature Below Normal…………………………………………….. 511
Cranking Fuel Pressure is Low……………………………………………….. 511
Engine Acceleration or Response Poor…………………………………………. 512
Engine Difficult to Start or Will Not Start (Exhaust Smoke)…………………….. 514
Coolant Temperature Above Normal – Sudden Overheat…………………………….. 516
Engine Noise Excessive – Combustion Knocks……………………………………. 517
Engine Noise Excessive……………………………………………………… 518
Engine Power Output Low…………………………………………………….. 520
Engine Runs Rough at Idle…………………………………………………… 522
Engine Runs Rough or Misfires……………………………………………….. 523
Engine Shuts Off Unexpectedly or Dies During Deceleration………………………. 524
Engine Speed Surges at Low or High Idle………………………………………. 525
Engine Speed Surges in PTO or Cruise Control………………………………….. 526
Engine Speed Surges Under Load or in Operating Range…………………………… 526
Engine Starts But Will Not Keep Running………………………………………. 530
Engine Vibration Excessive………………………………………………….. 531
Engine Will Not Crank or Cranks Slowly (Air Starter)…………………………… 532
Engine Will Not Crank or Cranks Slowly (Electric Starter)………………………. 533
Engine Will Not Reach Rated Speed (rpm)………………………………………. 534
Fault Code Warning Lights Do Not Illuminate…………………………………… 535
Fault Code Warning Lights Do Not Illuminate…………………………………… 535
Fuel Consumption Excessive………………………………………………….. 536
Fuel in Coolant……………………………………………………………. 537
Fuel in the Lubricating Oil…………………………………………………. 537
Intake Manifold Air Temperature Above Specification……………………………. 538
Intake Manifold Pressure (Boost) is Below Normal………………………………. 539
Lubricating Oil Consumption Excessive………………………………………… 540
Lubricating Oil Contaminated………………………………………………… 541
Lubricating Oil Loss……………………………………………………….. 541
Lubricating Oil Pressure High……………………………………………….. 542
Smoke, Black – Excessive……………………………………………………. 543
Smoke, White – Excessive……………………………………………………. 543
Turbocharger Leaks Engine Oil or Fuel………………………………………… 545
Maintenance Specifications…………………………………………………………. 546
General Engine………………………………………………………………… 546
Fuel System…………………………………………………………………… 548
Lubricating Oil System…………………………………………………………. 548
Cooling System………………………………………………………………… 549
Air Intake System……………………………………………………………… 549
Exhaust System………………………………………………………………… 550
Electrical System……………………………………………………………… 550
Specifications…………………………………………………………….. 550
Batteries (Specific Gravity)………………………………………………… 550
Cummins®/Fleetguard® Filter…………………………………………………….. 551
Specifications…………………………………………………………….. 551
General Information………………………………………………………… 551
Fuel Recommendations and Specifications………………………………………….. 552
Fuel Recommendations……………………………………………………….. 552
Lubricating Oil Recommendations and Specifications………………………………… 554
General Information………………………………………………………… 554
New Engine Break-in Oils……………………………………………………. 556
AfterMarket Oil Additive Usage………………………………………………. 556
Coolant Recommendations and Specifications……………………………………….. 557
Fully Formulated Coolant/Antifreeze………………………………………….. 557
Cooling System Sealing Additives…………………………………………….. 558
Cooling System Soluble Oils…………………………………………………. 559
Drive Belt Tension…………………………………………………………….. 559
Tension Chart……………………………………………………………… 559
Sealants……………………………………………………………………… 560
General Information………………………………………………………… 560
Cap Screw Markings and Torque Values…………………………………………….. 561
General Information………………………………………………………… 561
Cap Screw Markings and Torque Values – Metric…………………………………. 562
Cap Screw Markings and Torque Values – U.S. Customary………………………….. 563
Warranty…………………………………………………………………………. 564
All Engines United States and Canada Industrial (Off-Highway)………………………. 564
Coverage………………………………………………………………….. 564
Cummins Responsibilities……………………………………………………. 565
Owner Responsibilities……………………………………………………… 565
Limitations……………………………………………………………….. 566
Emission Warranty………………………………………………………….. 568
All Engines International Industrial (Off- Highway)……………………………….. 569
Coverage………………………………………………………………….. 569
Cummins Responsibilities……………………………………………………. 570
Owner Responsibilities……………………………………………………… 570
Limitations……………………………………………………………….. 571
California Emission Control System Warranty, Off-Highway…………………………… 573
Products Warranted…………………………………………………………. 573
Your Warranty Rights and Obligations…………………………………………. 573
Manufacturer’s Warranty Coverage…………………………………………….. 573
Coverage………………………………………………………………….. 574
Owner’s Warranty Responsibilities……………………………………………. 574
Replacement Parts………………………………………………………….. 575
Cummins Responsibilities……………………………………………………. 575
Emergency Repairs………………………………………………………….. 575
Warranty Limitations……………………………………………………….. 576
Drive Coupling (Main Pump) SP002931…………………………………………………….. 577
Safety Instructions……………………………………………………………….. 581
Applicable Models…………………………………………………………………. 581
Drive Coupling……………………………………………………………………. 582
Special Tools…………………………………………………………………….. 583
Installation of Drive Coupling……………………………………………………… 584
Installation Procedure…………………………………………………………. 586
Hydraulics………………………………………………………………………………. 587
Hydraulic System Troubleshooting, Testing and Adjustment SP002916………………………….. 589
Safety Instructions……………………………………………………………….. 593
Applicable Models…………………………………………………………………. 593
Hydraulic System – General Notes……………………………………………………. 594
Hydraulic Schematic……………………………………………………………….. 595
General Notes…………………………………………………………………. 595
Operation of Working Components…………………………………………………….. 597
Boom Operating Circuit…………………………………………………………. 597
Boom Up Circuit……………………………………………………………….. 597
Boom Down Circuit……………………………………………………………… 597
Arm Operating Circuit………………………………………………………….. 598
Arm Crowd Circuit……………………………………………………………… 598
Arm Dump Circuit………………………………………………………………. 598
Bucket Operating Circuit……………………………………………………….. 599
Bucket Crowd Circuit…………………………………………………………… 599
Bucket Dump Circuit……………………………………………………………. 599
Swing Operating Circuit………………………………………………………… 599
Right Swing Operating Circuit…………………………………………………… 599
Left Swing Operating Circuit……………………………………………………. 600
Swing Relief Valve and Makeup Valve……………………………………………… 600
Travel Operating Circuit……………………………………………………….. 600
Forward Travel Circuit…………………………………………………………. 600
Reverse Travel Circuit…………………………………………………………. 601
Procedural Troubleshooting Baseline Recommendations…………………………………… 602
Initial Checks and Tests to Establish Operating Condition of the Excavator…………… 602
Pilot Pressure……………………………………………………………………. 604
Adjustment and Testing…………………………………………………………. 604
Power Mode Valve………………………………………………………………….. 605
Current Signal and Hydraulic Pressure Adjustments…………………………………. 605
Swing Priority Valve………………………………………………………………. 606
Control Valve Pressure and Current Adjustments……………………………………. 606
Pressure Up Valve…………………………………………………………………. 607
Checks and Adjustments…………………………………………………………. 607
Pump Input Power Control…………………………………………………………… 609
Pump Regulator Adjustment………………………………………………………. 609
Flow Meter and Flow Meter Kit Installation and Testing………………………………… 612
Swing System Troubleshooting……………………………………………………….. 614
Precautions/Initial Checks……………………………………………………… 614
Swing Relief Valve Checking and Adjustment……………………………………….. 615
Troubleshooting – Swing Gearbox…………………………………………………….. 617
Troubleshooting – Hydraulic Problems………………………………………………… 618
Troubleshooting – Control Valve…………………………………………………….. 620
Troubleshooting – Travel Control Valve………………………………………………. 621
Troubleshooting – Joystick Control Valve…………………………………………….. 622
Accumulator SP002455………………………………………………………………….. 623
Safety Instructions……………………………………………………………….. 627
Applicable Models…………………………………………………………………. 627
General Description……………………………………………………………….. 628
Specifications………………………………………………………………… 630
Center Joint (Swivel) SP002917…………………………………………………………. 631
Safety Instructions……………………………………………………………….. 635
Applicable Models…………………………………………………………………. 635
General Description……………………………………………………………….. 637
Parts List……………………………………………………………………. 638
Troubleshooting, Testing and Adjustment……………………………………………… 639
Inspection……………………………………………………………………. 639
Testing………………………………………………………………………. 639
Disassembly………………………………………………………………………. 640
Reassembly……………………………………………………………………….. 641
Cylinders SP002918……………………………………………………………………. 643
Safety Instructions……………………………………………………………….. 647
Applicable Models…………………………………………………………………. 647
General Description……………………………………………………………….. 648
Theory of Operation……………………………………………………………. 648
Parts List……………………………………………………………………. 650
Special Tools and Materials………………………………………………………… 656
Piston Nut……………………………………………………………………. 656
Piston Jig……………………………………………………………………. 658
Steel Bushing Jig……………………………………………………………… 661
Dust Wiper Jig………………………………………………………………… 664
Slipper Seal Jig………………………………………………………………. 667
Slipper Seal Straightening Jig………………………………………………….. 670
Disassembly………………………………………………………………………. 673
Reassembly……………………………………………………………………….. 678
Swing Motor SP002919………………………………………………………………….. 683
Safety Instructions……………………………………………………………….. 687
Applicable Models…………………………………………………………………. 687
Instruction Manual………………………………………………………………… 688
Indication of Type…………………………………………………………….. 688
Specifications………………………………………………………………… 689
Construction and Principles of Working…………………………………………… 690
Precaution In Use……………………………………………………………… 697
Troubleshooting……………………………………………………………….. 701
Maintenance Manual………………………………………………………………… 704
Disassembling and Assembling……………………………………………………. 704
Maintenance Standards………………………………………………………….. 717
Travel Device SP002920………………………………………………………………… 719
Safety Instructions……………………………………………………………….. 723
Applicable Models…………………………………………………………………. 723
Product Overview………………………………………………………………….. 724
General Specifications…………………………………………………………. 724
External Dimensions……………………………………………………………….. 725
General Description……………………………………………………………….. 726
Operating Description……………………………………………………………… 729
Reduction Gear………………………………………………………………… 729
Function………………………………………………………………….. 729
Operating Description………………………………………………………. 729
Hydraulic Drives………………………………………………………………. 730
Function………………………………………………………………….. 730
Operating Principles and Description…………………………………………. 731
Precautions for Use……………………………………………………………….. 738
Installation (Refer to Diagram of External Dimensions)…………………………….. 738
Mounting Bolt Torque……………………………………………………….. 738
Tubing……………………………………………………………………….. 739
Fluid Selection……………………………………………………………….. 739
Maintenance and Inspection…………………………………………………………. 740
Daily Inspection………………………………………………………………. 740
Changing Fluid………………………………………………………………… 741
Changing Lubrication…………………………………………………………… 741
Seals Table………………………………………………………………………. 743
Troubleshooting…………………………………………………………………… 744
Outline of Maintenance…………………………………………………………….. 746
Tools………………………………………………………………………… 746
Bolts………………………………………………………………………… 746
Equipments……………………………………………………………………. 747
Fabricated Tools………………………………………………………………. 747
Torque……………………………………………………………………….. 751
Weight Table………………………………………………………………….. 751
Disassembling…………………………………………………………………….. 752
Work Preparation………………………………………………………………. 752
General Precautions for Work……………………………………………………. 752
Disassembling Order……………………………………………………………. 753
Maintenance Standards……………………………………………………………… 770
Seals………………………………………………………………………… 770
Maintenance Standards for Wearable Parts…………………………………………. 770
Assembling……………………………………………………………………….. 772
Preparation…………………………………………………………………… 772
General Precautions for Assembling Work………………………………………….. 772
Order of Assembling……………………………………………………………. 773
Performance Test…………………………………………………………… 789
Main Pump SP002930……………………………………………………………………. 791
Safety Instructions……………………………………………………………….. 795
Applicable Models…………………………………………………………………. 795
Disassembling and Reassembling Procedures……………………………………………. 797
Tool…………………………………………………………………………. 797
Disassembling Procedures……………………………………………………….. 798
Reassembling Procedures………………………………………………………… 802
Pump Maintenance Criteria………………………………………………………….. 806
Worn Part Replacement Criteria………………………………………………….. 806
Installation of Tandem Type Double-Pump………………………………………….. 807
Construction of Tandem Type Double- Pump…………………………………………. 808
Gear Pump SP002500……………………………………………………………………. 811
Safety Instructions……………………………………………………………….. 815
Applicable Models…………………………………………………………………. 815
Single Gear Pump………………………………………………………………….. 816
Disassembly…………………………………………………………………… 816
Reassembly……………………………………………………………………. 818
Main Control Valve SP002528……………………………………………………………. 823
Safety Instructions……………………………………………………………….. 827
Applicable Models…………………………………………………………………. 827
General Description……………………………………………………………….. 829
Theory of Operation……………………………………………………………. 830
Composite Operation……………………………………………………………. 841
Antidrift Valve……………………………………………………………….. 842
Disassembly………………………………………………………………………. 844
Precautions for Disassembly…………………………………………………….. 844
Disassembling Procedures……………………………………………………….. 844
Washing………………………………………………………………………….. 850
Inspection……………………………………………………………………….. 850
Assembling……………………………………………………………………….. 851
Subassembly…………………………………………………………………… 851
Assembling Control Valve……………………………………………………….. 854
Relief Valve……………………………………………………………………… 860
Main Relief Valve……………………………………………………………… 860
Overload Relief Valve………………………………………………………….. 864
Negacon Relief Valve…………………………………………………………… 867
Adjusting Relief Valve…………………………………………………………. 869
Installation……………………………………………………………………… 870
Operation………………………………………………………………………… 870
Control Valve Specification………………………………………………………… 871
Troubleshooting…………………………………………………………………… 872
Control Valve: Overall…………………………………………………………. 872
Hydraulic System: Overall………………………………………………………. 873
Remote Control Valve (Work Lever / Joystick) SP002921…………………………………….. 875
Safety Instructions……………………………………………………………….. 879
Applicable Models…………………………………………………………………. 879
General Description……………………………………………………………….. 881
Theory of Operation……………………………………………………………. 881
Parts List……………………………………………………………………. 882
Specifications………………………………………………………………… 884
Torques………………………………………………………………………. 884
Tools and Materials……………………………………………………………….. 884
Disassembly………………………………………………………………………. 885
Reassembly……………………………………………………………………….. 888
Start-up Procedures……………………………………………………………….. 896
Travel Control Valve (with Damper) SP002922……………………………………………… 897
Safety Instructions……………………………………………………………….. 901
Applicable Models…………………………………………………………………. 901
General Description……………………………………………………………….. 902
Theory of Operation……………………………………………………………. 902
Pressure Reducing Valve………………………………………………………… 903
Operating Theory of Damper Mechanism…………………………………………….. 904
Causes of Faults and Measures………………………………………………………. 905
Parts List……………………………………………………………………. 906
Specification…………………………………………………………………. 908
Torques………………………………………………………………………. 908
Removal………………………………………………………………………….. 909
Disassembly………………………………………………………………………. 912
Cleaning and Inspection (Wear Limits and Tolerances)………………………………….. 914
Reassembly……………………………………………………………………….. 915
Installation……………………………………………………………………… 920
Start-up Procedures……………………………………………………………….. 923
Solenoid Valve Assembly SP002923……………………………………………………….. 925
Safety Instructions……………………………………………………………….. 929
Applicable Models…………………………………………………………………. 929
Parts List……………………………………………………………………….. 930
Functions of 5-Solenoid Valve Assembly Package……………………………………….. 931
Functions of Solenoid Valve Assembly Package……………………………………… 931
Assembly Diagram and Tools Required……………………………………………… 934
Solenoid Valve Diagram…………………………………………………………. 936
Check Points and Solutions for Problems………………………………………….. 937
Breaker EPPR Valve (Option) SP002458……………………………………………………. 939
Safety Instructions……………………………………………………………….. 943
Applicable Models…………………………………………………………………. 943
Structure………………………………………………………………………… 944
Parts List……………………………………………………………………. 944
Functions and Operation……………………………………………………………. 945
Cautions for Operation…………………………………………………………….. 945
Maintenance Instructions…………………………………………………………… 946
Maintenance…………………………………………………………………… 946
Disassembly…………………………………………………………………… 947
Assembly……………………………………………………………………… 948
Hydraulic Schematic (DX140LCR-3) SP002924……………………………………………….. 951
Safety Instructions……………………………………………………………….. 955
Applicable Models…………………………………………………………………. 955
DX140LCR-3……………………………………………………………………….. 957
Electrical System………………………………………………………………………… 959
Electrical System SP002925…………………………………………………………….. 961
Safety Instructions……………………………………………………………….. 967
Applicable Models…………………………………………………………………. 967
Introduction……………………………………………………………………… 969
Electrical Supply System…………………………………………………………… 970
Engine Starting Circuit……………………………………………………………. 972
Start Operation……………………………………………………………….. 972
After Start…………………………………………………………………… 974
Engine Preheating System…………………………………………………………… 976
Engine Stop………………………………………………………………………. 978
Charging System…………………………………………………………………… 980
Monitoring System…………………………………………………………………. 981
Instrument Panel………………………………………………………………. 982
Monitoring System Schematic…………………………………………………….. 984
Operation………………………………………………………………………… 986
Instruments…………………………………………………………………… 986
Warning and Indicator Lights……………………………………………………….. 988
Indication of Warning Lights……………………………………………………. 988
Indication of Multifunction Gauge……………………………………………….. 989
Initial Operation…………………………………………………………………. 991
Mode Selector Switch………………………………………………………………. 991
Graphic Information Area Display……………………………………………………. 992
Overview……………………………………………………………………… 992
Main Menus for the Graphic Display Area………………………………………….. 993
Menu Selector Buttons………………………………………………………….. 993
Main Menu………………………………………………………………………… 994
Language……………………………………………………………………… 994
Set Clock…………………………………………………………………….. 995
Filter/Oil Info……………………………………………………………….. 995
Adjust Display………………………………………………………………… 996
Set Password (Lock and Unlock)………………………………………………….. 997
Vehicle Configuration………………………………………………………….. 998
Special Menu………………………………………………………………………1003
Entering/Accessing and Exiting/Escaping Menus……………………………………..1003
Special Menu Selections…………………………………………………………1004
Electronic Hydraulic Control System (EPOS)……………………………………………1022
Control System Schematic………………………………………………………..1022
Power Mode Control…………………………………………………………………1024
Operation……………………………………………………………………..1026
Power / Economy Mode Control – Circuit Diagram………………………………………..1030
Engine Control System………………………………………………………………1032
Engine Control Dial………………………………………………………………..1033
Engine Control Circuit Diagram………………………………………………………1034
Automatic Deceleration Control (Auto Idle Control)…………………………………….1036
Engine Overheat Protection System……………………………………………………1038
Power Boost Mode…………………………………………………………………..1040
Operation……………………………………………………………………..1040
Power Boost Control – Circuit Diagram…………………………………………….1042
Automatic Travel Speed Control………………………………………………………1044
Automatic Travel Speed Control – Circuit Diagram…………………………………..1046
Self-diagnostic Function……………………………………………………………1047
EPOS Controller………………………………………………………………..1047
Air Conditioner System……………………………………………………………..1049
Outline……………………………………………………………………….1049
Internal and External Filters……………………………………………………1050
Air-Conditioning System Layout…………………………………………………..1051
Air Conditioner/Heater Circuit Diagram……………………………………………1052
Air Conditioner/Heater Unit……………………………………………………..1053
Airflow Control………………………………………………………………..1056
Airflow Control Motor…………………………………………………………..1057
Blower Motor…………………………………………………………………..1057
Coolant Flow Control Valve………………………………………………………1058
Temperature Level Control and Display…………………………………………….1059
Control Panel………………………………………………………………….1060
Compressor…………………………………………………………………….1060
Receiver Dryer…………………………………………………………………1061
Troubleshooting……………………………………………………………………1062
Weight of R134a Gas Used In Machines…………………………………………………1064
Refrigerant System Repairs………………………………………………………….1065
Refrigerant Safe Handling Procedures……………………………………………..1065
Repair and Replacement Procedure…………………………………………………1066
Refrigerant Recovery……………………………………………………………1068
Vacuuming Refrigerant System…………………………………………………….1068
Leakage Check………………………………………………………………….1070
Refrigerant Charging……………………………………………………………1070
Inspecting System For Leakage……………………………………………………1072
Wiper System………………………………………………………………………1073
Wiper Circuit………………………………………………………………….1073
Wiper operation………………………………………………………………..1074
Lighting System……………………………………………………………………1076
Lighting System Circuit Diagram………………………………………………….1076
Kind of Light………………………………………………………………….1077
Operation……………………………………………………………………..1077
Overload Warning Device…………………………………………………………….1078
Overload Warning Device Circuit Diagram…………………………………………..1078
Audio Controller…………………………………………………………………..1079
Audio Controller Circuit Diagram…………………………………………………1079
Electrical Schematic SP002926…………………………………………………………..1081
Safety Instructions………………………………………………………………..1085
Applicable Models………………………………………………………………….1085
DX140LCR-3………………………………………………………………………..1087
Attachments………………………………………………………………………………1089
Boom and Arm SP002927………………………………………………………………….1091
Safety Instructions………………………………………………………………..1095
Applicable Models………………………………………………………………….1095
Front Attachment Pin Specifications………………………………………………….1096
DX140LCR-3…………………………………………………………………….1097
Front Attachment – Removal and Installation…………………………………………..1098
Arm Removal Procedure…………………………………………………………..1098
Boom Removal Procedure………………………………………………………….1100
Installation………………………………………………………………………1101
Arm Installation Procedure………………………………………………………1101
Boom Installation Procedure……………………………………………………..1101
Start-up Procedures………………………………………………………………..1102
Bucket SP002506……………………………………………………………………….1103
Safety Instructions………………………………………………………………..1107
Applicable Models………………………………………………………………….1107
Bucket Tooth Inspection and Replacement………………………………………………1108
Bucket O-ring Replacement…………………………………………………………..1109
Attachments……………………………………………………………………….1111
Bucket Replacement and Reversal………………………………………………….1111
Replacement……………………………………………………………………1112
Reversal………………………………………………………………………1113
Quick Coupler Operation (Optional)……………………………………………….1114
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