Doosan DX138LC Install guide

Shop
Manual
Doosan Infracore
DX138LC
DX140LC
Serial Number 6407 and Up
K1027955B

K1027955B Shop Manual
Copyright 2013 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
K1027955B
Serial Number 6407 and Up
DX138LC
DX140LC
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Table of Contents
Page I
1Table of Contents
Safety
Track Excavator Safety......................................................................... SP002984
Specifications
Specification for DX138LC/DX140LC................................................... SP002985
General Maintenance
General Maintenance Instructions........................................................ SP002454
Standard Torques................................................................................. SP002404
Upper Structure
Cabin (NON-ROPS).............................................................................. SP002994
Cabin (ROPS)....................................................................................... SP002995
Counterweight....................................................................................... SP002996
Fuel Tank.............................................................................................. SP002997
Fuel Transfer Pump (Opt)..................................................................... SP000021
Swing Bearing....................................................................................... SP001856
Swing Reduction Gear.......................................................................... SP002526
Lower Structure and Chassis
Track Assembly .................................................................................... SP002986
Engine and Drive Train
Drive Coupling (Main Pump)................................................................. SP001326
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ............... SP002214
Accumulator.......................................................................................... SP000028
Center Joint (Swivel)............................................................................. SP000029
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Table of Contents
Page II
Cylinders............................................................................................... SP000030
Swing Motor.......................................................................................... SP002527
Travel Device........................................................................................ SP002920
Main Pump............................................................................................ SP002517
Main Control Valve ............................................................................... SP002998
Remote Control Valve (Work Lever / Joystick) ..................................... SP001646
Travel Control Valve (with Damper)...................................................... SP002999
Solenoid Valve Assembly ..................................................................... SP000445
Breaker EPPR Valve (Option) .............................................................. SP002458
Hydraulic Schematic (DX138LC/DX140LC) ......................................... SP002991
Electrical System
Electrical System (NON-ROPS) ........................................................... SP002992
Electrical System (ROPS)..................................................................... SP002993
Electrical Schematic (NON-ROPS)....................................................... SP002265
Electrical Schematic (ROPS)................................................................ SP002266
Attachments
Boom and Arm...................................................................................... SP001331
Bucket................................................................................................... SP000939
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1Safety
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SP002984
Page 1
Track Excavator Safety
SP002984
TRACK EXCAVATOR SAFETYSP002984
Track
Excavator
Safety
Edition 1
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SP002984
Track Excavator Safety
Page 2
MEMO
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SP002984
Page 3
Track Excavator Safety
Table of Contents
Track Excavator Safety
Safety Instructions ................................................ 5
Applicable Models ................................................ 5
To the Operator of a DOOSAN Excavator............ 6
General Safety Essentials .................................... 9
Location of Safety Labels ................................... 10
Summary of Safety Precautions for Lifting in
Digging Mode ..................................................... 11
Unauthorized Modifications ................................ 12
General Hazard Information ............................... 12
Before Starting Engine ....................................... 22
Machine Operation ............................................. 25
Maintenance ....................................................... 33
Battery ................................................................ 42
Towing ................................................................ 44
Shipping and Transportation .............................. 45
Lifting With Sling ................................................. 45
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SP002984
Track Excavator Safety
Page 4
MEMO

SP002984
Page 5
Track Excavator Safety
SAFETY INSTRUCTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation and
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
MODEL SERIAL NUMBER RANGE
DX138LC 6407 and Up
DX140LC 5001 and Up

SP002984Track Excavator Safety
Page 6
TO THE OPERATOR OF A
DOOSAN 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-9
2. “Location of Safety Labels” on page-10
3. “Summary of Safety Precautions for Lifting in Digging
Mode” on page-11
4. “Unauthorized Modifications” on page-12
5. “General Hazard Information” on page-12
6. “Before Starting Engine” on page-22
7. “Machine Operation” on page-25
8. “Maintenance” on page-33
9. “Battery” on page-42
10. “Towing” on page-44
11. “Shipping and Transportation” on page-45
12. “Lifting With Sling” on page-45
DANGER
AVOID DEATH
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.

SP002984
Page 7
Track Excavator Safety
WARNING
AVOID DEATH OR SERIOUS INJURY
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 sent. 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.
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 must be alert
to the potential for personal injury or accidents. Always
observe safety precautions and follow recommended
procedures.

SP002984Track Excavator Safety
Page 8
Learn Signal Words Used with 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 "Exclamation Point"
symbol.
Safety precautions are described in SAFETY from page -10 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 any procedures,
contact a DOOSAN distributor.
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 threat of a hazardous situation that, if
not avoided, could result in serious injury or death. It may
also be used to alert against 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 detonate or explode if handled or treated carelessly.

SP002984
Page 9
Track Excavator Safety
GENERAL SAFETY ESSENTIALS
Accessory Applications
The excavator has been primarily designed for moving earth
with a bucket. For use as a grapple or for other object handling,
contact DOOSAN for proper installation and application. Lifting-
work applications (unless restricted or prohibited by local
regulations) are permitted in approved lift configuration, to rated
capacity only, with no side-loading. DO NOT use the machine
for activities for which it was not intended. DO NOT use the
bucket for lifting work, unless lift slings are used in the approved
configuration.
Use of an accessory hydraulic hammer (breaker), work in rough
terrain, demolition applications or other hazardous operation
may require installation of additional protective structures to
safeguard the operator.
Lifting Capacity Rating Configuration
Lifting capacity ratings that are printed at the end of this safety
section are based on the machine being level, on a firm
supporting surface, with hooks and slings attached in approved
configuration. Loads must be balanced and supported evenly.
Use tag lines to keep the load steady if wind conditions and
large surface area are a problem. Work crew hand signals,
individual tasks and safe procedures should all be universally
understood before the lift is made.
IMPORTANT
Before using the excavator to make lifts check municipal
and regional regulations or statutes that could apply.
Governing ordinances may require that all heavy lifting be
done with single purpose equipment specifically designed
for making lifts, or other local restrictions may apply.
Making heavy lifts with a general purpose excavator that
can be used for digging, loading, grading or other work may
be expressly forbidden by a regional injunction or other
legal prohibition. Always follow all of the other instructions,
guidelines and restrictions for Safe Lifting in the Operation
and Maintenance Manuals.

SP002984Track Excavator Safety
Page 10
LOCATION OF SAFETY LABELS
Location of safety labels (decals) can vary from unit to unit.
Refer to appropriate Operation and Maintenance Manual, and
parts manual for your unit.
Always replace damaged or faded decals.

SP002984
Page 11
Track Excavator Safety
SUMMARY OF SAFETY
PRECAUTIONS FOR LIFTING IN
DIGGING MODE
To lift safely while in Digging Mode, the following items must be
evaluated by the operator and the work site crew.
• Condition of ground support.
• Excavator configuration and attachments.
• Weight, lifting height and lifting radius.
• Safe rigging of the load.
• Proper handling of the suspended load.
Tag lines on opposite sides of the load can be very helpful in
keeping a suspended load secure, if they are anchored safely to
control points on the ground.
Always engage the "Digging Mode" control on the Instrument
Panel before using the excavator for lifting work.
DANGER
AVOID DEATH
Unsafe use of the excavator while making rated lifts could
cause serious, potentially fatal injuries or extensive
damage to the machine or nearby property. Do not let
anyone operate the machine unless they've been properly
trained and understand the information in the Operation
and Maintenance Manual.
WARNING
AVOID DEATH OR SERIOUS INJURY
NEVER wrap a tag line around your hands or body.
NEVER rely on tag lines or make rated lifts when wind gusts
are more than 48.3 km/h (30 MPH). Be prepared for any wind
gust when working with loads that have a large surface area.
WARNING
AVOID DEATH OR SERIOUS INJURY
If you need more information or have any questions or
concerns about safe operating procedures or working the
excavator correctly in a particular application or in the
specific conditions of your individual operating
environment, please consult your local DOOSAN
representative.

SP002984Track Excavator Safety
Page 12
UNAUTHORIZED
MODIFICATIONS
Any modification made without authorization or written approval
from DOOSAN can create a safety hazard, for which the
machine owner will be held responsible.
For safety's sake, replace all OEM parts with the correct
authorized or genuine
DOOSAN part. For example, not taking the
time to replace fasteners, bolts or nuts with the correct
replacement parts could lead to a condition where the safety of
critical assemblies are dangerously compromised.
GENERAL HAZARD
INFORMATION
Safety Rules
Only trained and authorized personnel can operate and maintain
the machine.
Follow all safety rules, precautions and instructions when
operating or performing maintenance on the machine.
Do not operate the machine if you are not feeling well, if you are
taking medication that makes you feel sleepy, if you have been
drinking, or if you are suffering from emotional problems. These
problems will interfere with your sense of judgment in
emergencies and can cause accidents.
When working with another operator or with a person on work
site traffic duty, be sure that all personnel know the nature of the
work and understand all hand signals that are to be used.
Always observe strictly any other rules related to safety.
Safety Features
Be sure that all guards and covers are installed in their proper
position. Have guards and covers repaired immediately if
damaged.
Be sure that you understand the method of use of safety
features such as safety lock lever and the seat belt, and use
them properly.
Never remove any safety features. Always keep them in good
operating condition.
Failure to use safety features according to the instructions in the
Operation and Maintenance Manual could result in serious
bodily injury.

SP002984
Page 13
Track Excavator Safety
Inside Operator's Cabin
When entering the operator's cabin, always remove all mud and
oil from the soles of your shoes. If you operate the travel pedal
with mud or oil stuck to your shoes, your foot may slip and this
can cause a serious accident.
After using the ashtray, make sure that any matches or
cigarettes are properly extinguished, and be sure to close the
ashtray. If the ashtray is left open, there is a danger of fire.
Do not stick suction pads to the window glass. Suction pads act
as a lens and can cause fire.
Do not leave lighters laying around the operator's cabin. If the
temperature inside the operator's cabin becomes high, there is a
danger that lighter may explode.
Do not use cellular telephones inside the operator's cabin when
driving or operating the machine. There is a danger that this may
lead to an unexpected accident.
Never bring any dangerous objects such as flammable or
explosive items into the operator's cabin.
To ensure safety, do not use the radio or music headphones
when operating the machine. There is a danger that this may
lead to a serious accident.
When operating the machine, do not put your hands or head out
of the window.
When standing up from the operator's seat, always place safety
lock lever securely in the "LOCK" position. If you accidentally
touch the work equipment levers when they are not locked, the
machine may suddenly move and cause serious injury or
damage.
When leaving the machine, completely lower the work
equipment to the ground, set safety lock lever to "LOCK"
position and stop engine. Use the key to lock all the equipment.
Always remove key and take it with you.
Clothing and Personal Protective Items
Secure long hair, and avoid loose clothing and jewelry. These
items have the tendency to catch on controls or protrude into
parts and cause serious injury or death.
Do not wear oily clothes. They are flammable.
Full eye protection, a hard hat, safety shoes and gloves may be
required at the work site.
While working on the machine, never use inadequate tools.
They could break or slip, causing injury, or they may not
adequately perform intended functions.
HAOA020L
Figure 1