Doosan DX140LC User manual

Operation and
Maintenance
Manual
EXCAVATOR
950106-00277CE

Copyright Doosan 2011950106-00277CE Operation and Maintenance Manual
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.
Operation and Maintenance Manual
950106-00277CE
Serial Number 5503 and Up (Except 5595, 5600)
July 2011
DX140LC
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950106-00277CE
I
Table of Contents
Table of Contents
Safety..........................................................................................1-1
To the Operator of a DOOSAN Excavator ........................................ 1-1
Location of Safety Labels................................................................... 1-4
Visibility Information ......................................................................... 1-15
Summary of Safety Precautions for Lifting in Digging Mode............ 1-17
Unauthorized Modifications.............................................................. 1-18
General Hazard Information............................................................. 1-18
Before Starting Engine..................................................................... 1-27
Machine Operation........................................................................... 1-30
Maintenance .................................................................................... 1-38
Battery.............................................................................................. 1-47
Towing ............................................................................................. 1-49
Shipping and Transportation............................................................ 1-50
Excavator Rated Lift Capacity Tables.............................................. 1-51
Operating Controls....................................................................2-1
Component Locations ........................................................................ 2-2
Operator's Area.................................................................................. 2-4
Operational Controls and Panels ....................................................... 2-6
Instrument Panel.............................................................................. 2-20
Multifunction Gauge and Graphic Information ................................. 2-26
Mode Selector Buttons..................................................................... 2-32
Setting Main Menu ........................................................................... 2-34
Flow Control..................................................................................... 2-43
Operation Selection Display............................................................. 2-45
Heater and Air Conditioner Control Panel........................................ 2-48
Stereo .............................................................................................. 2-54
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950106-00277CETable of Contents
II
Miscellaneous Electrical Devices..................................................... 2-55
Seat Adjustment............................................................................... 2-57
Ceiling Cover ................................................................................... 2-61
Front Windows ................................................................................. 2-62
Door Side Latch ............................................................................... 2-64
Cabin Storage Compartments ......................................................... 2-65
Ashtray............................................................................................. 2-65
Sun Visor ......................................................................................... 2-66
Hanger ............................................................................................. 2-67
Cup Holder....................................................................................... 2-67
Emergency Glass Breaking Tool ..................................................... 2-67
Miscellaneous Access Covers and Doors........................................ 2-68
Operation....................................................................................3-1
To Handle a New Excavator .............................................................. 3-1
Starting and Stopping the Engine ...................................................... 3-2
Safety Lever..................................................................................... 3-14
Travel ............................................................................................... 3-15
Operating Instructions...................................................................... 3-20
Operating Precautions ..................................................................... 3-27
Parking Excavator............................................................................ 3-32
Towing Procedure............................................................................ 3-33
Hydraulic Breaker ............................................................................ 3-34
Adjusting the Pump Flow ................................................................. 3-39
Operating Techniques...................................................................... 3-42
Operation Under Unusual Conditions .............................................. 3-44
Road Liners (Machine equipped with road liner) ............................. 3-48
Inspection, Maintenance and Adjustment...............................4-1
Preventive Maintenance .................................................................... 4-1
Preliminary Work Machine Setup for Maintenance............................ 4-4
Table of Recommended Lubricants ................................................... 4-6
Fluid Capacities ................................................................................. 4-8
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950106-00277CE
III
Table of Contents
Lubrication and Service Chart............................................................ 4-8
Maintenance Intervals...................................................................... 4-12
10 Hour / Daily Service .................................................................... 4-14
50 Hour / Weekly Service ................................................................ 4-25
250 Hour / Monthly Service.............................................................. 4-28
500 Hour / 3 Month Service ............................................................. 4-35
1,000 Hour / 6 Month Service .......................................................... 4-43
2,000 Hour / Yearly Service ............................................................. 4-51
4,000 Hour / Biennial Service .......................................................... 4-57
12,000 Hour / 6 Year Service........................................................... 4-58
Air-Conditioning System .................................................................. 4-59
Bolt and Nut Inspection.................................................................... 4-60
Bucket .............................................................................................. 4-68
Electrical System ............................................................................. 4-71
Engine Cooling System.................................................................... 4-75
Fuel Transfer Pump (Optional) ........................................................ 4-78
Handling of Accumulator.................................................................. 4-81
Track Tension .................................................................................. 4-82
Venting and Priming Hydraulic System............................................ 4-84
Long Term Storage .......................................................................... 4-86
Maintenance in Special Conditions.................................................. 4-88
Transportation ...........................................................................5-1
Loading and Unloading ...................................................................... 5-1
Lifting With Sling ................................................................................ 5-5
Troubleshooting ........................................................................6-1
Electrical System ............................................................................... 6-1
Engine................................................................................................ 6-2
Hydraulic System ............................................................................... 6-3
Swing System .................................................................................... 6-4
Travel System .................................................................................... 6-5
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950106-00277CETable of Contents
IV
Specification ..............................................................................7-1
Standard Specification ....................................................................... 7-1
Overall Dimensions............................................................................ 7-2
Working Range .................................................................................. 7-4
Approximate Weight of Workload Materials....................................... 7-6
Index ...........................................................................................8-1
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OP001443
1-1
Safety
OP001443
1Safety
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. “Location of Safety Labels” on page 1-4
2. “Visibility Information” on page 1-15
3. “Summary of Safety Precautions for Lifting in Digging
Mode” on page 1-17
4. “Unauthorized Modifications” on page 1-18
5. “General Hazard Information” on page 1-18
6. “Before Starting Engine” on page 1-27
7. “Machine Operation” on page 1-30
8. “Maintenance” on page 1-38
9. “Battery” on page 1-47
10. “Towing” on page 1-49
11. “Shipping and Transportation” on page 1-50
12. “Excavator Rated Lift Capacity Tables” on page 1-51
DANGER
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.
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OP001443Safety
1-2
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
WARNING
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 should be
alert to the potential for personal injury or accidents.
Always observe safety precautions and follow
recommended procedures.
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OP001443
1-3
Safety
indicated whenever you see the Safety Alert "Triangle," no
matter which signal word appears next to the "Exclamation
Point" symbol.
Safety precautions are described in SAFETY from page 1-4 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.
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OP001443Safety
1-4
LOCATION OF SAFETY LABELS
There are several specific warning signs on this machine. The
exact location of hazards and the description of the hazards are
reviewed in this section.
Please become familiarized with all warning signs.
Make sure that all the warning signs are legible. Clean the
warning signs or replace the warning signs if you cannot read
the words. Replace the illustrations if the illustrations are not
visible. When you clean the warning signs, use a cloth, water
and soap. Do not use solvent, gasoline, or other harsh
chemicals to clean the safety signs. Solvents, gasoline, or other
harsh chemicals could loosen the adhesive that secures the
warning sign. Loose adhesive will allow the warning sign to fall
off.
Replace any safety sign that is damaged, or missing. If a safety
sign is attached to a part that is replaced, install a safety sign on
the replacement part.
19 19
18 1874
16
11 11
13 12
15
9
8
1, 6,2,
3
20
5,
14
10
17
FG015969
Figure 1

OP001443
1-5
Safety
1. Warnings for Operation, Inspection
and Maintenance (950205-01466,
190-00092)
2. Warnings for High Voltage (190-00096)
190-00092
950205-01466
WARNING DANGER
At least 10m(33ft)
At least 5m(16ft)
At least 3m(10ft)
66.0 kv
275.0 kv
Line voltage
6.6 kv
Safe Distance
Keep machine and attachment a safe
SERIOUS INJURY OR DEATH
distance from electrical power lines.
ELECTROCUTION WILL CAUSE
IMPORTANT
AVOID INJURY OR DEATH
Never use the Excavator without instructions.
Read Operation & Maintenance Manual before operating.
Sound the horn to alert bystanders before operating.
Keep bystanders away from work area.
Never work under raised machine if supported only by
TO LEAVE THE EXCAVATOR :
1. Lower the attachment to the ground and make sure all
2. Lower safety lever to LOCK position.
3. Stop the engine and remove the key.
boom and arm.
controls are in neutral.
engine’s Electronic Control Unit (ECU).
Electrical welding on the frame can damage the
& Maintenance Manual before welding
Read and follow the instructions in the Operation
FG017941
FG017942
190-00096

OP001443Safety
1-6
3. Warnings When Opening a Front
Window (950205-01460)
4. Warnings for a High-pressure Cylinder
(950205-01463)
950205-01460
FG017943
950205-01463
FG017944

OP001443
1-7
Safety
5. Warnings When Adjusting Track
Tension (190-00521)
6. Warnings for Leaving Operator's Seat
(190-00094)
190-00521
FG017945
190-00094
FG017946

OP001443Safety
1-8
7. Warnings for Batteries Maintenance
(950205-01448, 190-00100)
8. Warnings for High Temperature
Hydraulic Oil (950205-01450, 190-00097)
FG017947
190-00100
950205-01448
DANGER
Keep arcs, sparks, flames and lighted tobacco
DO NOT store metal tools or flammable
Wear safety glasses and rubber gloves when
If battery acid contact occurs:
1. Flush your skin with water immediately and
2. Flush your eyes with water for 10-15 minutes.
3. Get medical attention immediately.
apply baking soda or lime to neutralize the
materials on or around batteries.
working with batteries.
BATTERY EXPLOSION OR CONTACT
WITH BATTERY ACID WILL CAUSE
SERIOUS INJURY OR DEATH
away.
acid.
FG017948
950205-01450
190-00097
Before opening cap:
1. Turn engine off.
2. Allow oil to cool.
3. Turn breather cap slowly
to relieve tank pressure.
WARNING
HOT PRESSURIZED OIL
CAN CAUSE SERIOUS
INJURY OR DEATH

OP001443
1-9
Safety
9. Warnings for Hot Coolant
(950205-01453, 190-00097)
10. Warnings for Handling an Accumulator
(
950205-01454, 190-00099)
190-00097
950205-01453
FG017949
Before opening cap, stop
FLUID HAZARD
HOT PRESSURIZED
engine and allow engine to
cool. Loosen cap slowly.
Do not loosen or open radiator
cap when engine is hot.
190-00099
950205-01454
Keep away from flame.
DO NOT weld on or drill into accumulator.
FG017950
EXPLOSION HAZARD CAN CAUSE
SERIOUS INJURY OR DEATH

OP001443Safety
1-10
11. Warnings for Rotating Parts
(950205-01467, 190-00095, 190-00557)
12. Warning Tag - Used When Inspection
and Maintenance (950205-01451,
190-00098A)
950205-01467
190-00095
190-00557
Rotating parts can cause
serious injury or death
Stop engine before servicing
FG017951
190-00098A
WARNING
950205-01451
DO NOT OPERATE
when performing inspection
or maintenance
FG017952

OP001443
1-11
Safety
13. Warning for a Hot Surface (190-00648A)
14. Caution for Hood (190-00522A)
190-00648A
FG015745
190-00522A
FG01296
5

OP001443Safety
1-12
15. Keep Out of Swing Area
(950205-01455, K1008571)
16. Warnings for Front Attachments
(950205-01464)
K1008571
DANGER
travel path.
AVOID INJURY
OR DEATH
swing area and
Keep out of
950205-01455
FG017953
950205-01464
FG017954

OP001443
1-13
Safety
17. Warning for Engine ECU (950205-01452)
18. Warning for Lifting, Tie Down
(K1042074A)
FG017955
950205-01452
the engine’s Electronic Control Unit (ECU).
Electrical welding on the frame can damage
Read and follow the instructions in the Operation
& Maintenance Manual before welding.
IMPORTANT
K1042074A
FG014828