PDF Shop Manual Doosan DX420LC Excavator - 3 MB
This is the complete factory shop manual for the Doosan DX420LC Excavator.
It provides comprehensive information for any repair or service procedure.
From the engine to the hydraulic system, every aspect of the machine is covered in detail, making it an indispensable resource for professional mechanics.
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950106-00013E
January 2011
EXCAVATOR
Shop
Manual
DX700LC
Serial Number 5001 and Up
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MEMO
Track Excavator Safety SP002135
Page 2
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Clothing and Personal Protective Items
Contain long hair, and avoid loose clothing and jewelry. They
can catch on controls or in protruding parts and cause serious
injury or death.
Do not wear oily clothes. They are highly 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 HAOA020L
adequately perform intended functions. Figure 1
Breathing Masks, Ear Protection May Be
Required
Do not forget that some risks to your health may not be
immediately apparent. Exhaust gases and noise pollution may
not be visible, but these hazards can cause disabling or
permanent injuries.
NOTE: The equivalent continuous a weighted sound
pressure level at the workstation for this machine is
73 dB (A).
Measurement is obtained on a dynamic machine
following the procedures and cabin conditions as
described in ISO 6396.
NOTE: The guaranteed sound power level emitted by the
machinery for this machine is 104 dB(A).
Measurement is obtained on a dynamic machine with
the procedures as described in 2000/14/EC.
Vibration Level Information
Hands/Arms: The weighted root mean square acceleration to
which the hands/arms are subjected, is less than 2.5 m/s2.
Whole body: The weighted root mean square acceleration to
which the whole body is subjected, is less than 0.5 m/s2.
Measurements are obtained on a representative machine, using
measuring procedures as described in the following standard:
ISO 2631/1. ISO 5349, and SAE J1166.
Track Excavator Safety SP002135
Page 13
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Travel Precautions Travel Posture
Never turn the starting switch to the "O" (OFF) position when
traveling. It is dangerous if the engine stops when the machine
is traveling. It will be impossible to operate the steering.
Attachment control levers should not be operated while
traveling.
Do not change selected travel mode (FAST/SLOW) while
traveling.
40 ~ 50 cm (16 ~ 20 in.)
Fold in work equipment so that the outer end of the boom is as
close to the machine as possible, and is 40 - 50 cm (16 - 20 in)
above ground. Incorrect
Never travel over obstacles or slopes that will cause the
machine to tilt severely. Travel around any slope or obstacle that
causes the machine to tilt 10 degrees or more to the right or left,
or 30 degrees or more from front to rear.
Do not operate the steering suddenly. The work equipment may
FG015845
hit the ground and cause the machine to lose its balance, and
this may damage the machine or structures in the area. Figure 17
When traveling on rough ground, travel at low speed, and avoid
sudden changes in direction.
Always keep to the permissible water depth. Permissible water
depth is to the center line of the upper track rollers.
When traveling over bridges or structures on private land, check
first that the bridge or structure can withstand the weight of the
machine. When traveling on public roads, check with the local
authorities and follow their instructions.
Track Excavator Safety SP002135
Page 24
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Precautions for Removal, Installation, and
Storage of Attachments
Before starting removal and installation of attachments, decide
the team leader.
Do not allow anyone except the authorized workers close to the
machine or attachment.
Place attachments that have been removed from the machine in
a safe place so that they do not fall. Put up a fence around the
attachments and take other measures to prevent unauthorized HDO1041L
persons from entering. Figure 38
Precautions When Working on Machine
When carrying out maintenance operations on the machine,
keep the area around your feet clean and tidy to prevent you
from falling. Always do the following;
• Do not spill oil or grease.
• Do not leave tools laying about.
• Watch your step when walking.
Never jump down from the machine. When getting on or off the
ARO1380L
machine, use the steps and handrails, and maintain a
Figure 39
three-point contact (both feet and one hand or both hands and
one foot) to support yourself securely.
If the job requires it, wear protective clothing.
To prevent injury from slipping or falling, when working on the
hood or covers, never use any part except the inspection
passage fitted with nonslip pads.
Lock Inspection Covers
When carrying out maintenance with the inspection cover open,
lock the cover securely in position with the lock bar.
If maintenance work is carried out with the inspection cover
open but not locked, there is danger that it may suddenly close
and cause injury if there is a gust of wind.
Track Excavator Safety SP002135
Page 35
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MEMO
Specification for DX700LC SP002136
Page 2
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Boom Type (One Piece) 7.7 m (25' 3") 6.65 m (21' 10")
3.55 m 2.9 m 4.2 m 2.9 m 2.6 m
Arm Type
(11' 8") (9' 6") (13' 9") (9' 6") (8' 6")
Bucket Type (SAE) 3.3 m3 3.3 m3 3.0 m3 3.9 m3 4.5 m3
13,250 mm 12,720 mm 13,865 mm 11,605 mm 11,345 mm
Max. Digging Reach A
(43' 6") (41' 9") (45' 6") (38' 1") (37' 3")
12,990 mm 12,450 mm 13,610 mm 11,305 mm 11,040 mm
Max. Digging Reach (Ground) B
(42' 7") (40' 10") (44' 8") (37' 1") (36' 3")
10,230 mm 10,790 mm 10,360 mm 9,860 mm 9,655 mm
Max. Radius Vertical C
(33' 7") (35' 5") (33' 12") (32' 35") (31' 8")
4,540 mm 4,530 mm 10,360 mm 3,800 mm 3,785 mm
Min. Radius 8' Line D
(14' 11") (14' 10") (33' 12") (12' 6") (12' 5")
2,350 mm 3,060 mm 170 mm 1,835 mm 2,050 mm
Min. Digging Reach E
(7' 9") (10' 0") (7") (6' 0") (6' 9")
5,780 mm 5,790 mm 5,810 mm 5,230 mm 5,195 mm
Min. Swing Radius F
(18' 12") (18' 12") (19' 1") (17' 2") (17' 1")
3,248 mm 3,950 mm 2,630 mm 3,080 mm 3,380 mm
Min. Loading Height G
(10' 8") (12' 12") (8' 8") (10' 1") (11' 1")
5,730 mm 4,060 mm 6,515 mm 3,450 mm 3,305 mm
Max. Vertical Wall Depth H
(18' 10") (13' 4") (21' 4") (11' 4") (10' 10")
8,320 mm 8,220 mm 8,660 mm 7,020 mm 6,940 mm
Max. Loading Height I
(27' 4") (26' 12") (28' 5") (23' 0") (22' 9")
8,270 mm 7,550 mm 8,910 mm 6,925 mm 6,620 mm
Max. Depth To 8' Line J
(27' 2") (24' 9") (29' 3") (22' 9") (21' 9")
10,470 mm 10,380 mm 10,795 mm 9,210 mm 9,135 mm
Max. Bucket Pin Height K
(34' 4") (34' 1") (35' 5") (30' 3") (29' 12")
8,410 mm 7,730 mm 9,030 mm 7,075 mm 6,780 mm
Max. Digging Depth L
(27' 7") (25' 4") (29' 8") (23' 3") (22' 3")
12,165 mm 12,040 mm 12,520 mm 10,740 mm 10,680 mm
Max. Digging Height M
(39' 11") (39' 6") (41' 1") (35' 3") (35' 0")
Bucket Angle d 179.4 deg 177.8 deg 179.4 deg 167.4 deg 166.4 deg
Specification for DX700LC SP002136
Page 13
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Swing Deceleration Force Test
4
With the boom, arm and bucket in the same position as for the
swing speed test, rotate the turntable so that the boom is evenly
centered between the side frames, pointing straight ahead.
Locate the 90° reference point, perpendicular to the boom. Mark
the turntable and undercarriage with paint at the 90° point. 3
Make several attempts to rotate the turntable exactly 90°,
starting from the boom straight ahead position. Engage the
swing lever and brake at the 90° point, shown as "swing stop" in
Figure 8. 2
Record how far the turntable drifts past the stop point,
measuring the distance between paint marks. Maximum
distance should be less than 900 mm (56°), in both Power Mode
and Standard Mode.
Reference
Description
Number
1 Start Swing
1
2 90° Swing
FG000659
3 Swing Force
Figure 8
4 Swing Stop
Specification for DX700LC SP002136
Page 24
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CAUTION
Observe the following safety precautions:
1. Use extra caution and adequate safety shielding when
welding near fuel and oil tanks, batteries, hydraulic
piping lines or other fire hazards.
2. Never weld when the engine is running. Battery cables
must be disconnected before the welding procedure is
started.
3. Never weld on a wet or damp surface. The presence of
moisture causes hydrogen embrittlement and
structural weakening of the weld.
4. If welding procedures are being performed near
cylinder rods, operator's cabin window areas or any
other assemblies that could be damaged by weld
spatters, use adequate shielding protection in front of
the assembly.
5. During equipment setup, always attach ground cables
directly to the area or component being welded to
prevent arcing through bearings, bushings, or
spacers.
6. Always use correct welding rods for the type of weld
being performed and observe recommended
precautions and time constraints. AWS Class E7018
welding rods for low alloy to medium carbon steel
must be used within two hours after removal from a
freshly opened container. Class E11018G welding rods
for T-1 and other higher strength steel must be used
within 1/2 hour.
HYDRAULIC SYSTEM -
GENERAL PRECAUTIONS
Always maintain oil level in the system at recommended levels.
Assemblies that operate under heavy loads, at high speed, with
extremely precise dimensional tolerances between moving parts
- pistons and cylinders, or shoes and swash plates, for example
- can be severely damaged if oil supply runs dry.
Assemblies can be run dry and damaged severely in a very
short time when piping or hoses are disconnected to repair leaks
and/or replace damaged components. Hoses that are
inadvertently switched during disassembly (inlet for outlet and
vice versa), air introduced into the system or assemblies that are
low on oil due to neglect or careless maintenance, could all
produce sufficient fluid loss to cause damage.
When starting the engine (particularly after long layoff or storage
intervals), make sure that all hydraulic controls and operating
General Maintenance Procedures SP000016
Page 7
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Abrasive Roller Wear
Pattern on races and rollers caused by fine abrasives.
Clean all parts and housings, check seals and bearings and
replace if leaking, rough or noisy.
Figure 13
Cracked Inner Race
Race cracked due to improper fit, cocking or poor bearing seat.
Replace all parts and housings, check seals and bearings and
replace if leaking.
Figure 14
Smears
Smearing of metal due to slippage caused by poor fitting,
lubrication, overheating, overloads or handling damage.
Replace bearings, clean related parts and check for proper fit
and lubrication.
Replace shaft if damaged.
Figure 15
General Maintenance Procedures SP000016
Page 18
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TYPE 8 PHOSPHATE COATED
HARDWARE
This chart provides tightening torque for general purpose
applications using original equipment standard hardware as
listed in the Parts Manual for the machine involved. DO NOT
SUBSTITUTE. In most cases, original equipment standard
hardware is defined as Type 8, coarse thread bolts and nuts and
thru hardened flat washers (Rockwell "C" 38 - 45), all phosphate
coated and assembled without supplemental lubrication (as
received) condition.
The torques shown below also apply to the following:
1. Phosphate coated bolts used in tapped holes in steel or
gray iron.
2. Phosphate coated bolts used with phosphate coated
prevailing torque nuts (nuts with distorted threads or plastic
inserts).
3. Phosphate coated bolts used with copper plated weld nuts.
Markings on bolt heads or nuts indicate material grade ONLY
and are NOT to be used to determine required torque.
Standard Torque ±10%
Nominal Thread Diameter Kilogram Meter Foot Pounds
(kg•m) (ft lb)
1/4" 1.1 8
5/16" 2.2 16
3/8" 3.9 28
7/16" 6.2 45
1/2" 9.7 70
9/16" 13.8 100
5/8" 19.4 140
3/4" 33.2 240
7/8" 53.9 390
1" 80.2 580
1 - 1/8" 113.4 820
1 - 1/4" 160.4 1160
1 - 3/8" 210.2 1520
1 - 1/2" 279.4 2020
1 - 3/4" 347.1 2510
2 522.8 3780
Standard Torques SP000813
Page 9
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MEMO
Cabin SP002148
Page 2
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SP002141
COUNTERWEIGHT SP002141
Counterweight
Edition 1
Counterweight SP002141
Page 1
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Counterweight SP002141
Page 12
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19. Tag and disconnect wires leading to fuel sender (1, Figure
11) on side of fuel tank (2). 2
1
FG016408
Figure 11
20. Install two 12 mm eyebolts in threaded holes (1 and 2, 3
Figure 12). Using a suitable lifting device, sling eyebolts. 1 2
21. Remove six bolts and spacers (4, Figure 12) holding tank
(3) to frame. Lift tank 25 mm (1") and make sure it is
balanced. Make sure that there are no other electrical
wires or hoses connected to tank. Completely remove tank
after inspection.
NOTE: The clear level gauge on the side of the tank is
easily damaged. Be careful of obstacles and
wind gusts.
22. Remove shims (5, Figure 12).
NOTE: If tank is to be reused note position and amount
of shims used for each mounting bolt location. 5
5
4
4 FG016409
Figure 12
Fuel Tank SP002142
Page 11
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GENERAL DESCRIPTION
Theory of Operation
Fuel
1
2 3
Fuel Tank
IN OUT
FG016185
Figure 1
Reference Reference
Description Description
Number Number
1 Body 3 Inlet Hose
2 Check Valve
The fuel pump consists of a motor, pump, switch, and hose
assembly.
Hose
Pump
FG016399
Figure 2
Fuel Transfer Pump (Opt) SP002143
Page 6
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SP002149
SWING REDUCTION GEARSP002149
Swing
Reduction Gear
Edition 1
Swing Reduction Gear SP002149
Page 1
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REMOVAL
1. Park on firm and level ground. O I
2. Lower front attachment (bucket) to ground.
3. Shut down engine.
4. Set safety lever on "RELEASED" position.
5. Turn starter switch to "I" (ON) position.
WARNING
DO NOT OPERATE ON OFF
when performing inspection
or maintenance
WARNING 190-00695A
FG016400
If engine must be running while performing Figure 2
maintenance, always use extreme caution. Always
have one person in cab at all times. Never leave cab
with engine running.
6. Fully stroke work levers (joysticks) in all directions to
relieve any pressure from accumulators.
7. Set safety lever on "LOCK" position.
8. Turn key to "O" (OFF) position and remove from starter
switch.
9. Hang a maintenance warning tag on controls.
10. Disconnect negative (-) battery cable leading to frame from
battery.
11. Tag and disconnect hoses from swing motor (1, Figure 3).
Plug and cap hoses and ports to prevent contamination
from entering hydraulic system or component.
12. Disconnect tube (2) from drain cock (3) and hose fitting (7)
from fill hole.
13. Remove twelve bolts and washers (4, Figure 3) holding
swing reduction gearbox (5) to frame.
14. Using a suitable lifting device, sling swing motor (1, Figure
3) and remove swing motor and reduction gearbox (5) as
an assembly from unit.
NOTE: A drain cock (3, Figure 3) and tube are on side
of gearbox. Be careful not to damage valve or
tube.
NOTE: There are two alignment pins (6, Figure 3), one
on each side of reduction gearbox flange.
Figure 3
Swing Reduction Gear SP002149
Page 12
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Figure 31
Assembly of the Carrier Subassembly 2
1. Put the carrier No.2 on the assembly die as shown in the
figure below.
Figure 32
2. Insert the bush No.2 in the planetary gear No.2 and put the
thrust washer No.2 on it.
Figure 33
Swing Reduction Gear SP002149
Page 23
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Figure 71
Figure 72
3. Put out the inner part of the prepared bearing (23024CD)
and assemble them again that its trade mark is visible,
insert it in the shaft as shown in the figure below, put the
bearing press fitting jig on it, and use a press to insert it.
Figure 73
Figure 74
Swing Reduction Gear SP002149
Page 34
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Figure 108
Assembly of the Motor
Supply of Gear Oil
Upon the completion of the noise test, remove the test motor
and pour gear oil of 2.5ℓ more.
Figure 109
Figure 110
Swing Reduction Gear SP002149
Page 45
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MEMO
Track Assembly SP002146
Page 2
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Lower Roller Disassembly
Lower Roller Disassembly or Reassembly Tool
Tool Remarker
a Press 50 ton
b Hammer -
135
20
120
c Pin Disassembly Jig
40
FG017046
d Lower Roller Support Jig
e Shaft Extract Jig
f Bushing Disassembly Jig
g Bushing Reassembly Jig
Track Assembly SP002146
Page 13
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5. Install idler (2, Figure 24) on the axle.
6. Install bearing (3, Figure 24) and pin (6) to the axle. 2
NOTE: Fill the idler assembly with new engine oil or
SAE 40 oil with approximately 535 cc. (18.1 oz)
7. Install plug (9, Figure 24) on the idler. 9
6
3
FG016582
Figure 24
Track Assembly SP002146
Page 24
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Track Spring Disassembly Diagram
2
8
5
6
7 9
FG016728
Figure 48
Reference Reference
Description Description
Number Number
2 Piston Rod 7 Plate
5 Bracket 8 Spring
6 Ring 9 Bolt
Track Assembly SP002146
Page 35
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Application procedure
1. Wipe the contact surfaces clean of all water, oil or grease.
The contact surfaces should be dry.
2. Apply a regular bead width of liquid gasket to one of the
contact surfaces. Make sure that the bead does not break
at this point.
NOTE: If there are special regulations concerning the
application procedure in the repair document,
please follow those regulations.
Work procedure
1. Wipe the joint surfaces of the bolt, bolt hole, and threads
clean of water, grease, and oil. The contact surfaces
should be dry.
2. Apply Loctite to the top 1/3 of the screw.
3. Tighten the bolt to the specified torque.
IMPORTANT
Figure 7
After tightening the bolt, do not apply excessive
torque or try to rotate the bolt until at least one hour
has passed, and the Loctite has hardened.
Engine SP002261
Page 11
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Flare nut
Tightening Torque Width Across Flats of Flare Nut
(For Medium and (mm)
Pipe Diameter
Large Size
Vehicles) Old New
12.8 - 18.6
ø4.76 mm 14 14
(1.3 - 1.9)
23.5 - 49
ø6.35 mm 17 17
(2.4 - 5.0)
23.5 - 49
Flare nut tightening ø8.0 mm 19 17
(2.4 - 5.0)
torque (service standard
44.1 - 93.2
value) N•m (kg•m) ø10.0 mm 22 19
(4.5 - 9.5)
58.8 - 137.3
ø12.0 mm 27 24
(6.0 - 14.0)
78.5 - 156.9
ø15.0 mm 30 30
(8.0 - 16.0)
Taper screw from connectors (brass)
N•m (kg•m)
Screw size PT (R) 1/8 PT (R) 1/4 PT (R) 3/8 PT (R) 1/12
2.0 - 14.7 4.9 - 15.7 9.8 - 16.7 9.8 - 17.7
-
(0.2 - 1.5) (0.5 - 1.6) (1.0 - 1.7) (1.0 - 1.8)
Special Tool Classification
A: Essential tool
Servicing operation cannot be done with any other tools than the
essential tool.
B: Recommend tool
Servicing work can be done with a general-purpose tool
commercially available. However, it is advisable to use the
recommended tool as much as possible for a reduced work time
and an improved safety in work operations.
C: Available tool
Although it takes a more working time, servicing operations can
be made with a tool commercially available as substitute for the
available tool.
Engine SP002261
Page 22
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Engine Accessories
Components
Figure 26
Reference Reference
Description Description
Number Number
1 Generator 3 Belt (Generator)
2 Starter Motor
Engine SP002261
Page 33
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15. Remove the oil cooler.
• Remove the oil cooler tightening bolt, insert and
tighten the removed bolts into the replacer holes (two
places) and remove the oil cooler.
Figure 51
16. Remove the level gauge and guide tube.
17. Remove the intake pipe.
Reference
Description
Number
1 Inlet Manifold
2 Gasket
3 Bolt
4 Bolt
5 Intake Pipe
Figure 52
18. Remove the primary EGR cooler.
Reference
Description
Number
1 Primary EGR Cooler
2 Gasket
3 Bolt
Figure 53
19. Remove the secondary EGR cooler.
• Remove the primary side (entrance side) fixing bolts.
Reference
Description
Number
1 Bolt
2 Secondary EGR Cooler
3 Bolt
4 Gasket
Figure 54
Engine SP002261
Page 44
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8. Clip the gasket and install the turbocharger to the exhaust
manifold. Pour a suitable quantity of engine oil into the
opening of the turbocharger and turn the turbine shaft
slightly, and then lubricate the shaft bearing.
• Tighten the turbocharger with a double nut.
Tightening torque: 40 N•m (4.1 kg•m/30 lb•ft)
Reference
Description
Number
1 Exhaust Bracket
2 Exhaust Manifold Figure 85