Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Doosan DX420LC-3 Excavator Shop Manual 950106-00398E – PDF DOWNLOAD
Original price was: $65.95.$31.95Current price is: $31.95.
Doosan DX420LC-3 Excavator Shop Manual 950106-00398E – PDF DOWNLOAD
Serial Number 1001 and Up
950106-00398E
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Doosan DX420LC-3 Excavator Shop Manual 950106-00398E – PDF DOWNLOAD
DESCRIPTION:
Doosan DX420LC-3 Excavator Shop Manual 950106-00398E – PDF DOWNLOAD
Serial Number 1001 and Up
950106-00398E
GENERAL:
Safe Operation is Operator’s Responsibility:
- Only trained and authorized personnel should operate and maintain the machine. Follow all safety rules, regulations and instructions when operating or performing maintenance on machine.
- Do not operate machine if you are under the influence of drugs or alcohol. An operator who is taking prescription drugs must get medical advice to determine if he or she can safely operate a machine. When working with other personnel on a work site, be sure that all personnel know nature of work and understand all hand signals that are to be used.
- Be sure that all guards and shields are installed in their proper location. Have guards and shields repaired or replaced immediately if damaged.
- Be sure that you understand the use and maintenance of all safety features such as safety lock lever and seat belt. Use them properly. Never remove, modify or disable any safety features. Always keep them in good operating condition. Always check for and know the location of underground and overhead utility lines before excavating.
- Failure to use and maintain safety features according to instructions in this manual, Safety Manual and Shop Manual can result in death or serious injury. 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
TABLE OF CONTENTS:
Doosan DX420LC-3 Excavator Shop Manual 950106-00398E – PDF DOWNLOAD
DX420LC-3..................................................................................................... 0 Table of Contents......................................................................................... 7 Safety.................................................................................................... 9 Track Excavator Maintenance Safety SP002322........................................................... 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............................................................. 18 Pressurized Fluids............................................................................ 19 Flying or Falling Objects..................................................................... 20 Personal Protective Equipment (PPE)........................................................... 20 Correction of Machine Problems................................................................ 20 Crushing and Cutting.......................................................................... 21 Hot Coolant and Oils - Burn Prevention........................................................ 22 Fire and Explosion Prevention................................................................. 22 Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)................................... 26 Electrical System and Electrical Shock........................................................ 26 Rollover Protective Structure (ROPS).......................................................... 27 Transportation.................................................................................... 30 Obey State and Local Over-the-Road Regulations................................................ 30 Loading and Unloading......................................................................... 30 Transporting Machine.......................................................................... 31 Operation......................................................................................... 32 Before Engine Starting........................................................................ 32 Work Site..................................................................................... 33 Mounting/Dismounting.......................................................................... 34 Cleaning...................................................................................... 35 Operator Station.............................................................................. 35 Seat Belt..................................................................................... 36 Visibility Information........................................................................ 37 Boost Starting or Charging Engine Batteries................................................... 38 Starting Engine............................................................................... 39 Swinging or Traveling......................................................................... 40 Lifting and Digging........................................................................... 42 Operation on Slopes........................................................................... 43 Towing........................................................................................ 44 Attachment.................................................................................... 45 Equipment Lowering with Engine Stopped........................................................ 45 Engine Stop................................................................................... 45 Parking Machine............................................................................... 46 Preservation/Storing Machine.................................................................. 47 Maintenance....................................................................................... 49 Warning Tag................................................................................... 52 Cleaning...................................................................................... 53 Proper Tools and Clothing..................................................................... 53 Disassembling Precautions..................................................................... 53 Use of Lighting............................................................................... 54 Fire and Explosion Prevention................................................................. 54 Burn Prevention............................................................................... 55 Rubber That Contains Fluorides................................................................ 56 Rubber and Plastics........................................................................... 57 Welding Repairs............................................................................... 58 Warning for Counterweight and Front Attachment Removal........................................ 59 Lock Inspection Covers........................................................................ 60 Working on Machine............................................................................ 60 Accumulator................................................................................... 61 Compressed Air................................................................................ 61 Track Tension Adjustments..................................................................... 62 Supports and Blocking for Work Equipment...................................................... 62 High-pressure Lines, Tubes and Hoses.......................................................... 63 Battery....................................................................................... 64 Environment and Circumstances..................................................................... 66 Work Site Areas Requiring Extra Caution....................................................... 66 High-voltage Cables........................................................................... 68 Underground Operation......................................................................... 69 Working in Water.............................................................................. 69 Working in Contaminated Environment........................................................... 69 Operation in Extreme Conditions............................................................... 70 Exhaust Ventilation........................................................................... 74 Asbestos Information.......................................................................... 74 Silica Dust Information....................................................................... 75 Disposal of Hazardous Materials............................................................... 75 Sound......................................................................................... 76 Vibration..................................................................................... 76 Specifications............................................................................................ 77 Specification for DX420LC-3 SP002670.................................................................. 79 Safety Instructions............................................................................... 83 Applicable Models................................................................................. 83 General Description............................................................................... 85 Component Locations............................................................................... 86 Overall Dimensions................................................................................ 88 Working Range..................................................................................... 90 General Specifications............................................................................ 92 Engine Performance Curves (Per KS-R1004 Standard)................................................. 94 Approximate Weight of Workload Materials.......................................................... 96 Performance Tests................................................................................. 98 Excavator Performance Measurements................................................................ 99 Test Conditions............................................................................... 99 Travel Speed and Travel Motor Balance (Steering Deviation) Tests.............................. 99 Speed Test................................................................................ 99 Travel Deviation.......................................................................... 101 Swing Speed and Deceleration Force Test....................................................... 101 Swing Speed Test.......................................................................... 101 Swing Deceleration Force Test............................................................. 102 Cylinder Performance Tests.................................................................... 103 Boom Cylinders Test....................................................................... 103 Arm Cylinder Test......................................................................... 103 Bucket Cylinder Test...................................................................... 103 Hydraulic Cylinder Natural Drop Test...................................................... 103 Travel Motor Jack-up Test................................................................. 103 General Maintenance....................................................................................... 105 General Maintenance Instructions SP002454............................................................. 107 Safety Instructions............................................................................... 111 Applicable Models................................................................................. 111 Welding Precautions and Instructions.............................................................. 112 Hydraulic System - General Precautions............................................................ 113 Maintenance Service and Repair Procedure.......................................................... 115 General Precautions........................................................................... 115 Hydraulic System Cleanliness and Oil Leaks........................................................ 116 Maintenance Precautions for Hydraulic System Service.......................................... 116 Oil Leakage Precautions....................................................................... 117 Cleaning and Inspection........................................................................... 118 General Instructions.......................................................................... 118 Bearing Inspection............................................................................ 119 Standard Torques SP002404............................................................................. 127 Safety Instructions............................................................................... 131 Applicable Models................................................................................. 131 Torque Values for Standard Metric Fasteners....................................................... 132 Torque Values for Standard U.S. Fasteners......................................................... 133 Type 8 Phosphate Coated Hardware.................................................................. 135 Torque Values for Hose Clamps..................................................................... 136 ORFS Swivel Nut Recommended Torque................................................................ 136 Torque Values for Split Flanges................................................................... 137 Torque Wrench Extension Tools..................................................................... 138 Torque Multiplication......................................................................... 138 Other Uses for Torque Wrench Extension Tools.................................................. 139 Tightening Torque Specifications (Metric)..................................................... 140 Upper Structure........................................................................................... 143 Cabin SP002324........................................................................................ 145 Safety Instructions............................................................................... 149 Applicable Models................................................................................. 149 Cabin Identification.............................................................................. 150 Rollover Protective Structure (ROPS).......................................................... 150 Removal........................................................................................... 152 Installation...................................................................................... 156 Counterweight SP002697................................................................................ 159 Safety Instructions............................................................................... 163 Applicable Models................................................................................. 163 General........................................................................................... 164 Warning for Counterweight and Front Attachment Removal........................................ 164 Removal........................................................................................... 166 Installation...................................................................................... 167 Fuel Tank SP002699.................................................................................... 169 Safety Instructions............................................................................... 173 Applicable Models................................................................................. 173 General Description............................................................................... 174 Parts List.................................................................................... 174 Specifications................................................................................ 175 Removal........................................................................................... 176 Installation...................................................................................... 180 Start-up Procedures............................................................................... 183 Fuel Transfer Pump (Option) SP002560.................................................................. 185 Safety Instructions............................................................................... 189 Applicable Models................................................................................. 189 General Description............................................................................... 190 Theory of Operation........................................................................... 190 Troubleshooting................................................................................... 192 Replacement of Rotor and Vane..................................................................... 192 Replacement of Rear Cover......................................................................... 193 Replacement of Armature........................................................................... 193 Swing Bearing SP002329................................................................................ 195 Safety Instructions............................................................................... 199 Applicable Models................................................................................. 199 Swing Bearing Maintenance......................................................................... 200 Operating Recommendation...................................................................... 200 Measuring Swing Bearing Axial Play............................................................ 200 Measuring Bearing Lateral Play................................................................ 200 Swing Bearing Basic Operation................................................................. 201 Disassembly................................................................................... 201 Assembly...................................................................................... 203 Lower Structure and Chassis............................................................................... 205 Track Assembly SP002561............................................................................... 207 Safety Instructions............................................................................... 211 Applicable Models................................................................................. 211 General Description............................................................................... 212 Track Tension..................................................................................... 213 Cleaning and Inspection (Wear Limits and Tolerances).............................................. 215 Track Shoe.................................................................................... 216 Lower Roller.................................................................................. 218 Upper Roller.................................................................................. 219 Front Idler................................................................................... 220 Track Shoes and Links............................................................................. 221 Track Removal................................................................................. 221 Track Installation............................................................................ 222 Front Idler Roller................................................................................ 224 Parts List.................................................................................... 224 Front Idler Roller Disassembly................................................................ 225 Front Idler Roller Reassembly................................................................. 227 Lower Roller...................................................................................... 228 Parts List.................................................................................... 228 Lower Roller Removal.......................................................................... 229 Lower Roller Disassembly...................................................................... 229 Lower Roller Reassembly....................................................................... 230 Lower Roller Installation..................................................................... 231 Upper Roller...................................................................................... 232 Parts List.................................................................................... 232 Upper Roller Removal.......................................................................... 233 Upper Roller Disassembly...................................................................... 233 Upper Roller Reassembly....................................................................... 235 Track Spring and Track Adjusting Cylinder......................................................... 236 Parts List.................................................................................... 236 Engine and Drivetrain..................................................................................... 239 Engine SP002654....................................................................................... 241 Safety Instructions............................................................................... 245 Applicable Models................................................................................. 245 Introduction...................................................................................... 246 Safety Information............................................................................ 246 Service Information Guide......................................................................... 247 Contents Included in Service Information...................................................... 247 Plastic Gauge................................................................................. 250 Recommended Liquid Gasket..................................................................... 251 Thread Locking Adhesive Agent................................................................. 254 Term.......................................................................................... 255 Abbreviations................................................................................. 256 Standard Bolts................................................................................ 259 Maintenance Information........................................................................... 264 Maintenance Precautions....................................................................... 264 Primary Specifications........................................................................ 269 Function, Structure, Operation................................................................ 272 Introduction to the Trouble Diagnosis......................................................... 329 Functional Inspection............................................................................. 343 Engine Compression Pressure Inspection........................................................ 343 Fuel System Check............................................................................. 345 Air Intake System Check....................................................................... 346 Exhaust System Check.......................................................................... 346 DPD Control System Check...................................................................... 347 EGR Control System Check...................................................................... 350 Starting System Check......................................................................... 351 Glow Control System Check..................................................................... 353 OBD System Check.............................................................................. 354 Inspection of the Diagnostic Light Warning Light Illumination Circuit System.................. 357 Inspection of the Diagnostic Light Warning Light Blinking Circuit System...................... 357 Inspection of the Starter Circuit System...................................................... 359 Symptom........................................................................................... 361 Engine Start Failure.......................................................................... 361 Engine stalling............................................................................... 363 Engine Hunching, Rough Idling................................................................. 366 Excessive White Smoke in the Exhaust Gas...................................................... 367 Excessive Black Smoke in the Exhaust Gas...................................................... 369 Abnormal Noise................................................................................ 370 Large Fuel Consumption........................................................................ 371 Large Oil Consumption......................................................................... 374 Insufficient Engine Output.................................................................... 375 DPD System Manual Regeneration Frequently..................................................... 377 DPD System Regeneration Long Time............................................................. 380 DTC Information................................................................................... 382 DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft Position Correlation................. 382 DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit......................... 382 DTC P0087 (Flash Code 225) Fuel Rail/ System Pressure - Too Low............................... 383 DTC P0088 (Flash Code 118) Fuel Rail/ System Pressure - Too High.............................. 384 DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance................................ 385 DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low........................ 386 DTC P0093 (Flash Code 227) Fuel System Leak Detected.......................................... 386 DTC P0102 (Flash Code 91) Mass Airflow Circuit Low Input...................................... 387 DTC P0103 (Flash Code 91) Mass Airflow Circuit High Input..................................... 388 DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low........................... 389 DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High.......................... 390 DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low....................... 390 DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High...................... 391 DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low................................ 392 DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High............................... 393 DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low................................ 394 DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High............................... 394 DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low.............................. 395 DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High............................. 397 DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1...................................... 398 DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2...................................... 398 DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3...................................... 399 DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4...................................... 400 DTC P0205 (Flash Code 275) Injector Circuit - Cylinder 5...................................... 401 DTC P0206 (Flash Code 276) Injector Circuit - Cylinder 6...................................... 401 DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition.......................... 402 DTC P0219 (Flash Code 543) Engine Overspeed Condition......................................... 403 DTC P0234 (Flash Code 42) Turbocharger Overboost Condition.................................... 403 DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low.............................. 404 DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High............................. 405 DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit.................................. 405 DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/ Performance............... 406 DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit.................................... 407 DTC P0341 (Flash Code 14) Camshaft Position Sensor Circuit Range/ Performance................. 408 DTC P0404 (Flash Code 45) Exhaust Gas Recirculation 1 Control Circuit Range/ Performance...... 408 DTC P0409 (Flash Code 44) Exhaust Gas Recirculation 1 Sensor Circuit.......................... 409 DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High..................... 410 DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low...................... 411 DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/ Performance Sensor 1.... 411 DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1.................... 412 DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1................... 413 DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/ Performance Sensor 2.... 414 DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2.................... 415 DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2................... 416 DTC P0522 (Flash Code 295) Oil Pressure Sensor Circuit Low.................................... 417 DTC P0523 (Flash Code 295) Oil Pressure Sensor Circuit High................................... 417 DTC P0560 (Flash Code 155) System Voltage..................................................... 418 DTC P0563 (Flash Code 35) System Voltage High................................................. 419 DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error...................... 419 DTC P0602 (Flash Code 154) Control Module Programming Error................................... 420 DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (Ram) Error........... 420 DTC P0606 (Flash Code 51) ECM/PCM Processor................................................... 421 DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance.................. 421 DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance......................... 422 DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit.................................. 422 DTC P0650 (Flash Code 77) Malfunction Indicator Light (MIL) Control Circuit................... 423 DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit.................................. 424 DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open........................... 425 DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High........................... 425 DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit.................................. 426 DTC P1062 (Flash Code 257) Fuel Pressure Regulator 1 Solenoid Control Circuit................. 427 DTC P1063 (Flash Code 258) Fuel Pressure Regulator 2 Solenoid Control Circuit................. 427 DTC P1093 (Flash Code 226) Fuel Rail Pressure (FRP) Too Low................................... 428 DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low............................... 429 DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High.............................. 429 DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group1.................... 430 DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group2.................... 431 DTC P1293 (Flash Code 221) Fuel Filter Pressure Sensor Circuit Low............................ 431 DTC P1294 (Flash Code 221) Fuel Filter Pressure Sensor Circuit High........................... 432 DTC P1404 (Flash Code 45) Exhaust Gas Recirculation 1 Closed Position Performance............. 433 DTC P140A (Flash Code 345) Exhaust Gas Recirculation 2 Control Circuit Range/ Performance..... 433 DTC P140B (Flash Code 344) Exhaust Gas Recirculation 2 Sensor Circuit......................... 434 DTC P140C (Flash Code 345) Exhaust Gas Recirculation 2 Closed Position Performance............ 435 DTC P1455 (Flash Code 132) PM Over Accumulation............................................... 436 DTC P1471 (Flash Code 149) DPD Insufficient Regeneration...................................... 437 DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance......................... 437 DTC P1655 (Flash Code 59) Sensor Reference Voltage 4 Circuit.................................. 438 DTC P1669 (Flash Code 75) DPD Light Control Circuit........................................... 439 DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input.......................... 440 DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input......................... 440 DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input.......................... 441 DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input......................... 442 DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2 Voltage Correlation.................... 442 DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit....................... 443 DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit....................... 444 DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low..................................... 445 DTC P2229 (Flash Code 71) Barometric Pressure Circuit High.................................... 446 DTC P2295 (Flash Code 248) Fuel Pressure Regulator 2 Solenoid Control Circuit Low............. 447 DTC P2296 (Flash Code 218) Fuel Pressure Regulator 2 Solenoid Control Circuit High............ 448 DTC P242F (Flash Code 131) DPD Restriction.................................................... 449 DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit........................... 449 DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance......... 450 DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low........................ 451 DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High....................... 452 DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position................... 453 DTC P2458 (Flash Code 139) DPD Regeneration Duration.......................................... 453 DTC U0001 (Flash Code 84) CAN-Bus Malfunction (ISO-CAN)....................................... 454 DTC U0073 (Flash Code 84) CAN-Bus Malfunction (J1939)......................................... 455 DTC U0101 (Flash Code 85) Lost Communication with TCM......................................... 455 DTC U0110 (Flash Code 87) Lost Communication with VNT System.................................. 456 DTC U0411 (Flash code 87) Turbo Charger Control Module Signal Malfunction..................... 456 DTC Mapping Table............................................................................. 457 Engine Control.................................................................................... 460 DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft Position Correlation................. 460 DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit......................... 461 DTC P0087 (Flash Code 225) Fuel Rail/ System Pressure - Too Low............................... 464 DTC P0088 (Flash Code 118) Fuel Rail/ System Pressure - Too High.............................. 468 DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance................................ 471 DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low........................ 474 DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low........................ 476 DTC P0092 (Flash Code 217) Fuel Pressure Regulator Control Circuit High....................... 477 DTC P0093 (Flash Code 227) Fuel System Leak Detected.......................................... 478 DTC P0102 (Flash Code 91) Mass Airflow Circuit Low Input...................................... 481 DTC P0103 (Flash Code 91) Mass Airflow Circuit High Input..................................... 482 DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low........................... 483 DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High.......................... 484 DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low....................... 486 DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High...................... 487 DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low................................ 488 DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High............................... 490 DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low................................ 491 DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High............................... 492 DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low.............................. 493 DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High............................. 495 DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1...................................... 496 DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2...................................... 498 DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3...................................... 500 DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4...................................... 502 DTC P0205 (Flash Code 275) Injector Circuit - Cylinder 5...................................... 503 DTC P0206 (Flash Code 276) Injector Circuit - Cylinder 6...................................... 505 DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition.......................... 507 DTC P0219 (Flash Code 543) Engine Overspeed Condition......................................... 508 DTC P0234 (Flash Code 42) Turbocharger Overboost Condition.................................... 509 DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low.............................. 511 DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High............................. 512 DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit.................................. 513 DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/ Performance............... 515 DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit.................................... 516 DTC P0341 (Flash Code 14) Camshaft Position Sensor Circuit Range/ Performance................. 518 DTC P0404 (Flash Code 45) Exhaust Gas Recirculation 1 Control Circuit Range/ Performance...... 519 DTC P0409 (Flash Code 44) Exhaust Gas Recirculation 1 Sensor Circuit.......................... 520 DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High..................... 522 DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low...................... 523 DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/ Performance Sensor 1.... 524 DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1.................... 525 DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1................... 526 DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/ Performance Sensor 2.... 528 DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2.................... 529 DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2................... 530 DTC P0522 (Flash Code 295) Oil Pressure Sensor Circuit Low.................................... 532 DTC P0523 (Flash Code 295) Oil Pressure Sensor Circuit High................................... 533 DTC P0560 (Flash Code 155) System Voltage..................................................... 534 DTC P0563 (Flash Code 35) System Voltage High................................................. 536 DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error...................... 537 DTC P0602 (Flash Code 154) Control Module Programming Error................................... 537 DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM) Error........... 538 DTC P0606 (Flash Code 51) ECM/PCM Processor................................................... 538 DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance.................. 539 DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance......................... 539 DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit.................................. 541 DTC P0650 (Flash Code 77) Malfunction Indicator Light (MIL) Control Circuit................... 543 DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit.................................. 544 DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open........................... 546 DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High........................... 547 DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit.................................. 548 DTC P1062 (Flash Code 257) Fuel Pressure Regulator 1 Solenoid Control Circuit................. 549 DTC P1063 (Flash Code 258) Fuel Pressure Regulator 2 Solenoid Control Circuit................. 550 DTC P1093 (Flash Code 226) Fuel Rail Pressure (FRP) Too Low................................... 551 DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low............................... 553 DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High.............................. 554 DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1................... 555 DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2................... 556 DTC P1293 (Flash Code 221) Fuel Filter Pressure Sensor Circuit Low............................ 556 DTC P1294 (Flash Code 221) Fuel Filter Pressure Sensor Circuit High........................... 558 DTC P1404 (Flash Code 45) Exhaust Gas Recirculation 1 Closed Position Performance............. 559 DTC P140A (Flash Code 345) Exhaust Gas Recirculation 2 Control Circuit Range/ Performance..... 560 DTC P140B (Flash Code 344) Exhaust Gas Recirculation 2 Sensor Circuit......................... 561 DTC P140C (Flash Code 345) Exhaust Gas Recirculation 2 Closed Position Performance............ 563 DTC P1455 (Flash Code 132) PM Over Accumulation............................................... 564 DTC P1471 (Flash Code 149) DPD Insufficient Regeneration...................................... 566 DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance......................... 568 DTC P1655 (Flash Code 59) Sensor Reference Voltage 4 Circuit.................................. 568 DTC P1669 (Flash Code 75) DPD Light Control Circuit........................................... 570 DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input.......................... 572 DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input......................... 573 DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input.......................... 575 DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input......................... 576 DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2 Voltage Correlation.................... 577 DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit....................... 579 DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit....................... 580 DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low..................................... 582 DTC P2229 (Flash Code 71) Barometric Pressure Circuit High.................................... 584 DTC P2295 (Flash Code 248) Fuel Pressure Regulator 2 Solenoid Control Circuit Low............. 585 DTC P2296 (Flash Code 218) Fuel Pressure Regulator 2 Solenoid Control Circuit High............ 586 DTC P242F (Flash Code 131) DPD Restriction.................................................... 587 DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit........................... 589 DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance......... 591 DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low........................ 593 DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High....................... 595 DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position................... 596 DTC P2458 (Flash Code 139) DPD Regeneration Duration.......................................... 597 DTC U0001 (Flash Code 84) CAN-Bus Malfunction (ISO-CAN)....................................... 600 DTC U0073 (Flash Code 84) CAN-Bus Malfunction (J1939)......................................... 601 DTC U0101 (Flash Code 85) Lost Communication with TCM......................................... 602 DTC U0110 (Flash Code 87) Lost Communication with VNT System.................................. 603 DTC U0411 (Flash code 87) Turbo Charger Control Module Signal Malfunction..................... 604 Mechanical........................................................................................ 606 Cylinder Head Cover........................................................................... 606 Cylinder Head Assembly........................................................................ 608 Idle Gear..................................................................................... 658 Cylinder Block................................................................................ 705 Crankshaft.................................................................................... 768 Piston........................................................................................ 831 Camshaft...................................................................................... 877 Flywheel...................................................................................... 886 Rocker Arm Shaft.............................................................................. 888 CMP Sensor.................................................................................... 895 Front Cover................................................................................... 896 Flywheel Housing.............................................................................. 903 Intake Throttle Valve......................................................................... 946 CKP Sensor.................................................................................... 948 Supplementary Information..................................................................... 949 Fuel System....................................................................................... 967 Fuel Supply Pump.............................................................................. 967 Injector...................................................................................... 985 Common Rail Assembly.......................................................................... 999 Fuel Filter...................................................................................1004 Pressure Limiter..............................................................................1010 Fuel Pressure Sensor..........................................................................1013 Fuel Filter Pressure Sensor...................................................................1022 Fuel Temperature Sensor.......................................................................1023 Supplementary Information.....................................................................1027 Cooling...........................................................................................1028 Water Pump Assembly...........................................................................1028 Thermostat....................................................................................1042 Radiator......................................................................................1051 Overheat Switch...............................................................................1053 Engine Coolant Temperature Sensor.............................................................1054 Coolant.......................................................................................1057 Generator Drive Belt..........................................................................1058 Supplementary Information.....................................................................1061 Lubrication.......................................................................................1064 Oil Pan.......................................................................................1064 Oil Pump Assembly.............................................................................1065 Oil Level Switch..............................................................................1069 Engine Oil....................................................................................1070 Piston Oil Jet................................................................................1071 Oil Cooler Assembly...........................................................................1073 Oil Pressure Sensor...........................................................................1087 Supplementary Information.....................................................................1088 Induction.........................................................................................1095 Boost Temperature Sensor......................................................................1095 Turbocharger Assembly.........................................................................1096 Intercooler...................................................................................1103 Air Cleaner Filter............................................................................1104 IMT Sensor....................................................................................1105 Boost Sensor..................................................................................1106 MAF Sensor....................................................................................1107 Supplementary Information.....................................................................1108 Exhaust...........................................................................................1109 DPD Assembly..................................................................................1109 Exhaust Differential Pressure Sensor..........................................................1116 Exhaust Gas Temperature Sensor................................................................1119 Supplementary Information.....................................................................1122 Aux. Emission Control Devices.....................................................................1123 EGR Valve.....................................................................................1123 Supplementary Information.....................................................................1131 Electrical........................................................................................1134 Glow Plug.....................................................................................1134 Generator.....................................................................................1140 Starter Assembly..............................................................................1153 ECM...........................................................................................1165 Supplementary Information.....................................................................1166 Wiring Diagram....................................................................................1169 Using the Wiring Diagram......................................................................1169 Location Diagram..............................................................................1172 Engine........................................................................................1176 Location Diagram..............................................................................1181 Connector List................................................................................1182 Engine Coolant Heater (Option) SP002328...............................................................1197 Safety Instructions...............................................................................1201 Applicable Models.................................................................................1201 Disassembly and Assembly..........................................................................1202 Changing the Circulating Pump.................................................................1202 Changing the Temperature Limiter..............................................................1204 Changing the Temperature Sensor...............................................................1205 Changing the Combustion Air Fan...............................................................1207 Changing the Burner, Flame Monitor and Glow Plug..............................................1209 Changing the Burner Head......................................................................1211 Changing the Heat Exchanger...................................................................1213 Drive Coupling (Main Pump) SP002562...................................................................1215 Safety Instructions...............................................................................1219 Applicable Models.................................................................................1219 Mounting Instructions for BoWEX FLE - PA Couplings................................................1220 Use of the BoWEX FLE - PA Coupling............................................................1220 Hydraulics................................................................................................1223 Hydraulic System Troubleshooting, Testing and Adjustment..............................................1225 Safety Instructions...............................................................................1229 Applicable Models.................................................................................1229 Hydraulic System - General Notes..................................................................1230 Hydraulic Schematic...............................................................................1231 General Notes.................................................................................1231 Operation of Working Components...................................................................1233 Boom Operating Circuit........................................................................1233 Boom Up Circuit...............................................................................1233 Boom Down Circuit.............................................................................1234 Arm Operating Circuit.........................................................................1234 Arm Crowd Circuit.............................................................................1235 Arm Dump Circuit..............................................................................1235 Bucket Operating Circuit......................................................................1236 Bucket Crowd Circuit..........................................................................1236 Bucket Dump Circuit...........................................................................1236 Swing Operating Circuit.......................................................................1237 Right Swing Operating Circuit.................................................................1237 Left Swing Operating Circuit..................................................................1237 Swing Relief Valve and Makeup Valve...........................................................1237 Travel Operating Circuit......................................................................1238 Forward Travel Circuit........................................................................1238 Reverse Travel Circuit........................................................................1238 Procedural Troubleshooting Baseline Recommendations...............................................1239 Initial Checks and Tests to Establish Operating Condition of the Excavator....................1239 Troubleshooting Summary...................................................................1239 Pilot Pressure....................................................................................1241 Adjustment and Testing........................................................................1241 Power Mode Valve..................................................................................1242 Current Signal and Hydraulic Pressure Adjustments.............................................1242 Pressure Up Valve.................................................................................1243 Checks and Adjustments........................................................................1243 Pump Input Power Control..........................................................................1245 Pump Regulator Adjustment.....................................................................1245 Flow Meter and Flow Meter Kit Installation and Testing............................................1248 Installation and Testing Procedure............................................................1248 Swing System Troubleshooting......................................................................1250 Precautions/Initial Checks....................................................................1250 Swing Relief Valve Checking and Adjustment....................................................1251 Troubleshooting - Swing Gearbox...................................................................1253 Troubleshooting - Hydraulic Problems..............................................................1254 Troubleshooting - Hydraulic Fan Drive System......................................................1256 Troubleshooting - Control Valve...................................................................1257 Troubleshooting - Travel Control Valve............................................................1258 Troubleshooting - Joystick Control Valve..........................................................1258 Accumulator SP002455..................................................................................1259 Safety Instructions...............................................................................1263 Applicable Models.................................................................................1263 General Description...............................................................................1264 Specifications................................................................................1266 Center Joint (Swivel) SP002545........................................................................1267 Safety Instructions...............................................................................1271 Applicable Models.................................................................................1271 General Description...............................................................................1273 Center Joint Disassembly Diagram..............................................................1273 Troubleshooting, Testing and Adjustment...........................................................1274 Inspection....................................................................................1274 Testing.......................................................................................1274 Disassembly.......................................................................................1275 Reassembly........................................................................................1278 Cylinders SP002769....................................................................................1281 Safety Instructions...............................................................................1285 Applicable Models.................................................................................1285 General Description...............................................................................1286 Theory of Operation...........................................................................1286 Parts List....................................................................................1288 Special Tools and Materials.......................................................................1294 Piston Nut....................................................................................1294 Piston Jig....................................................................................1296 Steel Bushing Jig.............................................................................1299 Dust Wiper Jig................................................................................1302 Slipper Seal Jig..............................................................................1305 Slipper Seal Straightening Jig................................................................1308 Disassembly.......................................................................................1311 Reassembly........................................................................................1316 Swing Device SP002653.................................................................................1321 Safety Instructions...............................................................................1325 Applicable Models.................................................................................1325 Structure and Principle of Operation..........................................................1326 Structure.................................................................................1326 Principle of Operation....................................................................1331 Valve Casing..............................................................................1332 Brake Part................................................................................1335 Operation Instructions........................................................................1336 Inspection................................................................................1336 Direction of Rotation.....................................................................1336 External Load at the End of Shaft.........................................................1337 Hydraulic Oil and Temperature Range.......................................................1337 Filter....................................................................................1338 Installation and Piping...................................................................1338 Oil Filling and Air Ventilation...........................................................1339 Cautions before Start Operation...........................................................1339 Troubleshooting...............................................................................1340 General Caution...........................................................................1340 Examination of Hydraulic Motor............................................................1340 Troubleshooting...........................................................................1341 Disassembly and Reassembly....................................................................1344 Tightening Torque of Bolts................................................................1344 Tools for Disassembly and Reassembly......................................................1344 Remove and Install Swing Device...................................................................1346 Removal.......................................................................................1346 Remove Swing Motor........................................................................1348 Install Swing Motor.......................................................................1348 Installation..................................................................................1349 Disassemble Swing Motor...................................................................1351 Reassemble Swing Motor....................................................................1355 Disassemble the Reduction Gear............................................................1361 Reassemble the Reduction Gear.............................................................1365 Maintenance Guidelines........................................................................1372 Replacement Standard of Worn Parts........................................................1372 Standard of Sliding Surface Correction....................................................1373 Travel Device SP002609................................................................................1375 Safety Instructions...............................................................................1379 Applicable Models.................................................................................1379 Basic Structure and Drawings..................................................................1381 Basic Structure of TM Motor...............................................................1381 Motor (M).................................................................................1382 Reduction Gear (R)........................................................................1384 Operation Principle...........................................................................1386 Reduction Gear............................................................................1386 Hydraulic Motor (Brake Valve, Parking Brake, High-Low 2- Stage Switching Mechanism).......1387 Operation Instructions........................................................................1395 Installation Method (refer to the Outline Drawing)........................................1395 Pipeline..................................................................................1395 Hydraulic Oil.............................................................................1396 Lubricant.................................................................................1397 Maintenance/Service.......................................................................1398 Troubleshooting...............................................................................1398 Maintenance Instructions......................................................................1400 Assembly, Disassembly, Jigs and Tools.....................................................1400 Remove and Install Travel Device..................................................................1403 Removal.......................................................................................1403 Disassembly...................................................................................1404 General Cautions..........................................................................1404 Disassembly Sequence......................................................................1404 Assembly......................................................................................1414 General Cautions..........................................................................1414 Assembly Sequence.........................................................................1414 Installation..................................................................................1431 Matters to Check after Assembly...............................................................1432 Performance Test..............................................................................1432 Main Pump SP002567....................................................................................1435 Safety Instructions...............................................................................1439 Applicable Models.................................................................................1439 Sectional View....................................................................................1440 A8VO200LA1KH1/63..............................................................................1440 General Repair Guidelines.........................................................................1442 Seal Kits and SUBASSEMBLIES.......................................................................1444 Sealing the DRIVESHAFT............................................................................1448 Gear Pump Sealing.................................................................................1450 REMOVING Control Housing..........................................................................1452 Control Module....................................................................................1456 Control Module LR.............................................................................1456 Control Module H..............................................................................1457 Removing the Controller...........................................................................1458 Valve Plate With Valves...........................................................................1460 REMOVE Rotary Groups..............................................................................1461 REMOVE Intermediate Wheel.........................................................................1464 Remove Auxiliary Drive............................................................................1466 Inspection........................................................................................1469 Assembling the Rotary Group.......................................................................1474 Pump Assembly.....................................................................................1476 Assembly Guideline............................................................................1477 Adjustment of the Hydraulic Component of the Rotary Group.....................................1478 Hydraulic Component - Measurement "D".............................................................1479 Measuring Device - Hydraulic Component 452 269................................................1479 Mounting Position.............................................................................1480 Measuring Procedure...........................................................................1482 Installation of Control Housing...................................................................1483 Assembly of Intermediate Wheel....................................................................1486 Installation of Gear Pump.........................................................................1487 Installation of Cover / Auxiliary Drive...........................................................1488 Assembly Guidelines for Tightening Torques........................................................1489 Bolts (To N 08.001)...........................................................................1489 Plugs with Internal Hexagon and Profile Seal Ring (to N 02.009)...............................1490 Seal-lock - Sealing Nuts (to N 02.100)........................................................1490 Gear Pump SP002568....................................................................................1491 Safety Instructions...............................................................................1495 Applicable Models.................................................................................1495 Disassembling Single Gear Pump (Opt)..............................................................1496 Reassembling Single Gear Pump (Opt)...............................................................1499 Fan Motor for Oil Cooler SP002576.....................................................................1503 Safety Instructions...............................................................................1507 Applicable Models.................................................................................1507 Disassembly.......................................................................................1509 Assembly..........................................................................................1512 Preassemble...................................................................................1512 Assembling....................................................................................1513 Fan Motor for Radiator SP002577.......................................................................1515 Safety Instructions...............................................................................1519 Applicable Models.................................................................................1519 View..............................................................................................1521 Option........................................................................................1521 General Repair Guidelines.........................................................................1522 Sealing Driveshaft................................................................................1523 Disassemble the Motor.............................................................................1526 Inspection Hints..................................................................................1533 Motor Assembly....................................................................................1534 Disassembly of the Flushing Valve.................................................................1539 Tools/Auxiliary Tools/ Tightening Torques.........................................................1540 Fan Pump SP002553.....................................................................................1541 Safety Instructions...............................................................................1545 Applicable Models.................................................................................1545 View..............................................................................................1547 ED - Valve....................................................................................1547 General Repair Guidelines.........................................................................1548 Sealing Driveshaft................................................................................1549 Sealing Control Valve.............................................................................1551 Disassembly.......................................................................................1552 Overview......................................................................................1552 Remove Rotary Group...........................................................................1555 Remove Control Device.........................................................................1556 Remove Shaft/Bearings.........................................................................1557 Cleaning and Inspection...........................................................................1558 Pump Assembly.....................................................................................1561 Adjustment of Taper Roller Bearing................................................................1563 Taper Roller Bearing Pretension...............................................................1563 Tools/Auxiliary Tools/ Tightening Torques.........................................................1570 Main Control Valve SP002656...........................................................................1571 Safety Instructions...............................................................................1575 Applicable Models.................................................................................1575 General Description...............................................................................1576 When All Spools are in Neutral................................................................1576 Neutral Passage (Figure 1 and Figure 2)...................................................1576 Signal Passage (Figure 2).................................................................1578 Single Operation..............................................................................1580 Travel Spool Shifting (Figure 3 and Figure 4).............................................1580 Swing Spool Shifting (Figure 4)...........................................................1582 Boom Spool Shifting.......................................................................1583 Spare Spool Shifting (Figure 8)...........................................................1586 Bucket Spool Shifting (Figure 8)..........................................................1586 Arm Spool Shifting........................................................................1587 Neutral-cut Spool Shifting (Figure 11)....................................................1590 Parallel Throttle for Arm (Figure 11).....................................................1590 Relief Valve..............................................................................1591 Combined Operation............................................................................1592 Travel Combined Operation (Figure 13).....................................................1592 Swing Combined Operation (Figure 14)......................................................1594 Antidrift Valve...............................................................................1595 Main Relief Valve.............................................................................1595 Overload Relief Valve.........................................................................1596 Low-pressure Relief Valve.....................................................................1598 Parts List....................................................................................1599 Spool Assembly (4, Bucket)................................................................1603 Spool Assembly (5, Boom)..................................................................1603 Spool Assembly (6, Travel)................................................................1603 Spool Assembly (7, Straight Travel).......................................................1604 Spool Assembly (8, Arm1)..................................................................1604 Spool Assembly (9, Service)...............................................................1604 Spool Assembly (10, Boom 2)...............................................................1605 Spool Assembly (11, Swing)................................................................1605 Spool Assembly (3, Arm 2).................................................................1605 Spool Assembly (20, Arm Regeneration Release Valve........................................1605 Spool Assembly (24).......................................................................1606 Poppet Assembly (36)......................................................................1606 Plug Assembly (51)........................................................................1606 Plug Assembly (58)........................................................................1606 Relief Valve Assembly (48)................................................................1607 Relief Valve Assembly (49)................................................................1607 Relief Valve Assembly (50)................................................................1608 Specifications................................................................................1608 Troubleshooting, Testing and Adjustment...........................................................1609 General.......................................................................................1609 Relief Valve..................................................................................1610 Hydraulic System..............................................................................1610 Adjustment of Relief Valve....................................................................1611 Main Relief Valve.........................................................................1611 Overload Relief Valve.....................................................................1611 Disassembly.......................................................................................1612 General Instructions for Disassembly..........................................................1612 Disassembly of Main Spool (3) - (11)..........................................................1613 Disassembly of Subspool (24)..................................................................1614 Disassembly of Subspool (20)..................................................................1614 Disassembly of Antidrift Valve of Boom and Arm................................................1614 Disassembly of Swing Load Check...............................................................1615 Disassembly of Load Check.....................................................................1615 Disassembly of Other Check Valves.............................................................1616 Disassembly Of Flange.........................................................................1616 Disassembly of Relief Valve...................................................................1616 Disassembly of Other Flange...................................................................1616 Disassembly of Main Relief Valve..............................................................1617 Disassembly of Low-pressure Relief Valve......................................................1618 Disassembly of Low-pressure Relief Valve......................................................1618 Cleaning and Inspection (Wear Limits and Tolerances)..............................................1619 Cleaning......................................................................................1619 Inspection....................................................................................1619 Reassembly........................................................................................1620 Subassembly...................................................................................1620 Main Spool (3) - (11).....................................................................1620 Subspool (20).............................................................................1620 Subspool (24).............................................................................1621 Boom, Arm Antidrift Valve.................................................................1621 Swing Load Check..........................................................................1621 Reassembly of Control Valve...................................................................1622 Reassembly of Load Check Valve............................................................1622 Reassembly of Swing Load Check............................................................1622 Reassembly of Other Check Valve...........................................................1622 Reassembly of Flange......................................................................1623 Reassembly of Boom and Arm Antidrift Valve................................................1623 Reassembly of Relief Valve................................................................1623 Reassembly of Subspool (24)...............................................................1624 Reassembly of Subspool (20)...............................................................1624 Reassembly of Main Spool (3) - (11).......................................................1624 Reassembly of Other Plugs.................................................................1625 Reassembly of Main Relief Valve...........................................................1626 Reassembly of Overload Relief Valve.......................................................1627 Reassembly of Low-pressure Relief Valve...................................................1627 Installation......................................................................................1628 Start-up Procedures...............................................................................1628 Remote Control Valve (Work Lever / Joystick) SP002578.................................................1629 Safety Instructions...............................................................................1633 Applicable Models.................................................................................1633 General Description...............................................................................1635 Theory of Operation...........................................................................1635 Structure.................................................................................1635 Function..................................................................................1635 Parts List....................................................................................1636 Specifications................................................................................1638 Performance...............................................................................1638 Torques.......................................................................................1638 Tools and Materials...............................................................................1638 Disassembly.......................................................................................1639 Reassembly........................................................................................1642 Start-up Procedures...............................................................................1650 Travel Control Valve (with Damper) SP002381...........................................................1651 Safety Instructions...............................................................................1655 Applicable Models.................................................................................1655 General Description...............................................................................1656 Theory of Operation...........................................................................1656 Pressure Reducing Valve.......................................................................1657 Operating Theory of Damper Mechanism..........................................................1658 Causes of Faults and Measures.....................................................................1659 Parts List....................................................................................1660 Specification.................................................................................1662 Torques.......................................................................................1662 Removal...........................................................................................1663 Disassembly.......................................................................................1666 Cleaning and Inspection (Wear Limits and Tolerances)..............................................1668 Reassembly........................................................................................1669 Installation......................................................................................1674 Start-up Procedures...............................................................................1677 Solenoid Valve Assembly SP002406......................................................................1679 Safety Instructions...............................................................................1683 Applicable Models.................................................................................1683 5-Solenoid Valve..................................................................................1684 Parts List....................................................................................1684 Functions of 5-Solenoid Valve Assembly........................................................1685 Assembly Diagram and Tools Required...........................................................1686 Cautions During Disassembly and Reassembly....................................................1687 Solenoid Valve Diagram........................................................................1688 Check Points and Solutions for Problems.......................................................1689 Breaker EPPR Valve (Option) SP002458..................................................................1691 Safety Instructions...............................................................................1695 Applicable Models.................................................................................1695 Structure.........................................................................................1696 Parts List....................................................................................1696 Functions and Operation...........................................................................1697 Cautions for Operation............................................................................1697 Maintenance Instructions..........................................................................1698 Maintenance...................................................................................1698 Disassembly...................................................................................1699 Assembly......................................................................................1700 Hydraulic Schematic SP002671..........................................................................1703 Safety Instructions...............................................................................1707 Applicable Models.................................................................................1707 DX420LC-3.........................................................................................1709 Electrical System.........................................................................................1711 Electrical System SP002571............................................................................1713 Safety Instructions...............................................................................1719 Applicable Models.................................................................................1719 Introduction......................................................................................1721 Electrical Supply System..........................................................................1722 Engine Starting Circuit...........................................................................1724 Start Operation...............................................................................1724 After Start...................................................................................1726 Engine Preheating System..........................................................................1728 Engine Stop.......................................................................................1730 Charging System...................................................................................1732 Monitoring System.................................................................................1733 Instrument Panel..............................................................................1734 Functional Check..............................................................................1734 Monitoring System Schematic...................................................................1736 Operation.........................................................................................1738 Instruments...................................................................................1738 Warning and Indicator Lights......................................................................1740 Indication of Warning Lights..................................................................1740 Indication of Multifunction Gauge.............................................................1742 Initial Operation.................................................................................1743 Graphic Information Area Display..................................................................1744 Overview......................................................................................1744 Main Menus for the Graphic Display Area.......................................................1744 Menu Selector Buttons.........................................................................1744 User Menu.........................................................................................1745 User Menu - Access and Escape Methods.........................................................1745 Special Menu......................................................................................1777 Entering/Accessing and Exiting/Escaping Menus.................................................1777 Special Menu Selections.......................................................................1778 Electronic Hydraulic Control System (EPOS)........................................................1802 Control System Schematic......................................................................1802 Power Plus Mode Control...........................................................................1804 Operation.....................................................................................1806 Power Mode Control - Circuit Diagram..............................................................1808 Engine Control System.............................................................................1810 Engine Control Dial...............................................................................1811 Engine Control Circuit Diagram....................................................................1812 Automatic Deceleration Control (Auto Idle Control)................................................1814 Engine Overheat Protection System.................................................................1816 Power Boost Mode..................................................................................1818 Operation.....................................................................................1818 Power Boost Control - Circuit Diagram.........................................................1820 Automatic Travel Speed Control....................................................................1822 Automatic Travel Speed Control - Circuit Diagram..............................................1824 Self-diagnostic Function..........................................................................1825 EPOS Controller...............................................................................1825 Air Conditioner System............................................................................1827 Outline.......................................................................................1827 Internal and External Filters.................................................................1828 Air-conditioning System Layout................................................................1830 Air Conditioner/heater Circuit Diagram........................................................1831 Air Conditioner/heater Unit...................................................................1832 Ambient Air Temperature Sensor................................................................1837 Sun Sensor....................................................................................1838 Control Panel.................................................................................1838 Compressor....................................................................................1846 Receiver Dryer................................................................................1846 Troubleshooting...................................................................................1847 Weight of R134a Gas Used In Machines..............................................................1849 Refrigerant System Repairs........................................................................1850 Refrigerant Safe Handling Procedures..........................................................1850 Repair and Replacement Procedure..............................................................1851 Refrigerant Recovery..........................................................................1853 Vacuuming Refrigerant System..................................................................1853 Leakage Check.................................................................................1855 Refrigerant Charging..........................................................................1855 Inspecting System For Leakage.................................................................1857 Wiper System......................................................................................1858 Wiper Circuit.................................................................................1858 Wiper operation...............................................................................1859 Lighting System...................................................................................1862 Lighting System Circuit Diagram...............................................................1862 Kind of Light.................................................................................1863 Operation.....................................................................................1863 Overload Warning Device...........................................................................1864 Overload Warning Device Circuit Diagram.......................................................1864 Audio Controller..................................................................................1865 Audio Controller Circuit Diagram..............................................................1865 Electrical Schematic SP002572.........................................................................1867 Safety Instructions...............................................................................1871 Applicable Models.................................................................................1871 DX420LC-3/DX490LC-3/DX530LC-3.....................................................................1873 Attachments...............................................................................................1875 Boom and Arm SP002669.................................................................................1877 Safety Instructions...............................................................................1881 Applicable Models.................................................................................1881 Front Attachment Pin Specifications...............................................................1882 DX420LC-3.....................................................................................1883 Front Attachment - Removal and Installation.......................................................1884 Arm Removal Procedure.........................................................................1884 Boom Removal Procedure........................................................................1886 Installation......................................................................................1887 Arm Installation Procedure....................................................................1887 Boom Installation Procedure...................................................................1887 Start-up Procedures...............................................................................1888 Bucket SP002421.......................................................................................1889 Safety Instructions...............................................................................1893 Applicable Models.................................................................................1893 Bucket Tooth Inspection and Replacement...........................................................1894 Bucket O-ring Replacement.........................................................................1895 Bucket Shimming Procedures........................................................................1897 New Bucket Installation.......................................................................1897 Shimming Procedures for Installed Bucket..................................................1898 Attachments.......................................................................................1899 Bucket Replacement and Reversal...............................................................1899 Replacement...................................................................................1900 Reversal......................................................................................1901 Quick Coupler Operation (Optional)............................................................1902 Attaching Work Tool.......................................................................1902 Removing the Work Tool....................................................................1904
DOOSAN DX420LC-3 EXCAVATOR SHOP MANUAL 950106-00398E – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
R.D
