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DOOSAN DX420LC-5 EXCAVATOR SHOP MANUAL 950106-01020E-1 – PDF DOWNLOAD
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DOOSAN DX420LC-5 EXCAVATOR SHOP MANUAL 950106-01020E-1 – PDF DOWNLOAD
Serial Number 10001
950106-01020E-1
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Description
DOOSAN DX420LC-5 EXCAVATOR SHOP MANUAL 950106-01020E-1 – PDF DOWNLOAD
DESCRIPTION:
DOOSAN DX420LC-5 EXCAVATOR SHOP MANUAL 950106-01020E-1 – PDF DOWNLOAD
Serial Number 10001
950106-01020E-1
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 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 approval of attachments, and their compatibility with optional kits.
- Attachments and attachment control systems that are compatible with the machine are required for safe and reliable machine operation. Do not exceed maximum operating weight (machine weight plus attachment) that is listed on ROPS certification plate.
- Make sure that all guards and shields are in place on machine and on work tool. Depending on type or combination of work equipment, there is a potential that work equipment could interfere with the cabin or other parts of machine.
- Before using unfamiliar work equipment, check if there is any potential of interference, and operate with caution.
- While you are performing any maintenance, testing, or adjustments to attachments, stay clear of the following areas: cutting edges, pinch points, and crushing surfaces.
- Never use attachment as a work platform or manlift. Contact your DOOSAN distributor about auxiliary hydraulic kits for attachments installation.
- If you are in doubt about compatibility of a particular attachment with a machine, consult your DOOSAN distributor.
TABLE OF CONTENTS:
DOOSAN DX420LC-5 EXCAVATOR SHOP MANUAL 950106-01020E-1 – PDF DOWNLOAD
DX420LC-5......................................................................................................... 0 NOTICE........................................................................................................ 7 Table of Contents............................................................................................. 9 Safety........................................................................................................ 11 Track Excavator Maintenance Safety........................................................................ 13 Safety Instructions................................................................................... 17 Safety Messages....................................................................................... 17 General............................................................................................... 18 Safe Operation is Operator's Responsibility....................................................... 18 Know Your Machine................................................................................. 18 Proper Work Tools and Attachments................................................................. 19 Pressurized Fluids................................................................................ 19 Flying or Falling Objects......................................................................... 20 Personal Protective Equipment (PPE)............................................................... 21 Correction of Machine Problems.................................................................... 21 Crushing and Cutting.............................................................................. 21 Hot Coolant and Oils - Burn Prevention............................................................ 22 Fire and Explosion Prevention..................................................................... 23 Fire Extinguisher and First-aid Kit (Emergency Medical Kit)....................................... 26 Electrical System and Electrical Shock............................................................ 27 Roll-over Protective Structure (ROPS)............................................................. 27 Transportation........................................................................................ 31 Obey State and Local Over-the-Road Regulations.................................................... 31 Loading and Unloading............................................................................. 31 Transporting Machine.............................................................................. 32 Operation............................................................................................. 33 Before Engine Starting............................................................................ 33 Work Site......................................................................................... 34 Mounting/Dismounting.............................................................................. 35 Cleaning.......................................................................................... 36 Operator Station.................................................................................. 36 Seat Belt......................................................................................... 37 Visibility Information............................................................................ 38 Boost Starting or Charging Engine Batteries....................................................... 39 Swinging or Traveling............................................................................. 41 Lifting and Digging............................................................................... 43 Operation on Slopes............................................................................... 44 Towing............................................................................................ 45 Attachment........................................................................................ 46 Equipment Lowering with Engine Stopped............................................................ 46 Engine Stop....................................................................................... 47 Parking Machine................................................................................... 47 Preservation/Storing Machine...................................................................... 48 Maintenance........................................................................................... 50 Cleaning.......................................................................................... 54 Proper Tools and Clothing......................................................................... 54 Disassembling Precautions......................................................................... 54 Use of Lighting................................................................................... 54 Fire and Explosion Prevention..................................................................... 55 Burn Prevention................................................................................... 56 Rubber That Contains Fluorides.................................................................... 57 Rubber and Plastics............................................................................... 58 Welding Repairs................................................................................... 59 Warning for Counterweight and Front Attachment Removal............................................ 60 Lock Inspection Covers............................................................................ 61 Working on Machine................................................................................ 61 Accumulator....................................................................................... 62 Compressed Air.................................................................................... 62 Track Tension Adjustments......................................................................... 63 Supports and Blocking for Work Equipment.......................................................... 63 High-pressure Lines, Tubes and Hoses.............................................................. 64 Battery........................................................................................... 65 Environment and Circumstances......................................................................... 67 Work Site Areas Requiring Extra Caution........................................................... 67 High-voltage Cables............................................................................... 69 Underground Operation............................................................................. 70 Working in Water.................................................................................. 70 Working in Contaminated Environment............................................................... 70 Operation in Extreme Conditions................................................................... 71 Exhaust Ventilation............................................................................... 75 Asbestos Information.............................................................................. 76 Silica Dust Information........................................................................... 76 Disposal of Hazardous Materials................................................................... 77 Sound............................................................................................. 78 Vibration......................................................................................... 78 Specifications................................................................................................ 79 Specifications............................................................................................ 81 Safety Instructions................................................................................... 85 General Description................................................................................... 85 Component Locations................................................................................... 86 General Dimensions.................................................................................... 90 Working Range......................................................................................... 92 General Specifications................................................................................ 94 Approximate Weight of Workload Materials.............................................................. 96 Performance Tests..................................................................................... 98 Purpose of Performance Tests...................................................................... 98 Kinds of Tests.................................................................................... 98 Performance Standards............................................................................. 98 Precautions for Evaluation of Test Data........................................................... 98 Definition of "Performance Standard".............................................................. 98 Preparation for Performance Tests..................................................................... 99 The Machine....................................................................................... 99 Test Area......................................................................................... 99 Precautions....................................................................................... 99 Make Precise Measurement.......................................................................... 99 Operational Performance Standard Table................................................................ 100 Operational Performance Test.......................................................................... 102 Hydraulic Cylinder Cycle Time..................................................................... 102 Travel Speed...................................................................................... 104 Track Revolution Speed............................................................................ 105 Mistrack Check.................................................................................... 107 Swing Speed....................................................................................... 109 Swing Function Drift Check........................................................................ 110 General Maintenance........................................................................................... 111 General Maintenance Instructions.......................................................................... 113 Safety Instructions................................................................................... 117 Welding Precautions and Instructions.................................................................. 118 Hydraulic System - General Precautions................................................................ 119 Maintenance Service and Repair Procedure.............................................................. 121 General Precautions............................................................................... 121 Hydraulic System Cleanliness and Oil Leaks............................................................ 122 Maintenance Precautions for Hydraulic System Service.............................................. 122 Oil Leakage Precautions........................................................................... 123 Cleaning and Inspection............................................................................... 124 General Instructions.............................................................................. 124 Bearing Inspection................................................................................ 125 Standard Torques.......................................................................................... 133 Safety Instructions................................................................................... 137 Torque Values for Standard Metric Fasteners........................................................... 138 Torque Values for Standard U.S. Fasteners............................................................. 139 Type 8 Phosphate Coated Hardware...................................................................... 141 Torque Values for Hose Clamps......................................................................... 142 ORFS Swivel Nut Recommended Torque.................................................................... 142 Torque Values for Split Flanges....................................................................... 143 Torque Wrench Extension Tools......................................................................... 144 Torque Multiplication............................................................................. 144 Other Uses for Torque Wrench Extension Tools...................................................... 145 Tightening Torque Specifications (Metric)......................................................... 146 Engine........................................................................................................ 149 Engine.................................................................................................... 151 Safety Instructions................................................................................... 157 Overview.............................................................................................. 158 Inspection............................................................................................ 159 Cleaning the Engine............................................................................... 159 Special Tools......................................................................................... 159 Mounting the Engine in a Universal Stand.......................................................... 169 Engine Identification................................................................................. 170 Engine Data Plate................................................................................. 170 Engine Specification.................................................................................. 171 Engine Performance Curves............................................................................. 172 Tightening Torques.................................................................................... 174 Normal Tightening Torque.......................................................................... 174 Special Tightening Torque......................................................................... 178 Cylinder.............................................................................................. 205 Cylinder Head..................................................................................... 205 Valve Mechanism................................................................................... 224 Cylinder Block.................................................................................... 227 Cylinder Liner.................................................................................... 242 Flywheel Housing.................................................................................. 249 Front Cover....................................................................................... 252 Oil Mist Separator................................................................................ 254 Actuating System...................................................................................... 260 Camshaft.......................................................................................... 260 Connecting Rod.................................................................................... 268 Crankshaft........................................................................................ 270 Flywheel.......................................................................................... 279 Piston............................................................................................ 284 Roller Tappet..................................................................................... 290 Intake Manifold................................................................................... 291 Power Take Off.................................................................................... 291 Torsion Damper.................................................................................... 292 Belt Circuit...................................................................................... 293 Timing Gear....................................................................................... 300 Lubrication System.................................................................................... 306 General Information............................................................................... 306 Centrifugal Oil Cleaner........................................................................... 308 Oil Cooler........................................................................................ 313 Oil Filter........................................................................................ 316 Oil Pump.......................................................................................... 317 Oil Sump.......................................................................................... 319 Oil Pressure Sensor............................................................................... 321 Troubleshooting Chips Found in the Engine......................................................... 322 Troubleshooting the Lubrication System............................................................ 326 Lubrication Oil Consumption....................................................................... 327 Exhaust System........................................................................................ 330 General Information............................................................................... 330 T113, Exhaust Temperature Sensor Before Catalytic Converter....................................... 346 T131 NOx Sensor................................................................................... 348 T116, Reductant Pick-up Unit...................................................................... 350 Evaporator........................................................................................ 355 V117 Reductant Doser.............................................................................. 356 V118, Coolant Valve for Heating the Reductant System.............................................. 362 V183 Reductant Pump............................................................................... 364 H25, H26 Electrically Heated Reductant Hose....................................................... 375 M4000 Electric Exhaust Brake...................................................................... 376 Reductant Tank.................................................................................... 382 Oxidation Catalytic Converter..................................................................... 389 Exhaust Manifold.................................................................................. 391 Variable Geometry Turbocharger.................................................................... 397 EGR System........................................................................................ 405 EGR Valve......................................................................................... 412 EGR Cooler........................................................................................ 417 Cooling System........................................................................................ 419 Internal Cleaning of Cooling System............................................................... 422 Charge Air Cooler................................................................................. 423 Charge Air Temperature Sensor..................................................................... 425 Charge Air Pressure Sensor........................................................................ 427 Coupling Coil for AC Compressor................................................................... 428 Thermostat........................................................................................ 429 Coolant Pump...................................................................................... 432 Coolant Temperature Sensor........................................................................ 433 Fuel System........................................................................................... 435 General Information............................................................................... 435 Accumulator....................................................................................... 440 Fuel Manifold..................................................................................... 441 Overflow Valve.................................................................................... 450 Feed Pump......................................................................................... 453 Injector.......................................................................................... 459 Fuel Filter....................................................................................... 465 Fuel Heater....................................................................................... 469 Fuel System Troubleshooting....................................................................... 470 Electrical System..................................................................................... 484 E44, Control Unit EMS............................................................................. 484 Control Unit EEC.................................................................................. 501 Engine Speed Sensor............................................................................... 506 T110 Oil Level Sensor............................................................................. 508 T111, Fuel Pressure Sensor........................................................................ 509 T125, Exhaust Back Pressure Sensor................................................................ 511 T135, Camshaft Position Sensor.................................................................... 512 V109, Solenoid Valve for Charge Pressure.......................................................... 514 V120, Fuel Inlet Metering Valve................................................................... 515 V141, V142, V143, V144, V145, V146 Solenoid Valve for Injector.................................... 517 T8, Coolant Level Monitor......................................................................... 518 P3, Alternator.................................................................................... 519 M1, Starter Motor................................................................................. 529 AC Compressor..................................................................................... 532 Electrical Parts.................................................................................. 535 EMS S8 (1/2).......................................................................................... 547 EMS S8 (2/2).......................................................................................... 549 EEC, EEC3 Exhaust Emission Control (9, 13 Liter Engines XPI).......................................... 551 Engine Coolant Heater (Option)............................................................................ 553 Safety Instructions................................................................................... 557 Disassembly and Assembly.............................................................................. 557 Changing the Circulating Pump..................................................................... 557 Changing the Temperature Limiter.................................................................. 559 Changing the Temperature Sensor................................................................... 560 Changing the Combustion Air Fan................................................................... 562 Changing the Burner, Flame Monitor and Glow Plug.................................................. 564 Changing the Burner Head.......................................................................... 566 Changing the Heat Exchanger....................................................................... 568 Upper Structure............................................................................................... 569 Cabin..................................................................................................... 571 Safety Instructions................................................................................... 575 Cabin Identification.................................................................................. 575 Roll-over Protective Structure (ROPS)............................................................. 575 Dimensions of Cabin Glass............................................................................. 584 Removal and Installation of Cabin Glass............................................................... 588 Removal of Cabin Glass............................................................................ 588 Installation of Cabin Glass....................................................................... 590 Installation of Upper Door Glass.................................................................. 595 Installation of Upper Front Glass................................................................. 595 Counterweight............................................................................................. 597 Safety Instructions................................................................................... 601 General............................................................................................... 602 Warning for Counterweight and Front Attachment Removal............................................ 602 Installation.......................................................................................... 605 Hydraulic Oil Tank........................................................................................ 607 Safety Instructions................................................................................... 611 General............................................................................................... 611 Specification..................................................................................... 611 Air Breather...................................................................................... 614 Removal............................................................................................... 615 Fuel Tank................................................................................................. 623 Safety Instructions................................................................................... 627 General............................................................................................... 627 Specification..................................................................................... 627 Parts List........................................................................................ 628 Installation.......................................................................................... 635 Completing Work....................................................................................... 636 Main Pump................................................................................................. 637 Safety Instructions................................................................................... 641 General............................................................................................... 641 Specifications.................................................................................... 641 Overview.......................................................................................... 644 Hydraulic Circuit................................................................................. 645 Parts List........................................................................................ 646 Theory of Operation............................................................................... 650 Section View.......................................................................................... 663 Removal............................................................................................... 664 Installation.......................................................................................... 673 Completing Work....................................................................................... 673 Assembly Guidelines for Tightening Torques............................................................ 674 Bolts............................................................................................. 674 Plugs with Internal Hexagon and Profile Seal Ring................................................. 675 Seal-lock - Sealing Nuts.......................................................................... 675 Disassembly and Reassembly............................................................................ 676 General Repair Guidelines......................................................................... 676 Seal Kits and Subassemblies....................................................................... 678 Sealing the Driveshaft............................................................................ 682 Gear Pump Sealing................................................................................. 684 Removing Control Housing.......................................................................... 685 Control Module.................................................................................... 688 Removing the Controller........................................................................... 690 Valve Plate with Valves........................................................................... 692 Remove Rotary Groups.............................................................................. 693 Remove Intermediate Wheel......................................................................... 696 Remove Auxiliary Drive............................................................................ 698 Inspection........................................................................................ 701 Assembling the Rotary Group....................................................................... 706 Pump Assembly..................................................................................... 708 Hydraulic Component - Measurement "D"............................................................. 711 Installation of Control Housing................................................................... 714 Assembly of Intermediate Wheel.................................................................... 717 Installation of Gear Pump......................................................................... 718 Installation of Cover/Auxiliary Drive............................................................. 719 Troubleshooting....................................................................................... 720 How to Proceed for Troubleshooting................................................................ 720 Malfunction Table................................................................................. 721 Drive Coupling (Main Pump)................................................................................ 723 Safety Instructions................................................................................... 727 General............................................................................................... 727 Specification..................................................................................... 727 Parts List........................................................................................ 728 Section View.......................................................................................... 730 Tools............................................................................................. 731 Disassembly........................................................................................... 732 Reassembly............................................................................................ 732 Main Control Valve........................................................................................ 735 Safety Instructions................................................................................... 739 General............................................................................................... 739 Specification..................................................................................... 739 Overview.......................................................................................... 740 Hydraulic Circuit................................................................................. 742 Parts List........................................................................................ 744 Theory of Operation............................................................................... 750 Section View.......................................................................................... 778 Removal............................................................................................... 779 Installation.......................................................................................... 788 Completing Work....................................................................................... 789 Disassembly........................................................................................... 790 Cautions on Disassembly........................................................................... 790 Disassembly of Main Spools........................................................................ 791 Disassembly of Load Check......................................................................... 797 Cleaning and Inspection (Wear Limits and Tolerances).................................................. 803 Cleaning.......................................................................................... 803 Inspection........................................................................................ 803 Reassembly............................................................................................ 804 Subassembly....................................................................................... 804 Main Spool........................................................................................ 804 Reassembly of Control Valve....................................................................... 807 Reassembly of Main Spool (3) - (11)............................................................... 813 Adjustment of Relief Valve........................................................................ 818 Troubleshooting, Testing and Adjustment............................................................... 820 General........................................................................................... 820 Relief Valve...................................................................................... 821 Hydraulic System.................................................................................. 821 Start-up Procedures................................................................................... 822 Swing Device.............................................................................................. 823 Safety Instructions................................................................................... 827 General............................................................................................... 827 Specification..................................................................................... 827 Overview.......................................................................................... 828 Hydraulics Circuit................................................................................ 829 Parts List........................................................................................ 830 Theory of Operation............................................................................... 835 Cautions for Operation................................................................................ 843 Precaution............................................................................................ 847 Tools for Disassembly and Assembly................................................................ 847 Removal............................................................................................... 849 Installation.......................................................................................... 853 Completing work....................................................................................... 853 Disassembly and Reassembly............................................................................ 854 Troubleshooting....................................................................................... 875 General Instructions.............................................................................. 875 Examination of Hydraulic Motor.................................................................... 875 Troubleshooting................................................................................... 876 Maintenance Instructions.............................................................................. 879 Replacement Standard of Worn Parts................................................................ 879 Standard of Sliding Surface Correction............................................................ 879 Fan Pump for Oil Cooler................................................................................... 881 Safety Instructions................................................................................... 885 General............................................................................................... 886 Specification..................................................................................... 886 Overview.......................................................................................... 887 Parts List........................................................................................ 888 Theory of Operation............................................................................... 890 Maintenance Guidelines................................................................................ 895 Sealing Control Valve............................................................................. 898 Tools............................................................................................. 898 Removal............................................................................................... 899 Installation.......................................................................................... 903 Completing Work....................................................................................... 903 Section View.......................................................................................... 904 EPPR Valve........................................................................................ 904 Disassembly........................................................................................... 905 Disassembly of Rotary Group....................................................................... 906 Disassembly of Shaft/Bearings..................................................................... 908 Reassembly............................................................................................ 912 Fan Motor for Oil Cooler.................................................................................. 919 Safety Instructions................................................................................... 923 General............................................................................................... 923 Specification..................................................................................... 923 Overview.......................................................................................... 924 Parts List and Section View....................................................................... 925 Precaution............................................................................................ 926 Tools............................................................................................. 926 Removal............................................................................................... 927 Installation.......................................................................................... 931 Completing Work....................................................................................... 931 Disassembly........................................................................................... 932 Reassembly............................................................................................ 935 Reassembly........................................................................................ 935 Assembly.......................................................................................... 936 Gear Pump (Rotation)...................................................................................... 939 Safety Instructions................................................................................... 943 General............................................................................................... 943 Specification..................................................................................... 943 Overview.......................................................................................... 944 Joystick Valve (Work Lever)............................................................................... 947 Safety Instructions................................................................................... 951 General............................................................................................... 951 Specifications.................................................................................... 951 Overview.......................................................................................... 952 Parts List........................................................................................ 954 Theory of Operation............................................................................... 956 Tools and Torques................................................................................. 957 Section View.......................................................................................... 958 Removal............................................................................................... 960 Installation.......................................................................................... 965 Completing work....................................................................................... 965 Disassembly........................................................................................... 966 Reassembly............................................................................................ 970 Travel Control Valve (with Damper)........................................................................ 977 Safety Instructions................................................................................... 981 General............................................................................................... 982 Specification..................................................................................... 982 Overview.......................................................................................... 983 Parts List........................................................................................ 984 Theory of Operation............................................................................... 986 Section View.......................................................................................... 988 Removal............................................................................................... 989 Installation.......................................................................................... 994 Completing Work....................................................................................... 995 Disassembly........................................................................................... 996 Reassembly............................................................................................ 999 Troubleshooting.......................................................................................1004 Solenoid Valve............................................................................................1005 Safety Instructions...................................................................................1009 General...............................................................................................1009 Specification.....................................................................................1009 Overview..........................................................................................1010 Parts List........................................................................................1012 Theory of Operation...............................................................................1013 Disassembly and Reassembly............................................................................1014 Troubleshooting.......................................................................................1015 EPPR Valve................................................................................................1017 Safety Instructions...................................................................................1021 General...............................................................................................1022 Specification.....................................................................................1022 Overview..........................................................................................1023 Hydraulic Circuit.................................................................................1024 Troubleshooting.......................................................................................1024 Accumulator...............................................................................................1025 Safety Instructions...................................................................................1029 General...............................................................................................1029 Specifications....................................................................................1031 Lower Structure and Chassis...................................................................................1033 Swing Bearing.............................................................................................1035 Safety Instructions...................................................................................1039 General...............................................................................................1040 General Description...............................................................................1040 Parts List........................................................................................1040 Maintenance Guidelines................................................................................1041 Disassembly...........................................................................................1042 Reassembly............................................................................................1044 Center Joint..............................................................................................1045 Safety Instructions...................................................................................1049 General...............................................................................................1049 General Description...............................................................................1049 Overview..........................................................................................1050 Section View..........................................................................................1052 Removal...............................................................................................1053 Installation..........................................................................................1057 Completing Work.......................................................................................1057 Disassembly...........................................................................................1058 Reassembly............................................................................................1061 Troubleshooting, Testing and Adjustment...............................................................1064 Inspection........................................................................................1064 Testing...........................................................................................1064 Travel Device.............................................................................................1065 Safety Instructions...................................................................................1069 General...............................................................................................1069 Specification.....................................................................................1069 Overview..........................................................................................1070 Theory of Operation...............................................................................1076 Cautions for Operation............................................................................1088 Precaution............................................................................................1092 Tools for Disassembly and Assembly................................................................1092 Tightening Torque.................................................................................1094 Removal...............................................................................................1095 Installation..........................................................................................1100 Completing Work.......................................................................................1100 Section View..........................................................................................1102 Disassembly...........................................................................................1104 Cautions on Disassembly...........................................................................1104 Disassembly Sequence..............................................................................1104 Reassembly............................................................................................1114 Cautions on Assembly..............................................................................1114 Assembly Sequence.................................................................................1114 Performance Test......................................................................................1131 Troubleshooting.......................................................................................1133 Track Assembly............................................................................................1135 Safety Instructions...................................................................................1139 General...............................................................................................1139 Track Tension.........................................................................................1140 Track Shoes and Links.................................................................................1142 Parts List........................................................................................1142 Track Removal.....................................................................................1143 Track Installation................................................................................1145 Wear Limits and Tolerances........................................................................1146 Sprocket..............................................................................................1148 Wear Limits and Tolerances........................................................................1148 Front Idler...........................................................................................1149 Overview..........................................................................................1149 Parts List........................................................................................1150 Front Idler Disassembly...........................................................................1151 Front Idler Reassembly............................................................................1153 Upper Roller..........................................................................................1154 Overview..........................................................................................1154 Parts List........................................................................................1155 Upper Roller Removal..............................................................................1156 Upper Roller Installation.........................................................................1156 Upper Roller Disassembly..........................................................................1156 Upper Roller Reassembly...........................................................................1158 Lower Roller..........................................................................................1159 Overview..........................................................................................1159 Parts List........................................................................................1160 Lower Roller Removal..............................................................................1161 Lower Roller Installation.........................................................................1161 Lower Roller Disassembly..........................................................................1161 Lower Roller Reassembly...........................................................................1162 Track Adjuster........................................................................................1164 Parts List........................................................................................1164 Disassembly.......................................................................................1165 Assembly..........................................................................................1166 Front.........................................................................................................1169 Boom and Arm..............................................................................................1171 Safety Instructions...................................................................................1175 Specifications........................................................................................1176 Removal...............................................................................................1178 Arm Removal.......................................................................................1178 Boom Removal......................................................................................1180 Installation..........................................................................................1181 Arm Installation..................................................................................1181 Boom Installation.................................................................................1181 Completing Work.......................................................................................1181 Bucket....................................................................................................1183 Safety Instructions...................................................................................1187 Bucket Tooth Inspection and Replacement...............................................................1188 Bucket O-ring Replacement.............................................................................1189 Bucket Shimming Procedures............................................................................ 0 New Bucket Installation........................................................................... 0 Shimming Procedures for Installed Bucket......................................................1191 Bucket Replacement and Reversal.......................................................................1192 Replacement.......................................................................................1193 Reversal..........................................................................................1194 Cylinders.................................................................................................1195 Safety Instructions...................................................................................1199 General...............................................................................................1199 General Description...............................................................................1199 Specification.....................................................................................1199 Parts List........................................................................................1200 Theory of Operation...............................................................................1208 Seal of Cylinder..................................................................................1209 Special Tools and Materials........................................................................... 0 Rod Bushing (DD-bushing) Pushing-in Jig...........................................................1217 Disassembly...........................................................................................1218 Reassembly............................................................................................1223 Troubleshooting.......................................................................................1227 Hydraulic System..............................................................................................1229 Hydraulic System..........................................................................................1231 Safety Instructions...................................................................................1235 General Description...................................................................................1235 Hydraulic Schematic...................................................................................1236 General Description...............................................................................1236 Hydraulic Component and Oil Flow......................................................................1238 Hydraulic Component...............................................................................1238 Main Oil Line.....................................................................................1240 Pilot Oil Line....................................................................................1241 Return Oil Line...................................................................................1242 Safety Cut-off Operation..............................................................................1243 Power Up Operation....................................................................................1244 Swing (Brake Release) Operation.......................................................................1246 Two Pump Operation....................................................................................1248 Travel Forward and Backward Operation.................................................................1249 Travel High-speed Operation...........................................................................1250 Travel Straight Operation.............................................................................1252 Boom Up Operation.....................................................................................1254 Boom Down Operation...................................................................................1256 Easy Boom Operation...................................................................................1258 Arm Dump Operation....................................................................................1260 Arm Crowd Operation...................................................................................1262 Bucket Dump Operation.................................................................................1264 Bucket Crowd Operation................................................................................1266 Combined Bucket Crowd and Boom Up Operation...........................................................1268 Combined Travel and Boom, Arm, Bucket or Swing Operation..............................................1270 Holding Valve Operation - Cylinder Locking............................................................1272 Holding Valve Operation - Cylinder Release............................................................1273 Main Relief & Over Load Relief Valve Operation........................................................1274 Hydraulic System Testing and Adjustment...................................................................1275 Safety Instructions...................................................................................1279 Procedural Troubleshooting Baseline Recommendations...................................................1280 Initial Checks and Tests to Establish Operating Condition of the Excavator........................1280 Pilot Pressure........................................................................................1282 Adjustment and Testing............................................................................1282 Power Mode Valve......................................................................................1283 Current Signal and Hydraulic Pressure Adjustments.................................................1283 Pressure Up Valve.....................................................................................1284 Checks and Adjustments............................................................................1284 Pump Input Power Control..............................................................................1286 Pump Regulator Adjustment.........................................................................1286 Installation and Testing of Flow Meter and Flow Meter Kit.............................................1289 Swing System Troubleshooting..........................................................................1291 Precautions/Initial Checks........................................................................1291 Swing Relief Valve Checking and Adjustment........................................................1292 Hydraulic System Troubleshooting..........................................................................1295 Safety Instructions...................................................................................1299 Hydraulic System......................................................................................1299 Unusual Noise Comes Out from Pump Connection......................................................1299 Engine Starts but Machine Does Not Operate........................................................1300 Hydraulic Oil is Cloudy...........................................................................1301 Hydraulic Oil Overheated..........................................................................1301 Hydraulic Pump Cavitation.........................................................................1302 Hydraulic Oil is Contaminated.....................................................................1302 Boom, Arm, Bucket Speed is Slow...................................................................1303 Boom, Arm or Bucket Power is Weak.................................................................1304 Cylinder Moves When Remote Control Valve is in the Neutral Position...............................1304 TR (L), TR (R) Swing Does Not Operate When Remote Control Valve Operated..........................1305 Swing Speed is Slow...............................................................................1306 Does Not Operate Boom Floating....................................................................1307 Machine Swings but Does Not Stop..................................................................1307 One Side Speed is Falls and the Machine Curves....................................................1308 Machine Does Not Stop on a Slope..................................................................1309 Travel Motor is Powerless (Travel Only)...........................................................1309 Machine Makes a Curved Travel, When Travel and Actuator Operation are Executed a the Same Time....1310 Does Not Travel is 2nd Speed or Auto Speed........................................................1310 Troubleshooting - Swing Gearbox.......................................................................1311 Troubleshooting - Hydraulic Problems..................................................................1312 Troubleshooting - Hydraulic Fan Drive System..........................................................1314 Troubleshooting - Main Pump...........................................................................1314 Troubleshooting - Control Valve.......................................................................1317 Troubleshooting - Travel Control Valve................................................................1318 Troubleshooting - Joystick Control Valve..............................................................1318 Electrical System.............................................................................................1319 Electrical System.........................................................................................1321 Safety Instructions...................................................................................1327 Introduction..........................................................................................1327 Electrical Supply System..............................................................................1328 Engine Starting Circuit...............................................................................1330 Start Operation...................................................................................1330 Engine Stop...........................................................................................1333 Monitoring System.....................................................................................1336 Instrument Panel..................................................................................1337 Functional Check..................................................................................1337 Monitoring System Schematic.......................................................................1338 Operation.............................................................................................1340 Instruments.......................................................................................1340 Warning and Indicator Lights.......................................................................... 0 Indication of Multifunction Gauge.................................................................1345 Initial Operation.....................................................................................1347 Graphic Information Area Display......................................................................1348 Overview..........................................................................................1348 Main Menus for the Graphic Display Area...........................................................1348 Menu Selector Buttons.............................................................................1348 User Menu.............................................................................................1349 User Menu - Access and Escape Methods.............................................................1349 Special Menu..........................................................................................1385 Entering/Accessing and Exiting/Escaping Menus.....................................................1385 Special Menu Selections...........................................................................1386 Failure Code..........................................................................................1402 Failure Code at Machine...........................................................................1402 Failure Code at Engine Side.......................................................................1405 Electronic Hydraulic Control System (EPOS)............................................................1422 Control System Schematic..........................................................................1422 Power Plus Mode Control...............................................................................1424 Operation.........................................................................................1426 Power Mode Control....................................................................................1428 Smart Power Control (SPC).............................................................................1430 Operation.........................................................................................1430 Engine Control System.................................................................................1433 Engine Control Dial...................................................................................1434 Engine Control........................................................................................1436 Automatic Deceleration Control (Auto Idle Control)....................................................1438 Engine Overheat Protection System.....................................................................1440 Power Boost Mode......................................................................................1443 Operation.........................................................................................1443 Power Boost Control...............................................................................1444 Automatic Travel Speed Control........................................................................1446 Water in Fuel Warning System..........................................................................1449 Operation.........................................................................................1449 Self-diagnostic Function..............................................................................1450 EPOS Controller...................................................................................1450 Air Conditioner System................................................................................1452 Outline...........................................................................................1452 Internal and External Filters.....................................................................1453 Air-Conditioning System Layout....................................................................1454 Air Conditioner/Heater Unit.......................................................................1456 Ambient Air Temperature Sensor....................................................................1461 Receiver Dryer....................................................................................1470 Troubleshooting.......................................................................................1471 Refrigerant System Repairs............................................................................1473 Refrigerant Safe Handling Procedures..............................................................1473 Repair and Replacement Procedure..................................................................1474 Refrigerant Recovery..............................................................................1476 Vacuuming Refrigerant System......................................................................1476 Leakage Check.....................................................................................1478 Refrigerant Charging..............................................................................1478 Inspecting System For Leakage.....................................................................1480 Wiper System.......................................................................................... 0 Wiper Operation...................................................................................1482 Lighting System....................................................................................... 0 Kind of Light.....................................................................................1485 Operation.........................................................................................1485 Overload Warning Device...............................................................................1486 Overload Warning Device Circuit Diagram...........................................................1486 Electrical System Troubleshooting.........................................................................1489 Safety Instructions...................................................................................1493 Electrical System.....................................................................................1493 When Starter Switch is Turn ON, Monitor Panel Display Does Not Appear.............................1493 Communication Error Flashes on the Panel..........................................................1494 Battery Charging Warning Light Lights, When Engine is Started.....................................1495 When Coolant Overheat Warning Light Lights, When Engine is Started................................1496 When Engine Oil Pressure Warning Light Lights, When Engine is Started.............................1496 When Water Separator Warning Light Lights, When Engine Is Started.................................1497 Does Not Control the Engine Control Dial..........................................................1497 Does Not Control the Engine Auto Idle (PA, PT)....................................................1498 When Pilot Cutoff Solenoid Does Not Operate.......................................................1498 When Does Not Operate Auto Travel Speed...........................................................1499 Does Not Operation Wiper Motor, When Starting Switch Is Turned ON.................................1500 All Actuators Speed are Slow (EPPR Valve).........................................................1501 Engine Stall (EPPR Valve).........................................................................1502 Options.......................................................................................................1503 One Way...................................................................................................1505 Safety Instructions...................................................................................1509 General...............................................................................................1509 General Description...............................................................................1509 Theory of Operation...............................................................................1509 Hydraulic Circuit.................................................................................1510 Caution for Installation..........................................................................1511 Installation Procedure................................................................................1512 Main Piping - One and Two-way.....................................................................1512 Main Piping - One Way.............................................................................1514 Pilot Piping - One Way............................................................................1518 Boom Piping - One and Two-way.....................................................................1520 Arm Piping - One and Two-way......................................................................1522 After Installation Precautions....................................................................1523 Air Bleeding......................................................................................1523 Completing Work.......................................................................................1524 Two-way...................................................................................................1525 Safety Instructions...................................................................................1529 General...............................................................................................1529 General Description...............................................................................1529 Theory of Operation...............................................................................1529 Structure.........................................................................................1530 Hydraulic Circuit.................................................................................1531 Caution for Installation..........................................................................1533 Installation Procedure................................................................................1534 Main Piping - One and Two-way.....................................................................1534 Main Piping - Two-way.............................................................................1536 Pilot Piping - Two-way............................................................................1540 Boom Piping - One and Two-way.....................................................................1544 Arm Piping - One and Two-way......................................................................1546 After Installation Precautions....................................................................1547 Air Bleeding......................................................................................1547 Completing Work.......................................................................................1548 Rotating..................................................................................................1549 Safety Instructions...................................................................................1553 General...............................................................................................1553 General Description...............................................................................1553 Theory of Operation...............................................................................1553 Structure.........................................................................................1554 Hydraulic Circuit.................................................................................1555 Caution for Installation..........................................................................1556 Installation Procedure................................................................................1558 Main Piping - Rotating............................................................................1558 Pilot Piping - Rotating...........................................................................1560 Boom Piping - Rotating............................................................................1562 Arm Piping - Rotating.............................................................................1564 After Installation Precautions....................................................................1565 Air Bleeding......................................................................................1565 Completing Work.......................................................................................1565 Quick Coupler.............................................................................................1567 Safety Instructions...................................................................................1571 General...............................................................................................1571 General Description...............................................................................1571 Theory of Operation...............................................................................1571 Hydraulic Circuit.................................................................................1572 Caution for Installation..........................................................................1573 Quick Coupler Operation...............................................................................1574 To Engage Attachment..............................................................................1574 To Release Attachment.............................................................................1577 Installation Procedure................................................................................1580 Main Piping - Quick Coupler.......................................................................1580 Electric Parts - Quick Coupler....................................................................1581 Boom Piping - Quick Coupler.......................................................................1582 Arm Piping - Quick Coupler........................................................................1584 After Installation Precautions....................................................................1585 Air Bleeding......................................................................................1585 Completing Work.......................................................................................1585 Schematic.....................................................................................................1587 Hydraulic Schematic / Electrical Schematic................................................................1589 Blank Page........................................................................................................1592 Blank Page........................................................................................................1594
DOOSAN DX420LC-5 EXCAVATOR SHOP MANUAL 950106-01020E-1 – PDF DOWNLOAD:
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
M.A
1 review for DOOSAN DX420LC-5 EXCAVATOR SHOP MANUAL 950106-01020E-1 – PDF DOWNLOAD
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Murphy Marcellus –
Always fast and great!