Daewoo Doosan DX420LC-3 Excavator Service Repair Manual Instant Download (Serial Number 10001 and Up)

1
Shop Manual DX420LC-3 Excavator
Serial Number 10001 and Up
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.
950106-00398E July 2012
Original Instructions
Copyright DOOSAN 2012
2
Table of Contents
Safety Track Excavator Maintenance Safety
..................................................
. SP002322 Specifications Specification for
DX420LC-3 ........................................
........................ SP002670 General
Maintenance General Maintenance Instructions
..................................................
...... SP002454 Standard Torques
..................................................
............................... SP002404 Upper
Structure Cabin ..................................
..................................................
................ SP002324 Counterweight...........
..................................................
.......................... SP002697 Fuel
Tank..............................................
................................................
SP002699 Fuel Transfer Pump (Option)
..................................................
.............. SP002560 Swing Bearing.............
..................................................
........................ SP002329 Lower
Structure and Chassis Track Assembly
..................................................
..................................
SP002561 Engine and Drivetrain
Engine............................................
..................................................
..... SP002654 Engine Coolant Heater (Option)
..................................................
......... SP002328 Drive Coupling (Main
Pump).............................................
.................... SP002562 Hydraulics Hydrauli
c System Troubleshooting, Testing and Adjustment
............... SP002655 Accumulator.............
..................................................
........................... SP002455 Center Joint
(Swivel)..........................................
................................... SP002545
3
Cylinders.........................................
..................................................
.... SP002769 Swing Device .......................
..................................................
............... SP002653 Travel
Device............................................
............................................
SP002609 Main Pump................................
..................................................
.......... SP002567 Gear Pump ....................
..................................................
..................... SP002568 Fan Motor for Oil
Cooler ...........................................
............................ SP002576 Fan Motor
for Radiator......................................
.................................... SP002577 Fan
Pump .............................................
................................................
SP002553 Main Control Valve ......................
..................................................
....... SP002656 Remote Control Valve (Work Lever
/ Joystick) .....................................
SP002578 Travel Control Valve (with
Damper)...........................................
........... SP002381 Solenoid Valve Assembly
..................................................
................... SP002406 Breaker EPPR Valve
(Option) .........................................
..................... SP002458 Hydraulic
Schematic.........................................
....................................
SP002671 Electrical System Electrical System
..................................................
................................
SP002571 Electrical Schematic ....................
..................................................
....... SP002572 Attachments Boom and
Arm...............................................
.......................................
SP002669 Bucket...................................
..................................................
.............. SP002421
4
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Track Excavator Maintenance
Safety
SP002322
Edition 4
Track Excavator Maintenance Safety
SP002322 Page 1
6
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation and Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments repairs or service. Untrained operators and failure to follow instructions can cause death or serious injury.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DX140LC-3 1001 and Up, 50001 and Up
DX180LC-3 1001 and Up, 50001 and Up
DX225LC-3 1001 and Up, 50001 and Up
DX255LC-3 1001 and Up, 50001 and Up
DX300LC-3 1001 and Up, 50001 and Up
DX340LC-3 1001 and Up, 10001 and Up
DX350LC-3 1001 and Up, 10001 and Up
DX380LC-3 10001 and Up
DX420LC-3 10001 and Up
SP002322 Page 5
Track Excavator Maintenance Safety
7
SAFETY MESSAGES Safety messages and safety decals
included in this manual and on the machine
provide instructions how to operate, service and
maintain the machine. Safety messages and safety
decals indicate potential hazards and describe
safety precautions required to avoid hazards.
Operator and maintenance personnel should read
and understand these safety messages and decals
before beginning operation or maintenance.
SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and Safety Instructions. This is a Safety Alert Symbol. Wherever it appears in this manual or on safety decals on the machine, you must be alert to the potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures.
Signal Words The signal words "DANGER",
"WARNING", "CAUTION" are used throughout safety
messages and safety decals in this manual or on
the machine. They indicate an existence of, and
the relative seriousness of, a hazard. All three
indicate that a safety risk is involved. Observe
the precautions indicated whenever a Safety
Alert Symbol is present, no matter which signal
word appears next to it.
DANGER
DANGER - This signal word is used on safety messages and safety labels and indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
WARNING - This signal word is used on safety messages and safety labels and indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Track Excavator Maintenance Safety Page 6
SP002322
8
CAUTION
CAUTION - This signal word is used on safety messages and safety labels and indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.
Other Signal Words In addition to safety signal
words, the following signal words are used to
indicate proper and effective use of machine.
IMPORTANT
This signal word identifies procedures which must be followed to avoid damage to machine.
The word "NOTE" identifies information for
effective use.
SAFETY DECALS Location of safety labels (decals)
can vary from unit to unit. Refer to appropriate
Operation and Maintenance Manual, and parts
manual for your unit. Always replace damaged or
faded decals.
SP002322 Page 7
Track Excavator Maintenance Safety
9
Engine and Drivetrain
10
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation and Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments repairs or service. Untrained operators and failure to follow instructions can cause death or serious injury.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DX420LC-3 10001 and Up
SP002654 Page 5
Engine
11
INTRODUCTION Safety Information
Repair Work Safety Information

1. Use an engine stand when removing the engine from
   the equipment. Be sure not to place the engine
   directly on the ground or allow the oil pan to
   come into contact with the ground or a hard
   surface.
2. When performing a procedure with two or more
   people, make sure to ensure each other's safety.
3. When repairing the electrical system, make sure
   to disconnect the cable from the negative (-)
   battery terminal before working. Keep arcs,
   sparks and cigarettes away when removing the
   battery cover.

FG023344
Figure 1

1. Do not leave the engine running for an extended
   period of time or perform painting in a poorly
   ventilated working environment.
2. Make sure to use only the special tools if the
   procedure requires them for the work. Performing
   the procedure using other tools can cause damage
   to parts or personal injury.
3. Inspect the tools, instruments, and special tools
   regularly, and prepare them before working. Do
   not use damaged or worn out tools such as a
   wrench that has lost its edges, a hammer with
   frayed edges, or a chipped chisel.
4. When performing work using a device such as a
   grinder, crane or welder, make sure to pay
   sufficient attention to the handling
   precautions. Wear work clothes and safety
   equipment in the other operations as required.
5. Be sure to check that there are no fuel leaks
   when performing maintenance on the fuel systems.
6. When handling flammable materials, be careful to
   not let them catch fire. Also make sure to wipe
   away any oil that sticks to rubber parts, as it
   can cause deterioration.

Sun Gear Holder Coupling FG022706
FG023345
Figure 32

• Replacement Parts and Part Number Safety
  Information
• Whenever disassembly is performed, make sure to
  replace the packing, oil seals, O-rings,
  crimping locknuts, bending lock plate, and split
  pins, etc., with new ones.
• Since the part numbers indicated in this manual
  may differ from the supply system and are
  subject to change, make sure to check the supply
  system and part numbers in the parts catalog.

Engine Page 6
SP002654
12
SERVICE INFORMATION GUIDE Contents Included in
Service Information

• Removal
• Includes the removal procedure for repairing
  parts and devices, etc.
• Installation
• Includes the installation procedure for repairing
  parts and devices, etc.
• Disassembly
• Includes the disassembly procedure for performing
  an overhaul of a unit or assembly part, etc.
• Assembly
• Includes the assembly procedure for performing an
  overhaul of a unit or assembly part, etc.
• Inspection
• Includes the inspection items for the parts that
  particularly require inspection to ensure
  continued performance of parts and devices. The
  standard values, set values, and limits for use
  of parts are included if they have these
  specifications set.
• Cleaning
• Includes the cleaning procedure for parts and
  devices, etc.
• Preparation
• Includes the preparatory procedure necessary
  before removing parts and devices, etc.
• Adjustment
• Includes the adjustment procedure when parts have
  to be adjusted to set values or standard values
  when performing assembly or installation.
• Measurement
• Includes the measurement procedure to judge if
  parts are installed correctly, etc.
• Drain

SP002654 Page 7
Engine
13

• Air Removal
• Includes the air removal procedure when air
  removal is necessary after replacing oil, etc.
  Writing Includes the writing procedure necessary
  after replacing the ECM or supply pump.
• Precaution
• Includes the maintenance precautions specific to
  each item.
• Disconnection
• Includes the disconnection procedures of wiring,
  piping, etc.
• Connection
• Includes the connection procedures for wiring,
  piping, etc.
• Setting
• Includes the setting procedure necessary after
  replacing the ECM, etc.
• Replacement
• Includes the replacement procedure for parts and
  oils, etc.
• Prioritized DTC
• Includes DTCs that need to be diagnosed and
  resolved before the relevant DTC when multiple
  DTCs are detected.
• Diagnosis
• Includes the diagnosis procedure for
  troubleshooting symptoms. DTCs are listed in the
  descending order of priority.
• Confirmation of Problem Resolution
• Includes procedures to clear the DTC and any
  necessary confirmation steps using numeric
  values, etc.
• Functional Description

Engine Page 8
SP002654
14
Function, Structure, Operation Engine Number
Figure 15
Reference Number Description
1 Engine Number Stamping
Reference Number Description
2 Function, Structure, Operation
Engine Page 32
SP002654
15
Engine Structural Diagram Function, Structure,
Operation
Figure 16
Figure 17
SP002654 Page 33
Engine
16
Figure 18
Engine Page 34
SP002654
17
Fuel System
Figure 19
Reference Number Description
1 Injector
2 Fuel Filter
3 Fuel Tank
Reference Number Description
4 Pre-fuel Filter
5 Supply Pump
6 Common Rail
IMPORTANT
Since the high-precision fuel system has been adopted, take care to prevent any foreign material from entering the fuel system. Do not disassemble the supply pump, common rail, or injector.
SP002654 Page 35
Engine
18
Common Rail
Figure 20
Reference Number Description
1 Pressure Limiter
2 Pressure Sensor
Reference Number Description
3 Flow Damper
Engine Page 36
SP002654
19
Fuel Supply Pump
Figure 21
Reference Number Description
1 Air Bleeder
2 Pump Control Valve (PCV)
Reference Number Description
3 Overflow Valve
4 CMP Sensor
SP002654 Page 37
Engine
20
Injector
1
3
2
FG023364
Figure 22
Reference Number Description
1 Injector Assembly
2 Gasket
Reference Number Description
3 O-ring
Fuel Filter
2
1
Reference Number Description
1 Priming Pump
2 Air Bleed
3 Case
4 Drain Plug
3
4
FG023365
Figure 23
Engine Page 38
SP002654
21
Cooling System The cooling system is a
forced-circulation system, and its main
components are the water pump, thermostat and
radiator. It cools the inside of the engine, oil
cooler, EGR gas, etc.
Figure 24
Reference Number Description
1 Sub-tank
2 Air Leak Pipe
3 EGR Cooler
4 Oil Cooler
Reference Number Description
5 Thermostat
6 Water Pump
7 Radiator
SP002654 Page 39
Engine
22
Water Pump The water pump is a centrifugal
impeller type pump and is driven by the engine
fan belt.
Figure 25
Reference Number Description
1 Pulley Center
2 Bearing
3 Seal Unit
4 Impeller
Reference Number Description
5 Shaft
6 Oil Seal
7 Retaining Ring
8 Oil Seal
Engine Page 40
SP002654
23
Thermostat The thermostat is a wax pellet type
and its initial open valve temperature is set to
80C (176F). The structure allows the water
temperature to be fine adjusted, and it is
assembled inside the thermostat housing unit.
FG023368
Figure 26 Lubrication System A gear type oil
pump, full-flow bypass integrated oil filter,
water- cooling oil cooler, oil relief valve and
piston cooling oil jet are adopted for the
lubrication system.
Figure 27
SP002654 Page 41
Engine
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Oil Pump Structural Diagram
Figure 28
Reference Number Description
1 Drive Gear
2 Drive Gear Shaft
3 Spring
Reference Number Description
4 Relief Valve
5 Driven Gear
SP002654
Engine Page 42
26
Induction System
Figure 29
Reference Number Description
1 VGS Actuator
2 VGS Device
3 Turbine Housing
Reference Number Description
4 Bearing Housing
5 Compressor Housing
SP002654 Page 43
Engine
27
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available for immediate download. https//www.eb
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