Daewoo Doosan DX700LC Excavator Service Repair Manual Instant Download (Serial Number 5001 and Up)

1
DX700LC Shop Manual 950106-00013E Serial Number
5001 and Up
Doosan reserves the right to improve our products
in a continuing process to provide the best
possible product to the market place. These
improvements can be implemented at any time with
no obligation to change materials on previously
sold products. It is recommended that consumers
periodically contact their distributors for
recent documentation on purchased equipment. This
documentation may include attachments and
optional equipment that is not available in your
machine's package. Please call your distributor
for additional items that you may
require. Illustrations used throughout this
manual are used only as a representation of the
actual piece of equipment, and may vary from the
actual item.
950106-00013E Shop Manual Copyright 2010 Doosan
2
Table of Contents
Safety Track Excavator Safety.....................
..................................................
.. SP002135 Specifications Specification for
DX700LC...........................................
......................... SP002136 General
Maintenance General Maintenance
Procedures........................................
................ SP000016 Standard Torques
..................................................
............................... SP000813 Upper
Structure Cabin ..................................
..................................................
................ SP002148 Counterweight...........
..................................................
.......................... SP002141 Fuel
Tank..............................................
................................................
SP002142 Fuel Transfer Pump (Opt).................
..................................................
.. SP002143 Swing Bearing.........................
..................................................
............ SP002165 Swing Reduction
Gear..............................................
............................ SP002149 Lower
Structure and Chassis Track Assembly
..................................................
..................................
SP002146 Engine and Drive Train
Engine............................................
..................................................
..... SP002261 Drive Coupling (Main
Pump).............................................
.................... SP000026 Hydraulics Hydrauli
c System Troubleshooting, Testing and Adjustment
............... SP002166 Accumulator.............
..................................................
........................... SP000028 Center Joint
(Swivel)..........................................
................................... SP002167
Table of Contents Page I
3
Cylinders.........................................
..................................................
.... SP002137 Swing Motor.........................
..................................................
............... SP002168 Travel
Motor.............................................
.............................................
SP002145 Travel Reduction Gear....................
..................................................
.... SP002144 Main Pump...........................
..................................................
............... SP002169 Regulator of Main Pump
..................................................
..................... SP002181 Gear Pump for
Pilot ............................................
.................................. SP000033 Main
Control Valve ....................................
...........................................
SP002171 Remote Control Valve (Work Lever /
Joystick) .....................................
SP002174 Travel Control Valve (with
Damper)...........................................
........... SP002172 Fan Motor (Fan Cooling
Drive) ...........................................
.................. SP002175 Fan Pump (Fan Cooling
Drive) ...........................................
.................. SP002176 Solenoid Valve
Assembly .........................................
............................ SP001622 Breaker
EPPR Valve (Opt) .................................
..................................
SP000192 Hydraulic Schematic (DX700LC)
..................................................
........ SP002147 Electrical System Electrical
System ...........................................
.......................................
SP002140 Electrical Schematic (DX700LC)
..................................................
........ SP002189 Attachments Boom and
Arm...............................................
.......................................
SP002138 Bucket...................................
..................................................
.............. SP002139 Auto Grease
System............................................
................................. SP002216
Table of Contents Page II
4
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Track Excavator
Safety
SP002135
Edition 1
SP002135 Page 1
Track Excavator Safety
6
SAFETY PRECAUTIONS CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual
or those contained within this section. Always
use tools and equipment that are in good working
order. Use lifting and hoisting equipment capable
of safely handling load. Remember, that
ultimately safety is your own personal
responsibility.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DX700LC 5001 and Up
SP002135 Page 5
Track Excavator Safety
7
TO THE OPERATOR OF A DOOSAN EXCAVATOR DANGER

• Unsafe use of the excavator could lead to serious
  injury or death. Operating procedures,
  maintenance and equipment practices or traveling
  or shipping methods that do not follow the
  safety guidelines on the following pages could
  cause serious, potentially fatal injuries or
  extensive damage to the machine or nearby
  property.
• Please respect the importance of taking
  responsibility for your own safety, and that of
  other people who may be affected by your
  actions.
• The safety information on the following pages is
  organized into the following sections
• General Safety Essentials on page 1-9
• Location of Safety Labels on page 1-10
• Summary of Safety Precautions for Lifting in
  Digging Mode on page 1-10
• Unauthorized Modifications on page 1-11
• General Hazard Information on page 1-11
• Before Starting Engine on page 1-20
• Machine Operation on page 1-23
• Maintenance on page 1-30
• Battery on page 1-39
• Towing on page 1-41
• Shipping and Transportation on page 1-42
• Lifting With Sling on page 1-42

SP002135
Track Excavator Safety Page 6
8
WARNING
Improper operation and maintenance of this
machine can be hazardous and could result in
serious injury or death. Operator and maintenance
personnel should read this manual thoroughly
before beginning operation or maintenance. Keep
this manual in the storage compartment to the
rear of the operator's seat, and have all
personnel involved in working on the machine
read the manual periodically. Some actions
involved in operation and maintenance of the
machine can cause a serious accident, if they are
not done in a manner described in this
manual. The procedures and precautions given in
this manual apply only to intended uses of the
machine. If you use your machine for any
unintended uses that are not specifically
prohibited, you must be sure that it is safe for
any others. In no event should you or others
engage in prohibited uses or actions as
described in this manual. DOOSAN delivers
machines that comply with all applicable
regulations and standards of the country to which
it has been shipped. If this machine has been
purchased in another country or purchased from
someone in another country, it may lack certain
safety devices and specifications that are
necessary for use in your country. If there is
any question about whether your product complies
with the applicable standards and regulations of
your country, consult DOOSAN or your DOOSAN
distributor before operating the machine.
SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and
Safety Instructions. This is the Safety Alert
Symbol. Wherever it appears in this manual or on
safety signs on the machine you should be alert
to the potential for personal injury or
accidents. Always observe safety precautions and
follow recommended procedures.
SP002135 Page 7
Track Excavator Safety
9
Learn the Signal Words Used with the Safety
Alert Symbol The words "CAUTION", "Warning", and
"DANGER" used throughout this manual and on
decals on the machine indicate degree of risk of
hazards or unsafe practices. All three degrees
of risk indicate that safety is involved. Observe
precautions indicated whenever you see the
Safety Alert "Triangle", no matter which signal
word appears next to the "Exclamation Point"
symbol.
CAUTION
This word is used on safety messages and safety
labels and indicates potential of a hazardous
situation that, if not avoided, could result in
minor or moderate injury. It may also be used to
alert against a generally unsafe practice.
WARNING
This word is used on safety messages and safety
labels and indicates potential of a hazardous
situation that, if not avoided, could result in
serious injury or death. It may also be used to
alert against a highly unsafe practice.
DANGER
This word is used on safety messages and safety
labels and indicates an imminent hazard of a
situation that, if not avoided, is very likely
to cause death or extremely serious injury. It
may also be used to alert against equipment that
may explode or detonate if handled or treated
carelessly. Safety precautions are described in
SAFETY from page -10 on. DOOSAN cannot predict
every circumstance that might involve a
potential hazard in operation and maintenance.
Therefore the safety messages in this manual and
on the machine may not include all possible
safety precautions. If any procedures or actions
not specifically recommended or allowed in this
manual are used, you must be sure that you and
others can do such procedures and actions safely
and without damaging the machine. If you are
unsure about the safety of some procedures,
contact a DOOSAN distributor.
SP002135
Track Excavator Safety Page 8
10
GENERAL SAFETY ESSENTIALS
Accessory Applications The excavator has been
primarily designed for moving earth with a
bucket. For use as a grapple or for other object
handling, contact DOOSAN for proper installation
and application. Lifting- work applications
(unless restricted or prohibited by local
regulations) are permitted in approved lift
configuration, to rated capacity only, with no
side-loading. DO NOT use the machine for
activities for which it was not intended. DO NOT
use the bucket for lifting work, unless lift
slings are used in the approved
configuration. Use of an accessory hydraulic
hammer (breaker), work in rough terrain,
demolition applications or other hazardous
operation may require installation of additional
protective structures to safeguard the
operator. Lifting Capacity Rating
Configuration Lifting capacity ratings that are
printed at the end of this safety section are
based on the machine being level, on a firm
supporting surface, with hooks and slings
attached in approved configuration. Loads must
be balanced and supported evenly. Use tag lines
to keep the load steady if wind conditions and
large surface area are a problem. Work crew hand
signals, individual tasks and safe procedures
should all be universally understood before the
lift is made.
IMPORTANT
Before using the excavator to make lifts check
municipal and regional regulations or statutes
that could apply. Governing ordinances may
require that all heavy lifting be done with
single purpose equipment specifically designed
for making lifts, or other local restrictions may
apply. Making heavy lifts with a general purpose
excavator that can be used for digging, loading,
grading or other work may be expressly forbidden
by a regional injunction or other legal
prohibition. Always follow all of the other
instructions, guidelines and restrictions for
Safe Lifting in the Operation and Maintenance
Manuals.
SP002135 Page 9
Track Excavator Safety
11
Swing Bearing
SP002165
Edition 1
SP002165 Page 1
Swing Bearing
12
SAFETY PRECAUTIONS CAUTION
Follow all safety recommendations and safe shop
practices outlined in the front of this manual
or those contained within this section. Always
use tools and equipment that are in good working
order. Use lifting and hoisting equipment capable
of safely handling load. Remember, that
ultimately safety is your own personal
responsibility.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DX700LC 5001 and Up
SP002165 Page 5
Swing Bearing
13
SWING BEARING MAINTENANCE
Operating Recommendation The service life of the
swing bearing may be extended if a conscious,
daily effort is made to equalize usage over both
ends of the excavator. If the excavator is used
in the same operating configuration day in and
day out (for example, with the travel motors
always under the counterweight, or with the
attachment over one side of the machine more
than the other), the bearing's service life
could be reduced. Taking a few minutes in the
middle of each work shift to reposition the
excavator, to work the opposite end of the
bearing, will provide a payoff in terms of more
even, gradual rate of wear and extended service
life.
Measuring Swing Bearing Axial Play Periodic,
regular checks of bearing displacement should be
made at least twice a year. Use a dial indicator.
Push the attachment against the ground to lift
the excavator off the ground and take
measurements at 4 points, 90 apart, around the
circumference of the bearing (Figure 1). Record
and keep all measurements. Play in the bearing
should increase minimally from one inspection to
the next. Eventually, however, as the bearing
begins to approach the limit of its service
life, clearance increases become much more
pronounced and the actual measured play in the
bearing could exceed twice the value that was
measured when the machine was new.
1
2
Measuring Bearing Lateral Play When vertical
checks are made, the side to side play in the
bearing can be checked by fully retracting the
arm and bucket cylinders and extending the tip
of the bucket as far forward as it will go. With
the excavator parked on a flat, level surface and
the bucket tip just off the ground, push against
the bucket sideways to take up all of the
lateral clearance in the bearing. (Less than 100
lb of force should be required to move the bucket
over all the way.) Check lateral play in both
directions and record the values. When the
bearing is beginning to approach the end of its
service life, measured lateral clearance should
start to show larger and larger increases.
FG000533
Figure 1
SP002165
Swing Bearing Page 6
14
Swing Bearing Basic Operation The swing bearing,
which connects the upper structure with the
lower structure, consists of a inner ring, outer
ring and roller. During swing movement, power
from the swing motor is transferred to the
pinion by planetary gears connected to gears on
the inner ring, which is fixed in the
undercarriage. Ball bearings turn the outer ring.
Reference Number Description
1 Roller
2 Seal A
3 Seal B
4 Retainer
5 Outer Ring
6 Inner Ring
7 Tapered Pin
8 Plug
Figure 2
Rebuilding Swing Bearing 1. Remove tip of tapered
pin (1, Figure 3) using grinder and tap lightly
to remove debris.
Figure 3 2. Remove plug (1, Figure 4) using a
M10 x 1.5 bolt.
Figure 4
SP002165 Page 7
Swing Bearing
15
3. Lift outer ring and check that inner ring can
move freely. See Figure 5, if not, replace seal
(3, 4, Figure 4).
Figure 5 4. Turn inner ring and use magnet bar
(1, Figure 6) to remove steel rollers (2).
2
1
FG016688
Figure 6 5. Turn inner ring and use wire (1,
Figure 7) to remove retainers (2).
Figure 7
SP002165
Swing Bearing Page 8
16
Swing Reduction Gear
SP002149
Edition 1
SP002149 Page 1
Swing Reduction Gear
17
REMOVAL

1. Park on firm and level ground.
2. Lower front attachment (bucket) to ground.
3. Shut down engine.
4. Set safety lever on "RELEASED" position.
5. Turn starter switch to "I" (ON) position.

O
I
WARNING
DO NOT OPERATE when performing inspection or
maintenance 190-00695A
ON OFF
WARNING
FG016400
Figure 2
If engine must be running while performing
maintenance, always use extreme caution. Always
have one person in cab at all times. Never leave
cab with engine running.

1. Fully stroke work levers (joysticks) in all
   directions to relieve any pressure from
   accumulators.
2. Set safety lever on "LOCK" position.
3. Turn key to "O" (OFF) position and remove from
   starter switch.
4. Hang a maintenance warning tag on controls.
5. Disconnect negative (-) battery cable leading to
   frame from battery.
6. Tag and disconnect hoses from swing motor (1,
   Figure 3). Plug and cap hoses and ports to
   prevent contamination from entering hydraulic
   system or component.
7. Disconnect tube (2) from drain cock (3) and hose
   fitting (7) from fill hole.
8. Remove twelve bolts and washers (4, Figure 3)
   holding swing reduction gearbox (5) to frame.
9. Using a suitable lifting device, sling swing
   motor (1, Figure 3) and remove swing motor and
   reduction gearbox (5) as an assembly from unit.

NOTE
A drain cock (3, Figure 3) and tube are on side
of gearbox. Be careful not to damage valve or
tube. There are two alignment pins (6, Figure 3),
one on each side of reduction gearbox flange.
NOTE
Figure 3
SP002149
Swing Reduction Gear Page 12
18
DISASSEMBLY
NOTE
Clean all exterior surfaces of the gearbox before
beginning disassembly.
1. Remove the drain plugs and allow all oil to
drain from the gearbox.
IMPORTANT
Use a clean, dry container (with at least 11
liters, or 2.9 gallons capacity) to catch gear
oil. A clean container allows an evaluation to
be made of the used oil. The presence or
relative lack of metal wear shavings in the used
oil or obvious deterioration or contamination of
the oil can provide a useful indicator of the
motors general condition.
FG005086
Figure 4

1. Remove the socket cap screws that hold the cover
   to the gearbox housing. Remove the cover from
   the housing.
2. Remove the sun gear.
3. Thread an eye bolt into each of the three shafts
   that support the 1st level planetary gears. Loop
   lifting straps through the eye bolts and lift
   the planetary gears and the first planetary
   mounting plate out of the gearbox.
4. Slide sun gear off the shaft and out of the
   gearbox.

HNA3051I
Figure 5
6. Thread an eye bolt into carrier No. 2. Loop
lifting straps through the eye bolts and lift
the gear housing assembly out of the gearbox.
FG017131
Figure 6
SP002149 Page 13
Swing Reduction Gear
19
7. Use a flat tipped punch to drive the spring
pin back into the shaft, so that the shaft can
be pulled out of the carrier No. 2. Drive back
the spring pins on the other two shafts.
HNA3053I
Figure 7 8. Hold the planet gear No. 2 and side
plate No. 2 with one hand and slide the gear
shaft out of the carrier No. 2. Use this method
to remove the two remaining gear shafts, gears,
and plates. Use the punch to drive the spring
pins out of the shafts. Use new spring pins when
assembling the gearbox.
HNA3054I
Figure 8 9. Sealant has been applied to the
joint where the ring gear and the gear case
meet. It will be necessary to pry the ring gear
from the gear case, to separate the two parts.
HNA3055I
Figure 9 10. Use a screwdriver to pry the snap
ring from the output side of the gear case.
HNA3056I
Figure 10
SP002149
Swing Reduction Gear Page 14
20
11. Insert the gear case into a hydraulic press.
Position the gear case so that the input end of
the shaft is facing up. Insert a metal spacer
into the bore of the shaft. Press down on the
shaft until the shaft, with the spacer, plate,
and roller bearing attached, is pressed out of
the gear case.
HNA3057I
Figure 11 12. Reach into the gear case and
remove the roller bearing.
HNA3058I
Figure 12 13. Use a hammer and a screwdriver to
drive the seal out of the gear case.
NOTE
It is only necessary to disassemble the shaft
when one of the shaft components is damaged
(bearing, spacer, etc.) and needs replacement.
HNA3059I
Figure 13
SP002149 Page 15
Swing Reduction Gear
21

1. Set the shaft down into a metal pipe that has an
   inside diameter of 145 mm. The pipe should
   contact the bearing inner race only. Place a
   metal spacer on top of the shaft. Use a
   hydraulic press to press down on the spacer until
   the bearing is free of the shaft. Slide the
   shaft spacer, plate, bearing and bearing spacer
   off the shaft.
2. Use a nonflammable, nontoxic solvent to clean all
   gearbox parts. Dry the parts with compressed
   air. Inspect all parts before assembly. Replace
   any parts that show damage or obvious signs of
   wear.

FG003570
Figure 14
SP002149
Swing Reduction Gear Page 16
22

• ASSEMBLY
• Shaft and S/R Bearing Shrinkage Fitting
• Washing of the shaft
• Remove liquid like anti-corrosion liquid on the
  shaft and then use an air gun to remove all of
  remaining foreign substance.
• Insert the spacer in the prepared shaft as shown
  in the figure below and put and heat the bearing
  on the specified heater.

FG004999
Figure 15
FG003570
Figure 16
SP002149 Page 17
Swing Reduction Gear
23
FG001995
Figure 17 3. Lift the bearing when the
temperature of the heater reaches 90 - 100C
(194 - 212F) and put it into the shaft with
both hands holding it horizontally. To do so,
insert it slowly about 4 to 5 mm that the
bearing takes its seat by itself and then push
it with force that it sticks to the spacer
assembled into the shaft.
FG005005
Figure 18
FG005006
Figure 19
SP002149
Swing Reduction Gear Page 18
24
4. After completing the assembly of the bearing,
allow the bearing to air dry for one to two
hours.
FG003569
Figure 20 Assembly of the Carrier
Subassembly Washing of the Carrier Use a dipping
washer to wash the carrier which was got rid of
burr through a corner end finishing (shaping)
process, check again if foreign substance is
removed completely, and put it on the assembly
die. Washing of Planet Gears Check if planet
gears are washed well and have any dent and put
them on the assembly die. Assembly of the
Carrier Subassembly 1 1. Put the carrier No.1 on
the assembly jig as shown in the figure below.
Figure 21
SP002149 Page 19
Swing Reduction Gear
25
2. Put the pin assembly No.1 on the pin hole
correctly and insert it with a press.
Figure 22
Figure 23
3. After its pressure insert, check its state
visually.
Figure 24
SP002149
Swing Reduction Gear Page 20
26
4. Insert the pin assembly 1 in the 3 remaining
parts with a pressure in the same way.
Figure 25 5. Turn over the carrier in which the
pin is inserted and put the thrust washer No.1
on 4 pins as shown in the figure below.
Figure 26
Figure 27
SP002149 Page 21
Swing Reduction Gear
27
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6. Assemble the planetary gear No.1.
Figure 28 7. Put thrust washer No.3 as shown in
the figure below.
Figure 29 8. Engage the snap ring (for ø40 axis)
to each groove of the pin 1 and turn the gear to
check if it rotates smooth.
Figure 30
SP002149
Swing Reduction Gear Page 22
29
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