Doosan DX420LC Crawler Excavator Workshop Repair Service Manual PDF, Serial 5001 and Up, K1009096E, K1009096AE - MDSDX420OPEK.zip

A full-service repair guide, complete with electrical schematics, for the Doosan DX420LC Crawler Excavator, offering the same technical detail professionals rely on to keep, troubleshoot, fix, and service the machine.

Inside the Doosan DX420LC Crawler Excavator workshop service repair manual you'll find:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 1,775 pages

File Format: PDF (bookmarked, Searchable, Printable, high quality)

Language: English

“K1009096E.pdf”

Doosan DX420LC Crawler Excavator Shop Manual

Serial Number 5001 and Up; K1009096E; 900 pages

MAIN SECTIONS

Safety

Track Excavator Safety... SP000256

Specifications

Specification for DX420LC.. SP000257

General Maintenance

General Maintenance Procedures... SP000016

Standard Torques... SP000017

Upper Structure

Cabin ... SP000018

Counterweight.. SP000265

Fuel Tank... SP000264

Swing Bearing.. SP000262

Swing Reduction Gear.. SP000249

Lower Structure and Chassis

Track Assembly ... SP000263

Air Conditioner ... SP000025

Engine and Drive Train

Drive Coupling (Main Pump)... SP000026

Hydraulics

Hydraulic System Troubleshooting, Testing and Adjustment ... SP000273

Accumulator... SP000028

Center Joint (Swivel)... SP000181

Cylinders.. SP000030

Swing Motor... SP000261

Travel Motor (With Gearbox) .. SP000266

Main Pump... SP000186

Control Valve (KVMG-400-DA)... SP000187

Remote Control Valve (Work Lever / Joystick) .. SP000189

Travel Control Valve (With Damper).. SP000070

Solenoid Valve Assembly ... SP000191

Breaker EPPR Valve (Opt) ... SP000192

Fan Motor (Vane Type)... SP000209

Gear Pump (Fan Cooling Drive) ... SP000208

Fan Cooling Flow In-Out Change Valve .. SP000207

Hydraulic Schematic (DX420LC).. SP000274

Electrical System

Electrical System .. SP000269

Electrical Schematic (DX420LC) .. SP000275

Attachments

Boom and Arm... SP000040

Bucket.. SP000041

“K1009096AE.pdf”

Doosan DX420LC Crawler Excavator Shop Manual

Serial Number 5327 and Up; K1009096AE; 862 pages

Table of Contents

Safety

Track Excavator Safety... SP000907

Specifications

Specification for DX420LC.. SP001755

General Maintenance

General Maintenance Procedures... SP000016

Standard Torques... SP000813

Upper Structure

Cabin ... SP001737

Counterweight.. SP001756

Fuel Tank... SP001757

Fuel Transfer Pump (Opt)... SP000021

Swing Bearing.. SP001856

Swing Reduction Gear.. SP001740

Lower Structure and Chassis

Track Assembly ... SP000263

Engine and Drive Train

Drive Coupling (Main Pump)... SP000026

Hydraulics

Hydraulic System Troubleshooting, Testing and Adjustment ... SP001758

Accumulator... SP000028

Center Joint (Swivel)... SP000181

Cylinders.. SP000030

Swing Motor... SP000261

Travel Motor (With Gearbox) .. SP000266

Main Pump... SP000186

Gear Pump (Fan Cooling Drive) ... SP000208

Main Control Valve ... SP000187

Remote Control Valve (Work Lever / Joystick) .. SP000189

Travel Control Valve (With Damper).. SP001743

Fan Motor (Vane Type)... SP000209

Fan Cooling Flow In-Out Change Valve .. SP000207

Solenoid Valve Assembly ... SP001622

Breaker EPPR Valve (Opt) ... SP000192

Hydraulic Schematic (DX420LC).. SP001769

Electrical System

Electrical System.. SP001759

Electrical Schematic DX420LC... SP001857

Attachments

Boom and Arm... SP001851

Bucket.. SP001852

...

TABLE OF CONTENTS

CENDX4200002 - Electrical Wiring Diagrams......1

DX420 Electrical Schematics......2

DX420 Hydraulic Schematics......3

DX420LC Performance Data......4

K1009096AE - DX420LC Shop Manual......5

DX420LC......5

Table of Contents......9

Safety......11

Track Excavator Safety......13

Safety Precautions......17

Applicable Models......17

To the Operator of a DOOSAN Excavator......18

Learn the Signal Words Used with the Safety Alert Symbol......20

General Safety Essentials......21

Accessory Applications......21

Lifting Capacity Rating Configuration......21

Location of Safety Labels......22

Summary of Safety Precautions for Lifting in Digging Mode......22

Unauthorized Modifications......23

General Hazard Information......23

Safety Rules......23

Safety Features......24

Inside Operator's Compartment......24

Clothing and Personal Protective Items......25

Breathing Masks, Ear Protection May Be Required......25

Vibration Level Information......25

Recommendations for Limiting Vibrations......26

Mounting and Dismounting......27

Fuel, Oil and Hydraulic Fluid Fire Hazards......27

Precautions When Handling Fluids at High Temperature......28

Asbestos Dust Hazard Prevention......28

Injury from Work Equipment......29

Fire Extinguisher and First Aid Kit......29

Protection from Falling or Flying Objects......30

Attachment Precautions......30

Accumulator......31

Indoor Ventilation......31

Emergency Exit......31

Before Starting Engine......32

Work Site Precautions......32

Checks Before Starting Engine......33

Engine Starting......34

Before Operating Machine......35

Machine Operation......36

When Swinging or Changing Direction of Travel......36

Travel Precautions......37

Traveling on Slopes......38

Prohibited Operations......38

Precautions for Operation......39

Avoid High Voltage Cables......40

Protecting Cabin from Falling Object (Optional)......40

Operate Carefully on Snow, Ice and in Very Cold Temperatures......41

Operations on Slopes......41

Parking Machine......42

Never Let Anyone Ride on Attachment......42

Maintenance......43

Warning Tag......43

Clean Before Inspection or Maintenance......43

Proper Tools......44

Use of Lighting......44

Fire Prevention and Explosion Prevention......44

Burn Prevention......45

Welding Repairs......45

Treatment for Electrical Welding to the Body Structure......46

Warning for Counterweight and Front Attachment Removal......47

Precautions for Removal, Installation, and Storage of Attachments......47

Precautions When Working on Machine......47

Lock Inspection Covers......48

Crushing Prevention and Cutting Prevention......48

Track Tension Adjustments Require Caution......48

Supports and Blocking for Work Equipment......49

Action When Abnormality Is Found During Inspection......49

Precautions with High-pressure Lines, Tubes and Hoses......49

Waste Materials......50

Battery......51

Battery Hazard Prevention......51

Boost Starting or Charging Engine Batteries......52

Towing......53

Precautions When Towing......53

Shipping and Transportation......54

Obey State and Local Over-the-Road Regulations......54

Lifting With Sling......54

Specifications......55

Specification for DX420LC......57

Safety Precautions......61

Applicable Models......61

General Description......63

Component Locations......64

General Dimensions (DX420LC)......66

Working Range......68

General Specifications......70

Engine Performance Curves (Per DIN6270 Standard)......72

Approximate Weight of Workload Materials......74

Performance Tests......76

Excavator Performance Standards......77

Test Conditions......77

Travel Speed and Travel Motor Balance (Steering Deviation) Tests......77

Speed Test......77

Travel Deviation......79

Swing Speed and Deceleration Force Test......79

Swing Speed Test......79

Swing Deceleration Force Test......80

Cylinder Performance Tests......81

Boom Cylinders Test......81

Arm Cylinder Test......81

Bucket Cylinder Test......81

Hydraulic Cylinder Natural Drop Test......81

Travel Motor Jack-up Test......82

General Maintenance......83

General Maintenance Procedures......85

Safety Precautions......89

Applicable Models......89

Welding Precautions and Guidelines......90

Hydraulic System - General Precautions......91

Maintenance Service and Repair Procedure......93

General Precautions......93

Hydraulic System Cleanliness and Oil Leaks......94

Maintenance Precautions for Hydraulic System Service......94

Oil Leakage Precautions......95

Cleaning and Inspection......96

General Guidelines......96

Bearing inspection......97

Normal Bearing......98

Bent Cage......98

Galling......99

Abrasive Step Wear......99

Etching......100

Misalignment......100

Indentations......100

Fatigue Spalling......101

Brinelling......101

Cage Wear......101

Abrasive Roller Wear......102

Cracked Inner Race......102

Smears......102

Frettage......103

Heat Discoloration......103

Stain Discoloration......103

Standard Torques......105

Safety Precautions......109

Applicable Models......109

Torque Values for Standard Metric Fasteners......110

Torque Values for Standard U.S. Fasteners......111

Type 8 Phosphate Coated Hardware......113

Torque Values for Hose Clamps......114

Torque Values for Split Flanges......115

Torque Wrench Extension Tools......116

Torque Multiplication......116

Other Uses for Torque Wrench Extension Tools......117

Tightening Torque Specifications (Metric)......118

I. "Loctite" Fastener Adhesives......119

II. "Loctite" Pipe Thread Sealant......119

III. "Loctite" gasket/flange sealer......119

IV. "Loctite" retaining compounds......120

V. "Loctite" Adhesives......120

Upper Structure......121

Cabin......123

Safety Precautions......127

Applicable Models......127

Removal......128

Installation......132

Counterweight......135

Safety Precautions......139

Applicable Models......139

General......140

Warning for Counterweight and Front Attachment Removal......140

Removal......142

Installation......143

Fuel Tank......145

Safety Precautions......149

Applicable Models......149

General Description......150

Parts List......150

Specifications......151

Removal......152

Installation......156

Start-up Procedures......158

Fuel Transfer Pump (Opt)......159

Safety Precautions......163

Applicable Models......163

General Description......164

Theory of Operation......164

Troubleshooting......165

Replacement of Rotor and Vane......165

Replacement of Rear Cover......166

Replacement of Armature......166

Swing Bearing......167

Safety Precautions......171

Applicable Models......171

Swing Bearing Maintenance......172

Operating Recommendation......172

Measuring Swing Bearing Axial Play......172

Measuring Bearing Lateral Play......172

Swing Bearing Basic Operation......173

Disassembly......173