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Doosan DX420LC-5 Excavator Operation & Maintenance Manual 950106-01019NA-1 – PDF DOWNLOAD
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Doosan DX420LC-5 Excavator Operation & Maintenance Manual 950106-01019NA-1 – PDF DOWNLOAD
Serial Number 10001
950106-01019NA-1
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Description
Doosan DX420LC-5 Excavator Operation & Maintenance Manual 950106-01019NA-1 – PDF DOWNLOAD
DESCRIPTION:
Doosan DX420LC-5 Excavator Operation & Maintenance Manual 950106-01019NA-1 – PDF DOWNLOAD
Serial Number 10001
950106-01019NA-1
Foreword:
- This Operation & Maintenance Manual was written to give owner or operator instructions on safe operation and maintenance of DOOSAN equipment.
- READ AND UNDERSTAND THIS OPERATION AND MAINTENANCE MANUAL BEFORE OPERATING YOUR DOOSAN EQUIPMENT.
- Keep this manual in the cabin so it is always available. If it is lost, order another one from your DOOSAN distributor.
- If there are any questions, contact your DOOSAN distributor. This manual may illustrate options and accessories not installed on your equipment.
- Any modification made without written authorization or approval from DOOSAN can create a safety hazard.
- Always replace parts with genuine DOOSAN parts or DOOSAN authorized replacement parts.
Intended Use:
- This Operation & Maintenance Manual was written to give owner or operator instructions on safe operation and maintenance of DOOSAN equipment.
- READ AND UNDERSTAND THIS OPERATION AND MAINTENANCE MANUAL BEFORE OPERATING YOUR DOOSAN EQUIPMENT.
- Keep this manual in the cabin so it is always available. If it is lost, order another one from your DOOSAN distributor.
- If there are any questions, contact your DOOSAN distributor.
- This manual may illustrate options and accessories not installed on your equipment. Any modification made without written authorization or approval from DOOSAN can create a safety hazard.
- Always replace parts with genuine DOOSAN parts or DOOSAN authorized replacement parts.
Engine and Emission Control SystemMaintenance:
- Proper inspection, maintenance and repair is essential to keeping engine and machine systems properly operating.
- This includes proper inspection and maintenance of the machine’s emission control system.
- This could include machine and engine components, such as an EGR (Exhaust Gas Recirculation) system, fuel system, turbocharger, electrical system, air intake system and/or cooling system. As a heavy-duty off-road diesel engine owner, you are responsible for performing required maintenance.
- The required maintenance procedures are outlined in this Operation & Maintenance Manual, or Shop Manual.
- Do not remove, alter, or render inoperative, any emission control system.
Machine Capacity:
- Do not exceed machine capacity by modifying machine or using unapproved attachments.
- Exceeding machine capacity can adversely affect machine performance characteristics such as: stability, system certifications such as brakes and steering, the Roll-over Protective Structure (ROPS) and can result in death or serious injury.
- Contact your DOOSAN distributor for further information.
Attachments:
- These and other attachments are approved for use on this machine.
- Do not use unapproved attachments.
- Attachments not manufactured by DOOSAN may not be approved. See your DOOSAN distributor for information about approved attachments and attachment manuals.
• Buckets
• Hydraulic Breakers
• Grapples
• Plate Compactors
• Quick Couplers
TABLE OF CONTENTS:
Doosan DX420LC-5 Excavator Operation & Maintenance Manual 950106-01019NA-1 – PDF DOWNLOAD
DX420LC-5....................................................................................................................................................... 0
Foreword.................................................................................................................................................... 9
Intended Use............................................................................................................................................ 9
Engine and Emission Control System Maintenance.......................................................................................................... 9
Machine Capacity........................................................................................................................................ 10
Attachments............................................................................................................................................. 10
Engine Identification................................................................................................................................... 12
Engine Data Plate................................................................................................................................... 12
Your Machine Serial Numbers............................................................................................................................. 12
Safety Messages......................................................................................................................................... 12
Signal Words........................................................................................................................................ 13
Other Signal Words.................................................................................................................................. 13
AEM Safety Manual (North America Only).................................................................................................................. 14
Federal Emission Control Systems........................................................................................................................ 15
Emission Control System Warranty Statement.......................................................................................................... 15
General Warranty Provisions..................................................................................................................... 15
Warranty Period................................................................................................................................. 15
The Warranty on Emission-related Parts Shall be Interpreted as Follows:......................................................................... 16
Parts Covered by the Warranty................................................................................................................... 17
General Warranty Limitations.................................................................................................................... 18
Specific Warranty Exclusions.................................................................................................................... 19
Customer Support................................................................................................................................ 20
California Emission Control Warranty Statement...................................................................................................... 20
Your Warranty Rights and Obligations................................................................................................................ 20
Manufacturer's Warranty Coverage.................................................................................................................... 20
Owner's Warranty Responsibilities................................................................................................................... 21
Catalytic Converter................................................................................................................................. 21
Safety...................................................................................................................................................... 25
Safety Decals........................................................................................................................................... 26
Safety Decals With Text............................................................................................................................. 26
Safety Decals Without Text (No-Text)................................................................................................................ 27
Information and Location for Safety Decals.......................................................................................................... 28
Information and Location for Safety Decals (Continued).............................................................................................. 29
25. Do Not Lift (950205-03570).................................................................................................................. 39
26. DEF (AdBlue) (950205-01489A)................................................................................................................ 39
General................................................................................................................................................. 40
Safe Operation is Operator's Responsibility......................................................................................................... 40
Know Your Machine................................................................................................................................... 40
Proper Work Tools and Attachments................................................................................................................... 41
Pressurized Fluids.................................................................................................................................. 41
Flying or Falling Objects........................................................................................................................... 42
Personal Protective Equipment (PPE)................................................................................................................. 43
Correction of Machine Problems...................................................................................................................... 43
Crushing and Cutting................................................................................................................................ 43
Hot Coolant and Oils - Burn Prevention.............................................................................................................. 44
Fire and Explosion Prevention....................................................................................................................... 45
Maintenance..................................................................................................................................... 45
Operation....................................................................................................................................... 45
Electrical...................................................................................................................................... 46
Hydraulic System................................................................................................................................ 46
Fueling......................................................................................................................................... 47
Never Use Ether Starting Aids................................................................................................................... 47
Welding and Grinding............................................................................................................................ 47
If a Fire Occurs................................................................................................................................ 48
Fire Extinguisher and First-aid Kit (Emergency Medical Kit)......................................................................................... 48
Electrical System and Electrical Shock.............................................................................................................. 49
Roll-over Protective Structure (ROPS)............................................................................................................... 49
ROPS Certification.............................................................................................................................. 50
Protecting Cabin from Flying or Falling Objects (Optional)...................................................................................... 51
Emergency Exit from Operator's Station.......................................................................................................... 52
Transportation.......................................................................................................................................... 53
Obey State and Local Over-the-Road Regulations...................................................................................................... 53
Loading and Unloading............................................................................................................................... 53
Transporting Machine................................................................................................................................ 54
Operation............................................................................................................................................... 55
Before Engine Starting.............................................................................................................................. 55
Machine Condition............................................................................................................................... 55
Work Site........................................................................................................................................... 56
Mounting/Dismounting................................................................................................................................ 57
Cleaning............................................................................................................................................ 58
Operator Station.................................................................................................................................... 58
Seat Belt........................................................................................................................................... 59
Visibility Information.............................................................................................................................. 60
Work Site Rules................................................................................................................................. 60
Boost Starting or Charging Engine Batteries......................................................................................................... 61
Swinging or Traveling............................................................................................................................... 63
Lifting and Digging................................................................................................................................. 65
Operation on Slopes................................................................................................................................. 66
Towing.............................................................................................................................................. 67
Attachment.......................................................................................................................................... 68
Equipment Lowering with Engine Stopped.............................................................................................................. 68
Engine Stop......................................................................................................................................... 69
Parking Machine..................................................................................................................................... 69
Preservation/Storing Machine........................................................................................................................ 70
Check After Long-term Parking................................................................................................................... 71
Maintenance............................................................................................................................................. 72
Cleaning............................................................................................................................................ 75
Proper Tools and Clothing........................................................................................................................... 75
Disassembling Precautions........................................................................................................................... 75
Use of Lighting..................................................................................................................................... 75
Fire and Explosion Prevention....................................................................................................................... 76
Burn Prevention..................................................................................................................................... 77
Rubber That Contains Fluorides...................................................................................................................... 78
Rubber and Plastics................................................................................................................................. 79
Waste Hazardous to the Environment.............................................................................................................. 79
Check List After Fire........................................................................................................................... 79
Welding Repairs..................................................................................................................................... 80
Preparation for Electrical Welding on Body Structure............................................................................................ 80
Warning for Counterweight and Front Attachment Removal.............................................................................................. 81
Lock Inspection Covers.............................................................................................................................. 82
Working on Machine.................................................................................................................................. 82
Accumulator......................................................................................................................................... 83
Compressed Air...................................................................................................................................... 83
Track Tension Adjustments........................................................................................................................... 84
Supports and Blocking for Work Equipment............................................................................................................ 84
High-pressure Lines, Tubes and Hoses................................................................................................................ 85
Battery............................................................................................................................................. 86
Battery Hazard Prevention....................................................................................................................... 86
Environment and Circumstances........................................................................................................................... 88
Work Site Areas Requiring Extra Caution............................................................................................................. 88
Digging Under an Overhang....................................................................................................................... 88
Deep Digging.................................................................................................................................... 88
Drop-off or Edge................................................................................................................................ 89
Poor Visibility................................................................................................................................. 89
Loose or Soft Ground............................................................................................................................ 89
High-voltage Cables................................................................................................................................. 90
Underground Operation............................................................................................................................... 91
Working in Water.................................................................................................................................... 91
Working in Contaminated Environment................................................................................................................. 91
Operation in Extreme Conditions..................................................................................................................... 92
Operation In Extreme Cold....................................................................................................................... 92
Operation in Extreme Heat....................................................................................................................... 93
Operation In Dusty and Sandy Areas.............................................................................................................. 94
Operation in Rainy or Humid Conditions.......................................................................................................... 95
Operation in Saltwater Areas.................................................................................................................... 95
Operation at High Altitudes..................................................................................................................... 96
Operation During Electrical Storms.............................................................................................................. 96
Exhaust Ventilation................................................................................................................................. 96
Ventilation for Enclosed Area................................................................................................................... 96
Asbestos Information................................................................................................................................ 97
Silica Dust Information............................................................................................................................. 97
Disposal of Hazardous Materials..................................................................................................................... 98
Sound............................................................................................................................................... 98
Vibration Information............................................................................................................................... 99
Hand/Arm Vibration Level........................................................................................................................ 99
Whole Body Vibration Level...................................................................................................................... 99
Guidelines for Use and Working Conditions of Earth-moving Machinery to Reduce Vibration Levels (ISO/TR 25398 Annex E)........................... 99
Operating Controls..........................................................................................................................................101
Component Locations.....................................................................................................................................102
Operator's Area.........................................................................................................................................106
Operational Controls and Panels.........................................................................................................................108
1. Starter Switch...................................................................................................................................110
2. Heater and Air Conditioner Control Panel.........................................................................................................111
3. Power Socket for 12 Volt.........................................................................................................................111
4. Cigarette Lighter................................................................................................................................111
5. Smart Power Control Switch.......................................................................................................................112
6. Engine Speed Control Dial........................................................................................................................112
7. Travel Speed Selector Switch.....................................................................................................................112
8. Light Switch.....................................................................................................................................113
9. Intelligent Floating Boom Switch (Optional)......................................................................................................113
10. Cabin Work Light Switch (Optional)..............................................................................................................113
11. Audio Control Panel.............................................................................................................................114
12. Wiper Control Panel.............................................................................................................................115
13. Quick Coupler Switch (Optional).................................................................................................................116
14. Air Compressor Switch (Optional)................................................................................................................117
15. Warning Light Switch (Optional).................................................................................................................117
16. Lower Wiper Switch (Optional)...................................................................................................................117
17. Travel/Swing Alarm Switch (Optional)............................................................................................................118
18. Overload Warning Switch (Optional)..............................................................................................................118
19. Power Socket for 12 Volt (Optional).............................................................................................................119
20. Horn Button (Left-hand Work Lever)..............................................................................................................119
21. Breaker/Booster Button (Right-hand Work Lever)..................................................................................................119
22. Rotating Switch.................................................................................................................................120
23. Shear Switch....................................................................................................................................120
24. Display Monitor.................................................................................................................................121
25. Photo Sensor....................................................................................................................................121
26. Safety Lever....................................................................................................................................121
27. Auxiliary Mode Switch...........................................................................................................................122
28. Hour Meter......................................................................................................................................122
29. Emergency Start Mode Switch.....................................................................................................................122
30. One Touch Deceleration Button...................................................................................................................123
31. Intelligent Floating Boom Temporary Reset Button................................................................................................123
32. Selector Switch Control Panel...................................................................................................................123
33. Jack Assembly...................................................................................................................................125
34. Micro Phone (Optional)..........................................................................................................................126
Display Monitor.........................................................................................................................................127
Functional Check....................................................................................................................................127
Password Activated..................................................................................................................................128
1. Fuel Gauge.......................................................................................................................................128
2. DEF (AdBlue) Level Gauge.........................................................................................................................128
3. Engine Coolant Temperature Gauge.................................................................................................................129
4. Hydraulic Oil Temperature Gauge..................................................................................................................129
5. Multifunction Gauge and Graphic Information Area.................................................................................................130
6. ECO Gauge........................................................................................................................................131
7. Trip Meter.......................................................................................................................................131
8. Digital Clock....................................................................................................................................132
9. Display Warning Symbols..........................................................................................................................132
10. Warning Light...................................................................................................................................139
11. Function Buttons................................................................................................................................139
12. Mode Selector Buttons...........................................................................................................................141
13. Selector Function Display.......................................................................................................................143
14. Jog Switch......................................................................................................................................143
15. Camera Mode Selector/ESC Button.................................................................................................................143
16. Multimedia Selector Button......................................................................................................................144
Launch Menu.........................................................................................................................................145
Warning Pop-up Window...............................................................................................................................148
Warning Pop-up Windows List.....................................................................................................................150
User Menu...............................................................................................................................................151
User Menu - Access and Escape Methods...............................................................................................................151
Access Method...................................................................................................................................151
Escape Method...................................................................................................................................151
User Menu.......................................................................................................................................151
Switch Operation Indication.........................................................................................................................188
Heater and Air Conditioner Control Panel................................................................................................................191
Location of Controls and Vents......................................................................................................................191
Control Panel.......................................................................................................................................192
1. Automatic Temperature Control Button.........................................................................................................192
2. Off Button...................................................................................................................................193
3. Temperature Control Button...................................................................................................................193
4. Temperature Unit Selector Button.............................................................................................................193
5. Mode Selector Button.........................................................................................................................193
6. Air Inlet Selector Button....................................................................................................................195
7. Fan Speed Selector Buttons...................................................................................................................195
8. Air Conditioner Button.......................................................................................................................195
9. Defroster Button.............................................................................................................................196
10. LCD Display.................................................................................................................................196
Memory Function.....................................................................................................................................196
Additional Operating Instructions...................................................................................................................196
Miscellaneous Electrical Devices........................................................................................................................198
Cabin Light.........................................................................................................................................198
Pilot Cutoff Switch.................................................................................................................................198
Circuit Breaker (80 A)..............................................................................................................................198
Circuit Breaker (30 A)..............................................................................................................................199
Fuse Boxes..........................................................................................................................................199
Seat Adjustment......................................................................................................................................... 0
6. Seat Belt........................................................................................................................................ 0
Seat Belt Locking and Unlocking.................................................................................................................202
7. Storage Compartment..............................................................................................................................202
8. Left and Right Control Stand Adjustment..........................................................................................................202
Engine Emergency Stop Switch............................................................................................................................204
Emergency Exit Glass Breaking Tool......................................................................................................................204
Miscellaneous Convenience Devices....................................................................................................................... 0
Front Windows.......................................................................................................................................206
Front Upper Window..............................................................................................................................206
Door Side Latch.....................................................................................................................................208
Cabin Storage Compartments..........................................................................................................................209
Sunglasses Case.....................................................................................................................................209
Sun Visor...........................................................................................................................................210
Front Window Visor..............................................................................................................................210
Ceiling Window Visor............................................................................................................................210
Miscellaneous Access Covers and Doors...................................................................................................................212
Side Door...........................................................................................................................................212
Storage Box Door....................................................................................................................................212
Opening.........................................................................................................................................212
Closing.........................................................................................................................................212
Engine Cover........................................................................................................................................213
Air Gun and Compressor (Optional).......................................................................................................................214
Air Gun (Optional)..................................................................................................................................214
How to Use Air Compressor...........................................................................................................................214
Operation...................................................................................................................................................217
To Operate a New Excavator..............................................................................................................................217
Lubrication and Filters.............................................................................................................................218
Starting and Stopping Engine............................................................................................................................218
Inspection Before Starting Engine...................................................................................................................218
Walk Around Checks..............................................................................................................................218
Checks Before Starting Engine...................................................................................................................219
Operational Checks Before Starting Engine...........................................................................................................221
Engine Start........................................................................................................................................222
After start limit logic.........................................................................................................................224
Cold Weather Starting...............................................................................................................................224
Engine Coolant Heater (Optional)....................................................................................................................226
Plug Heater (Optional)..............................................................................................................................228
Starting Engine with a Booster Cable................................................................................................................229
Connecting Booster Batteries....................................................................................................................229
Disconnecting Booster Batteries.................................................................................................................230
Hydraulic System Warm-up............................................................................................................................230
Hydraulic System Warm-up - Cold Weather.............................................................................................................231
Stopping Engine.....................................................................................................................................233
Checks and Maintenance After Stopping Engine........................................................................................................234
Safety Lever............................................................................................................................................234
Travel..................................................................................................................................................235
Automatic Travel Speed Control......................................................................................................................235
Travel Control Lever Operation......................................................................................................................236
General Travel Instructions.........................................................................................................................237
Straight Travel Pedal (Optional)....................................................................................................................239
Operating.......................................................................................................................................240
Locking Pedal...................................................................................................................................240
Operating Instructions..................................................................................................................................241
Engine Speed Control................................................................................................................................241
Emission Control System.............................................................................................................................241
Reaction at Low Reductant Level.................................................................................................................241
Reaction to Faults in SCR System (Only EPA).....................................................................................................242
Mode Selection......................................................................................................................................243
Power Mode......................................................................................................................................243
Work Mode.......................................................................................................................................244
Auto Idle Mode..................................................................................................................................244
Boost Mode......................................................................................................................................245
Work Levers (Joysticks) (ISO Pattern)...............................................................................................................246
Left-hand Work Lever (Joystick) (Figure 55 and Figure 56).......................................................................................246
Right-hand Work Lever (Joystick) (Figure 55 and Figure 58)......................................................................................246
Work Levers (Joysticks) (BHL Pattern)...............................................................................................................248
Left-hand Work Lever (Joystick) (Figure 59 and Figure 61).......................................................................................248
Right-hand Work Lever (Joystick) (Figure 59 and Figure 62)......................................................................................248
Intelligent Floating Boom Control (Optional)........................................................................................................249
Intelligent Floating Boom Mode..................................................................................................................249
Operating a Breaker.............................................................................................................................249
Truck Loading...................................................................................................................................250
Smart Power Control (SPC)...........................................................................................................................251
Operating Precautions...................................................................................................................................252
Working in Water....................................................................................................................................258
Escaping From Mud...................................................................................................................................258
Track On One Side Stuck.........................................................................................................................258
Tracks On Both Sides Stuck......................................................................................................................258
Parking Excavator.......................................................................................................................................259
Towing Procedure........................................................................................................................................260
Attachments.............................................................................................................................................261
Bucket Replacement and Reversal.....................................................................................................................261
Replacement.........................................................................................................................................261
Reversal (If Applicable)............................................................................................................................263
Hydraulic Attachments (Optional)........................................................................................................................264
Breaker Operation...................................................................................................................................264
Selection of Hydraulic Breaker..................................................................................................................264
Hydraulic Hoses and Tubing for Breaker..........................................................................................................264
Breaker Operating Precautions...................................................................................................................265
To Activate Breaker.............................................................................................................................267
Hydraulic Oil and Filter Service Intervals......................................................................................................268
Shear Operation.....................................................................................................................................269
To Activate Shear...............................................................................................................................270
Rotating Operation..................................................................................................................................273
Quick Coupler Operation.............................................................................................................................274
To Engage Attachment............................................................................................................................274
To Release Attachment...........................................................................................................................278
Lifting Objects.........................................................................................................................................279
Lifting Unknown Weight..............................................................................................................................280
Lifting Known Weight................................................................................................................................280
Pick and Carry......................................................................................................................................280
Lifting Objects with Quick Coupler......................................................................................................................281
Operation Under Abnormal Conditions.....................................................................................................................283
Operation In Extreme Cold...........................................................................................................................283
Operation in Extreme Heat...........................................................................................................................284
Operation In Dusty and Sandy Areas..................................................................................................................286
Operation in Rainy or Humid Conditions..............................................................................................................286
Operation in Saltwater Areas........................................................................................................................287
Operation at High Altitudes.........................................................................................................................287
Operation During Electrical Storms..................................................................................................................287
Equipment Lowering with Engine Stopped..............................................................................................................288
Machine without a Boom Lock Valve...............................................................................................................288
Machine with a Boom Lock Valve..................................................................................................................290
Long Term Storage.......................................................................................................................................291
Before Storage......................................................................................................................................291
During Storage......................................................................................................................................292
After Storage.......................................................................................................................................292
Inspection, Maintenance and Adjustment......................................................................................................................293
Maintenance Information.................................................................................................................................293
Operational Hour Meter Reading......................................................................................................................293
DOOSAN Genuine Replacement Parts....................................................................................................................293
DOOSAN Genuine Lubricants...........................................................................................................................293
Windshield Washer Fluid.............................................................................................................................293
Fresh and Clean Lubricants..........................................................................................................................293
Check Drained Oil and Used Filter...................................................................................................................293
Fuel Strainer.......................................................................................................................................293
Welding Instructions................................................................................................................................294
Do Not Drop Things Inside Machine...................................................................................................................294
Dusty Work Site.....................................................................................................................................294
Avoid Mixing Lubricants.............................................................................................................................294
Locking Inspection Covers...........................................................................................................................294
Hydraulic System - Air Bleeding.....................................................................................................................295
Hydraulic Hose Installation.........................................................................................................................295
Checks After Inspection and Maintenance Works.......................................................................................................295
Safety Precautions..................................................................................................................................296
Machine Setup Position for Maintenance..................................................................................................................297
Maintenance Handling Access.............................................................................................................................299
Entering/Leaving/Climbing On Machine................................................................................................................299
Handling Oil, Fuel, DEF (AdBlue), Coolant...............................................................................................................300
Oil.................................................................................................................................................300
Fuel................................................................................................................................................300
DEF (AdBlue)........................................................................................................................................302
Grease..............................................................................................................................................303
Coolant and Water for Dilution......................................................................................................................303
Filters.............................................................................................................................................304
Electrical System Maintenance...........................................................................................................................305
Recommend Fuel, Coolant, and Lubricant..................................................................................................................306
Lubrication.........................................................................................................................................306
Symbols for "Lubrication and Service Chart".........................................................................................................307
Fluid Capacities........................................................................................................................................311
Table of Recommended Lubricants.........................................................................................................................312
Maintenance Intervals...................................................................................................................................314
10 Hour / Daily Service.................................................................................................................................317
Grease Boom, Arm and Front Attachment Pins (for first 100 hours)....................................................................................317
Check Engine Oil Level..............................................................................................................................317
Check for Leaks in Hydraulic System.................................................................................................................317
Check Level of Hydraulic Oil Tank...................................................................................................................318
Check for Leaks in Fuel System......................................................................................................................319
Check Fuel Level....................................................................................................................................319
Check DEF (AdBlue) Tank.............................................................................................................................321
Check Water Separator & Pre Fuel Filter (Fuel Prefilter) and Drain Water As Required................................................................322
Check Oil Level of Swing Reduction Gear.............................................................................................................323
Clean Dust Net in Front of Oil Cooler and Radiator..................................................................................................324
Oil Cooler......................................................................................................................................324
Radiator........................................................................................................................................324
Check Cooling System and Refill As Required.........................................................................................................325
Check Level of Window Washer Liquid.................................................................................................................325
Inspect Bucket Teeth and Side Cutters for Signs of Wear.............................................................................................326
Inspect Cooling Fan Blade...........................................................................................................................326
Check Air Intake System and Emission Control System Components......................................................................................327
Inspect Seat Belt for Proper Operation..............................................................................................................327
Inspect Rear View Camera for Proper Operation (If Equipped).........................................................................................327
Inspect Mirrors for Damage and Adjust and Clean as Required.........................................................................................328
Inspect Structure for Cracks and Faulty Welds.......................................................................................................328
Check Operation of All Switches and Travel Alarm (If Equipped)......................................................................................328
Check the Operation of Pilot Cutoff Switch..........................................................................................................328
Inspection and Maintenance of the Pilot Cutoff Switch...........................................................................................328
Check Operation of All Exterior Lights, Horn and Control Console Indicator and Display Monitor......................................................329
Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds.....329
Check Operation of All Controls and Linkages........................................................................................................330
50 Hour / Weekly Service................................................................................................................................331
Perform All Daily Service Checks....................................................................................................................331
Grease Arm and Bucket Joint Pins....................................................................................................................331
Grease Swing Bearing................................................................................................................................332
Drain Water and Sediment from Fuel Tank.............................................................................................................332
Check Air Compressor and Drain Water as Required....................................................................................................333
Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)...................................................................333
Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers)....................................333
250 Hour / Monthly Service..............................................................................................................................334
Perform All Daily and 50 Hour Service Checks........................................................................................................334
Grease Boom and Arm Joint Pins......................................................................................................................334
Change Breaker Filter (Optional)....................................................................................................................336
Check Oil Bath Precleaner (Optional)................................................................................................................336
Clean Oil Bath Precleaner (Optional)................................................................................................................337
Replace Hydraulic Oil Return Filter (After First 250 Hours).........................................................................................339
Change Pilot Filter (After First 250 Hours).........................................................................................................339
Inspect Pins and Bushings of the Front End Attachments for Signs of Wear............................................................................339
Check Fluid Levels in Batteries.....................................................................................................................339
Inspect for Any Loose or Missing Nuts and Bolts.....................................................................................................339
Inspect Fuel System Hose Clamps.....................................................................................................................339
500 Hour / 3 Month Service..............................................................................................................................340
Perform All Daily, 50 and 250 Hour Service Checks...................................................................................................340
Grease Swing Gear and Pinion........................................................................................................................340
Change Engine Oil and Filter........................................................................................................................341
Clean Air-conditioning Outer Filter.................................................................................................................343
Check and Clean Air-conditioning Inner Filter.......................................................................................................344
Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Cores............................................................345
Clean Outer Filter of Air Cleaner...................................................................................................................346
Change of Water Separator & Pre Fuel Filter (Fuel Prefilter)........................................................................................348
Change Main Fuel Filter.............................................................................................................................349
Bleeding Fuel System............................................................................................................................351
Check Oil Level in Travel Reduction Gear (One on Each Side of Unit).................................................................................353
Change Oil in Travel Reduction Gear (One on Each Side of Unit) (After First 500 Hours)..............................................................353
Change Oil in Swing Reduction Gear (Drain and Refill After First 500 Hours).........................................................................353
1,000 Hour / 6 Month Service............................................................................................................................354
Perform All Daily, 50, 250 and 500 Hour Service Checks..............................................................................................354
Grease Swing Reduction Gear.........................................................................................................................354
Change Hydraulic Oil Tank Breather Filter...........................................................................................................354
Change Pilot Filter.................................................................................................................................356
Change DEF (AdBlue) Filter..........................................................................................................................357
Change DEF(AdBlue) Breather Filter..................................................................................................................357
Change Oil in Travel Reduction Gear (One on Each Side of Unit)......................................................................................358
Change Oil in Swing Reduction Gear..................................................................................................................359
Change Air-conditioning Outer Filter................................................................................................................360
Change Air-conditioning Inner Filter................................................................................................................361
Check Drive Belt....................................................................................................................................361
Check Air Conditioner Refrigerant...................................................................................................................363
Change Fuel Cap Filter..............................................................................................................................364
Check and Adjust Engine**...........................................................................................................................365
2,000 Hour / Yearly Service............................................................................................................................. 0
Check and Adjust Valve Clearance....................................................................................................................368
Clean Centrifugal Oil Cleaner.......................................................................................................................369
Change Radiator Coolant.............................................................................................................................371
Hydraulic Oil Exchange and Suction Strainer Cleaning................................................................................................373
Check Alternator and Starter**......................................................................................................................375
Check All Rubber Antivibration Shock Mounts.........................................................................................................375
Perform and Record Results of Cycle Time Tests......................................................................................................375
Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage.....................................................................375
Check, Adjust Valve Clearance**.....................................................................................................................375
Check Head Bolt Torques.............................................................................................................................375
4,000 Hour / Biennial Service...........................................................................................................................376
Major Parts - Periodic Replacement..................................................................................................................376
12,000 Hour / 6 Year Service............................................................................................................................377
Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 (CEN)).........................................................................377
Air-conditioning System.................................................................................................................................378
Check Control Panel.................................................................................................................................378
Check Air Conditioner Hoses.........................................................................................................................378
Check Condenser.....................................................................................................................................378
Check Magnetic Clutch...............................................................................................................................378
Check Belt Tension..................................................................................................................................378
Bolt and Nut Inspection.................................................................................................................................379
Bucket..................................................................................................................................................388
Bucket Tooth Replacement............................................................................................................................388
Bucket O-ring Replacement...........................................................................................................................389
Bucket Shimming Procedures.............................................................................................................................. 0
Shimming Procedures for Installed Bucket............................................................................................................391
Electrical System.......................................................................................................................................392
Battery.............................................................................................................................................392
Batteries in Cold Weather.......................................................................................................................392
Inspection of Battery Electrolyte Level.........................................................................................................393
Check Charging State............................................................................................................................393
Check Battery Terminals.........................................................................................................................393
Battery Replacement.............................................................................................................................393
Fuses...............................................................................................................................................394
Fuse Boxes......................................................................................................................................394
Fuse Identification.............................................................................................................................395
Engine Cooling System...................................................................................................................................396
General.............................................................................................................................................396
Types of Antifreeze.............................................................................................................................397
Antifreeze Concentration Tables.....................................................................................................................398
Table of Standards for Allowed Tap Water............................................................................................................398
Fuel Transfer Pump (Optional)...........................................................................................................................399
Handling of Accumulator.................................................................................................................................401
Track Tension...........................................................................................................................................402
Venting and Priming Hydraulic System....................................................................................................................404 Main System Pump....................................................................................................................................404
Hydraulic Cylinders.................................................................................................................................404
Swing Motor.........................................................................................................................................405
Travel Motor........................................................................................................................................405
General Venting.....................................................................................................................................405
Maintenance in Special Conditions.......................................................................................................................406
Transportation..............................................................................................................................................407
Loading and Unloading................................................................................................................................... 0
Counterweight....................................................................................................................................... 0
Removal.........................................................................................................................................409
Installation....................................................................................................................................410
Lifting Machine.........................................................................................................................................414
Troubleshooting.............................................................................................................................................415
Electrical System.......................................................................................................................................415
Engine..................................................................................................................................................416
Variable Geometry turbocharger (VGT)....................................................................................................................420
Lubrication System......................................................................................................................................421
Hydraulic System........................................................................................................................................422
Air Compressor (Optional)...............................................................................................................................423
Swing System............................................................................................................................................424
Travel System...........................................................................................................................................424
Hydraulic Fan Drive System..............................................................................................................................425
Specification...............................................................................................................................................427
Standard Specification..................................................................................................................................427
Overall Dimensions......................................................................................................................................428
Disassembled Parts, Dimension and Weight................................................................................................................429
Components..........................................................................................................................................429
Boom............................................................................................................................................429
Arm.............................................................................................................................................430
Counterweight...................................................................................................................................430
Ground Pressure.........................................................................................................................................431
Digging Force...........................................................................................................................................431
Working Range...........................................................................................................................................432
Excavator Rated Lift Capacity Tables....................................................................................................................434
Approximate Weight of Workload Materials................................................................................................................453
Index.......................................................................................................................................................455
DOOSAN DX420LC-5 EXCAVATOR OPERATION & MAINTENANCE MANUAL 950106-01019NA-1 - PDF DOWNLOAD:IMAGES PREVIEW OF THE MANUAL:
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
