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Doosan DX490LC-5 DX530LC-5 Excavator Operation & Maintenance Manual 950106-01004NA-1 – PDF DOWNLOAD
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Doosan DX490LC-5 DX530LC-5 Excavator Operation & Maintenance Manual 950106-01004NA-1 – PDF DOWNLOAD
DX490LC-5 / DX530LC-5
Serial Number 10001 and Up
Serial Number 10001 and Up
950106-01004NA-1
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Description
Doosan DX490LC-5 DX530LC-5 Excavator Operation & Maintenance Manual 950106-01004NA-1 – PDF DOWNLOAD
DESCRIPTION:
Doosan DX490LC-5 DX530LC-5 Excavator Operation & Maintenance Manual 950106-01004NA-1 – PDF DOWNLOAD
DX490LC-5 / DX530LC-5
Serial Number 10001 and Up
Serial Number 10001 and Up
950106-01004NA-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:
- The machine is intended to be used under normal conditions for applications described in this manual.
- If it is used for other purposes, or in potentially hazardous environments, special precautions must be followed and the machine must be equipped for such use.
- Examples include, but are not limited to, are: falling object guards, work lights, etc. Do not engage in prohibited uses as described in this manual.
- Contact your DOOSAN distributor for further information.
Engine and Emission Control System Maintenance:
- 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 DX490LC-5 DX530LC-5 Excavator Operation & Maintenance Manual 950106-01004NA-1 – PDF DOWNLOAD
DX490LC-5/DX530LC-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) (DX490LC-5 Only).............................................................................................. 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 Swing Reduction Gear..................................................................................................................358 Change Air-conditioning Outer Filter................................................................................................................359 Change Air-conditioning Inner Filter................................................................................................................360 Check Drive Belt....................................................................................................................................360 Check Air Conditioner Refrigerant...................................................................................................................362 Change Fuel Cap Filter..............................................................................................................................363 Check and Adjust Engine**...........................................................................................................................364 2,000 Hour / Yearly Service............................................................................................................................. 0 Check and Adjust Valve Clearance....................................................................................................................367 Change Oil in Travel Reduction Gear (One on Each Side of Unit)......................................................................................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 Track Frame Extension and Retraction................................................................................................................411 Track Width Adjustment..........................................................................................................................411 Frame Retraction................................................................................................................................411 Frame Extension.................................................................................................................................412 Lifting Machine.........................................................................................................................................417 Troubleshooting.............................................................................................................................................419 Electrical System.......................................................................................................................................419 Engine..................................................................................................................................................420 Variable Geometry turbocharger (VGT)....................................................................................................................424 Lubrication System......................................................................................................................................425 Hydraulic System........................................................................................................................................426 Air Compressor (Optional)...............................................................................................................................427 Swing System............................................................................................................................................428 Travel System...........................................................................................................................................428 Hydraulic Fan Drive System..............................................................................................................................429 Specification...............................................................................................................................................431 Standard Specification..................................................................................................................................432 DX490LC-5...........................................................................................................................................432 DX530LC-5...........................................................................................................................................433 Overall Dimensions......................................................................................................................................434 Variable Track (1/2)................................................................................................................................434 Variable Track (2/2)................................................................................................................................435 Fixed Track.........................................................................................................................................436 Disassembled Parts, Dimension and Weight................................................................................................................437 Components..........................................................................................................................................437 Boom............................................................................................................................................437 Arm.............................................................................................................................................438 Counterweight...................................................................................................................................438 Ground Pressure.........................................................................................................................................439 Digging Force...........................................................................................................................................440 Working Range...........................................................................................................................................442 Variable Track......................................................................................................................................442 Fixed Track.........................................................................................................................................444 Excavator Rated Lift Capacity Tables....................................................................................................................446 DX490LC-5...........................................................................................................................................448 DX490LC-5...........................................................................................................................................449 DX490LC-5...........................................................................................................................................450 DX490LC-5...........................................................................................................................................451 DX490LC-5...........................................................................................................................................452 DX490LC-5...........................................................................................................................................453 DX490LC-5...........................................................................................................................................454 DX490LC-5...........................................................................................................................................455 DX490LC-5...........................................................................................................................................456 DX490LC-5...........................................................................................................................................457 DX490LC-5...........................................................................................................................................458 DX490LC-5...........................................................................................................................................459 DX490LC-5...........................................................................................................................................460 DX490LC-5...........................................................................................................................................461 DX490LC-5...........................................................................................................................................462 DX490LC-5...........................................................................................................................................463 DX490LC-5...........................................................................................................................................464 DX490LC-5...........................................................................................................................................465 DX490LC-5...........................................................................................................................................466 DX490LC-5...........................................................................................................................................467 DX490LC-5...........................................................................................................................................468 DX490LC-5...........................................................................................................................................469 DX490LC-5...........................................................................................................................................470 DX490LC-5...........................................................................................................................................471 DX490LC-5...........................................................................................................................................472 DX490LC-5...........................................................................................................................................473 DX490LC-5...........................................................................................................................................474 DX490LC-5...........................................................................................................................................475 DX530LC-5...........................................................................................................................................476 DX530LC-5...........................................................................................................................................477 DX530LC-5...........................................................................................................................................478 DX530LC-5...........................................................................................................................................479 DX530LC-5...........................................................................................................................................480 DX530LC-5...........................................................................................................................................481 DX530LC-5...........................................................................................................................................482 DX530LC-5...........................................................................................................................................484 DX530LC-5...........................................................................................................................................486 DX530LC-5...........................................................................................................................................488 DX530LC-5...........................................................................................................................................489 DX530LC-5...........................................................................................................................................493 DX530LC-5...........................................................................................................................................497 DX530LC-5...........................................................................................................................................500 DX530LC-5...........................................................................................................................................504 DX530LC-5...........................................................................................................................................511 DX530LC-5...........................................................................................................................................524 DX530LC-5...........................................................................................................................................528 DX530LC-5...........................................................................................................................................532 DX530LC-5...........................................................................................................................................536 DX530LC-5...........................................................................................................................................539 DX530LC-5...........................................................................................................................................543 DX530LC-5...........................................................................................................................................550 DX530LC-5...........................................................................................................................................563 DX530LC-5...........................................................................................................................................567 DX530LC-5...........................................................................................................................................571 DX530LC-5...........................................................................................................................................575 DX530LC-5...........................................................................................................................................578 DX530LC-5...........................................................................................................................................582 DX530LC-5...........................................................................................................................................586 DX530LC-5...........................................................................................................................................590 DX530LC-5...........................................................................................................................................594 DX530LC-5...........................................................................................................................................597 Approximate Weight of Workload Materials................................................................................................................601 Index.......................................................................................................................................................603
DOOSAN DX490LC-5 DX530LC-5 EXCAVATOR OPERATION & MAINTENANCE MANUAL 950106-01004NA-1 – PDF DOWNLOAD:
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