Daewoo Excavator DX480LC DX520LC Operation & Maintenance Manual – PDF

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Daewoo Excavator DX480LC DX520LC Operation & Maintenance Manual K1008702E – PDF DOWNLOAD

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Daewoo Excavator DX480LC DX520LC Operation & Maintenance Manual K1008702E – PDF DOWNLOAD

Language : English
Pages : 298
Downloadable : Yes
File Type : PDF

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Daewoo Excavator DX480LC DX520LC Operation & Maintenance Manual K1008702E – PDF DOWNLOAD

Safety..........................................................................................................  7
	To the Operator of a DOOSAN Daewoo Excavator................................................................  7
		Learn the Signal Words Used with the Safety Alert Symbol................................................  9
	Location of Safety Labels................................................................................... 11
		1. Warnings for Operation, Inspection and Maintenance (19000688, 19000092)............................ 13
		2. Warnings for High Voltage (19000689, 19000096)..................................................... 13
		3. Warnings When Opening a Front Window (21903388, 19000093).......................................... 14
		4. Warnings for a Highpressure Cylinder (19000122).................................................... 14
		5. Warnings When Adjusting Track Tension (21903386A, 19000521)........................................ 15
		6. Warnings for Leaving Operator's Seat (19000693, 19000094).......................................... 15
		7. Warnings for Batteries Maintenance (21902533A, 19000100)........................................... 16
		8. Warnings for High Temperature Hydraulic Oil (19000691, 19000097)................................... 16
		9. Warnings for Hot Coolant (19000692, 19000097)...................................................... 17
		10. Warnings for Handling an Accumulator (19000703, 19000099)......................................... 17
		11. Warnings for Rotating Parts (19000694, 19000095, 19000557)....................................... 18
		12. Warning Tag  Used When Inspection and Maintenance (19000695, 19000098)........................... 18
		13. Warning for a Hot Surface (19000648A).............................................................. 19
		14. Caution for Hood (19000522)........................................................................ 19
		15. Keep Out of the Swing Area (21903379, K1008571).................................................... 20
		16. Warnings for Front Attachments (19000652).......................................................... 20
	Summary of Safety Precautions for Lifting in Digging Mode................................................... 21
	Unauthorized Modifications.................................................................................. 22
	General Hazard Information.................................................................................. 22
		Safety Rules............................................................................................ 22
		Safety Features......................................................................................... 22
		Inside Operator's Compartment........................................................................... 23
		Clothing and Personal Protective Items.................................................................. 23
		Breathing Masks, Ear Protection May Be Required......................................................... 24
		Vibration Level Information............................................................................. 24
		Recommendations for Limiting Vibrations................................................................. 24
		Mounting and Dismounting................................................................................ 25
		Fuel, Oil and Hydraulic Fluid Fire Hazards.............................................................. 26
		Precautions When Handling Fluids at High Temperature.................................................... 26
		Asbestos Dust Hazard Prevention......................................................................... 27
		Injury from Work Equipment.............................................................................. 27
		Fire Extinguisher and First Aid Kit..................................................................... 27
		Protection from Falling or Flying Objects............................................................... 28
		Attachment Precautions.................................................................................. 29
		Accumulator............................................................................................. 29
		Indoor Ventilation...................................................................................... 29
		Emergency Exit.......................................................................................... 30
	Before Starting Engine...................................................................................... 31
		Work Site Precautions................................................................................... 31
		Checks Before Starting Engine........................................................................... 32
		Engine Starting......................................................................................... 32
		Before Operating Machine................................................................................ 33
	Machine Operation........................................................................................... 35
		When Swinging or Changing Direction of Travel........................................................... 35
		Travel Precautions...................................................................................... 36
		Traveling on Slopes..................................................................................... 37
		Prohibited Operations................................................................................... 37
		Precautions for Operation............................................................................... 38
		Avoid High Voltage Cables............................................................................... 39
		Protecting Cabin from Falling Object (Optional)......................................................... 39
		Operate Carefully on Snow, Ice and in Very Cold Temperatures............................................ 40
		Operations on Slopes.................................................................................... 40
		Parking Machine......................................................................................... 41
		Never Let Anyone Ride on Attachment..................................................................... 41
	Maintenance................................................................................................. 42
		Warning Tag............................................................................................. 42
		Clean Before Inspection or Maintenance.................................................................. 42
		Proper Tools............................................................................................ 43
		Use of Lighting......................................................................................... 43
		Fire Prevention and Explosion Prevention................................................................ 43
		Burn Prevention......................................................................................... 44
		Welding Repairs......................................................................................... 45
		Warning for Counterweight and Front Attachment Removal.................................................. 46
		Precautions for Removal, Installation, and Storage of Attachments....................................... 47
		Precautions When Working on Machine..................................................................... 47
		Lock Inspection Covers.................................................................................. 47
		Crushing Prevention and Cutting Prevention.............................................................. 47
		Track Tension Adjustments Require Caution............................................................... 48
		Supports and Blocking for Work Equipment................................................................ 48
		Action When Abnormality Is Found During Inspection...................................................... 48
		Precautions with Highpressure Lines, Tubes and Hoses................................................... 49
		Waste Materials......................................................................................... 50
	Battery..................................................................................................... 51
		Battery Hazard Prevention............................................................................... 51
		Boost Starting or Charging Engine Batteries............................................................. 52
	Towing...................................................................................................... 53
		Precautions When Towing................................................................................. 53
	Shipping and Transportation................................................................................. 54
		Obey State and Local OvertheRoad Regulations.......................................................... 54
	Excavator Rated Lift Capacity Tables........................................................................ 55
		DX480LC................................................................................................. 58
		DX520LC................................................................................................. 61
Operating Controls.............................................................................................. 63
	Component Locations......................................................................................... 66
	Operator's Area............................................................................................. 68
	Operational Controls and Panels............................................................................. 70
		1. Starter Switch....................................................................................... 72
		2. Engine Speed Control Dial............................................................................ 72
		3. Quick Clamp Switch (Optional)........................................................................ 73
		4. Auxiliary Mode Switch................................................................................ 73
		5. Engine Emergency Stop Switch......................................................................... 73
		6. Audio Control Panel.................................................................................. 74
		7. Travel Speed Selector Switch......................................................................... 75
		8. Light Switch......................................................................................... 32
		9. Breaker / Boost / Shear Selector Switch.............................................................. 76
		10. Cabin Work Light Switch (Optional).................................................................. 76
		11. Warning Light Switch (Optional)..................................................................... 76
		12. Lower Wiper Switch (Optional)....................................................................... 77
		13. Heater and Air Conditioner Control Panel............................................................ 77
		14. Wiper Switch Panel.................................................................................. 77
		15. Cigarette Lighter................................................................................... 79
		16. Power Socket for 12 Volt............................................................................ 79
		17. Travel/Swing Alarm Switch (Optional)................................................................ 79
		18. Overload Warning Switch (Optional).................................................................. 80
		19. Fuel Heater Switch (Optional)....................................................................... 80
		20. Seat Warmer Switch (Optional)....................................................................... 80
		21. Horn Button (Lefthand Work Lever).................................................................. 81
		22. Rotating Buttons.................................................................................... 81
		23. Booster Button (Righthand Work Lever).............................................................. 81
		24. Shear Buttons....................................................................................... 82
		25. Instrument Panel.................................................................................... 82
		26. Safety Lever........................................................................................ 82
		27. Photo Sensor........................................................................................ 83
		28. 2Pump Flow Control Switch (Optional)............................................................... 83
		29. Reverse Fan Switch.................................................................................. 83
	Instrument Panel............................................................................................ 85
		Functional check........................................................................................ 86
		Password Activated...................................................................................... 86
		1. Fuel Gauge........................................................................................... 87
		2. Engine Coolant Temperature Gauge..................................................................... 87
		3. Hydraulic Oil Temperature Gauge...................................................................... 88
		4. Multifunction Gauge and Graphic Information Area..................................................... 88
		5. Digital Clock........................................................................................ 88
		6. Hour Meter........................................................................................... 89
		7. Charge Warning Light................................................................................. 89
		8. Engine Oil Pressure Warning Light.................................................................... 89
		9. Engine Coolant Temperature Warning Light............................................................. 90
		10. Engine Check Warning Light.......................................................................... 90
		11. Preheating Indicator Light.......................................................................... 91
		12. Work Light Indicator Light.......................................................................... 91
	Multifunction Gauge and Graphic Information................................................................. 92
		Communication Indicator................................................................................. 92
		Communication Error Warning............................................................................. 93
		Engine Speed............................................................................................ 93
		Battery Voltage......................................................................................... 93
		Front Hydraulic Pump Pressure........................................................................... 94
		Rear Hydraulic Pump Pressure............................................................................ 94
		Abnormal State Warning Symbols.......................................................................... 94
	Mode Selector Buttons....................................................................................... 97
		1. Power Mode Selector Button........................................................................... 97
		2. Trenching Mode Selector Button....................................................................... 98
		3. Auto Idle Selector Button............................................................................175
		4. Flow Control Button.................................................................................. 98
	Setting Main Menu........................................................................................... 99
		1. Up Arrow Button...................................................................................... 99
		2. Down Arrow Button....................................................................................100
		3. Display Selector Button (ESC  Escape)...............................................................100
		4. SelectionButton.....................................................................................100
		Display Selection and Escaping..........................................................................101
		Main Menu............................................................................................... 39
		Language................................................................................................178
		Set Clock...............................................................................................291
		Filter / Oil Info.......................................................................................103
		Adjust Display..........................................................................................105
		Set Password (Lock and Unlock)..........................................................................106
	Flow Control................................................................................................108
		Adjusting Flow Rate.....................................................................................109
		Escape..................................................................................................109
	Operation Selection Display.................................................................................110
		Power Boost Selection...................................................................................110
		Breaker Selection.......................................................................................110
		Shear Selection.........................................................................................110
		Overload Alarm Selection (Optional).....................................................................111
		Quick Clamp Operation Selection (Optional)..............................................................111
	Heater and Air Conditioner Control Panel....................................................................112
		Location of Controls and Vents..........................................................................112
		Control Panel...........................................................................................113
		Memory Function.........................................................................................117
		Additional Operating Instructions.......................................................................117
	Stereo......................................................................................................118
		Stereo..................................................................................................118
		CD Player (Optional)....................................................................................119
	Miscellaneous Electrical Devices............................................................................120
		Cabin Light.............................................................................................120
		Pilot Cutoff Switch.....................................................................................120
		Circuit Breaker.........................................................................................120
		Fusible Link............................................................................................121
		Fuse Boxes..............................................................................................121
	Seat Adjustment.............................................................................................122
		1. Forward / Backward Adjustment........................................................................122
		2. Seat Tilt and Height Adjustment......................................................................122
		3. Suspension Adjustment................................................................................122
		4. Reclining Position Adjustment........................................................................123
		5. Armrest Angle Adjustment.............................................................................123
		6. Lumbar Support Adjustment............................................................................123
		7. Headrest.............................................................................................123
		8. Seat Belt............................................................................................172
		9. Seat Backpocket.....................................................................................124
		10. Left and Right Control Stand Adjustment.............................................................124
		11. Left and Right Control Stand Height Adjustment......................................................124
		12. Air Suspension Seat (Optional)......................................................................125
		13. Heating the Operator's Seat (Optional)..............................................................125
	Ceiling Cover...............................................................................................126
		Opening the Ceiling Cover...............................................................................126
		Closing the Ceiling Cover...............................................................................126
	Front Windows...............................................................................................127
		Front Upper Window......................................................................................127
		Front Bottom Window.....................................................................................128
	Door Side Latch.............................................................................................129
	Cabin Storage Compartments..................................................................................130
	Ashtray.....................................................................................................130
	Sun Visor...................................................................................................131
	Hanger......................................................................................................131
	Cup Holder..................................................................................................132
	Door Window Holder..........................................................................................132
	Emergency Glass Breaking Tool...............................................................................132
	Miscellaneous Access Covers and Doors.......................................................................133
		Side Door...............................................................................................133
		Battery Box Door........................................................................................133
		Engine Cover............................................................................................133
Operation.......................................................................................................135
	To Handle a New Excavator...................................................................................135
		Lubrication and Filters.................................................................................136
	Starting and Stopping the Engine............................................................................136
		Inspection Before Starting Engine.......................................................................136
		Operational Checks Before Starting Engine...............................................................137
		Engine Start............................................................................................138
		Cold Weather Starting...................................................................................140
		Starting Engine With a Booster Cable....................................................................141
		Hydraulic System Warmup................................................................................143
		Hydraulic System Warmup – Cold Weather.................................................................144
		Engine Shut Down........................................................................................145
		Check and Confirmation After Stopping Engine............................................................146
	Safety Lever................................................................................................147
	Travel......................................................................................................148
		Automatic Travel Speed Control..........................................................................148
		Travel Control Lever Operation..........................................................................150
		General Travel Instructions.............................................................................151
	Operating Instructions......................................................................................154
		Engine Speed Control....................................................................................154
		Mode Selection..........................................................................................154
		Work Levers (Joysticks) (ISO Style).....................................................................157
	Operating Precautions.......................................................................................158
		Working in Water........................................................................................162
	Parking Excavator...........................................................................................163
	Towing Procedure............................................................................................164
	Hydraulic Breaker...........................................................................................165
		Selection of Hydraulic Breaker..........................................................................165
		Hydraulic Hoses and Tubing for Breaker..................................................................165
		Hydraulic Breaker Operation.............................................................................165
		Hydraulic Oil and Filter Service Intervals..............................................................169
	Adjusting the Pump Flow.....................................................................................170
		Shear Pedal Valve (Optional)............................................................................171
		Rotating Pedal Valve (Optional).........................................................................172
	Operating Techniques........................................................................................ 56
		Lifting.................................................................................................173
	Operation Under Unusual Conditions..........................................................................175
		Operation In Extreme Cold...............................................................................175
		Operation in Extreme Heat...............................................................................176
		Operation in Dusty or Sandy Areas.......................................................................177
		Operation in Rainy or Humid Conditions.................................................................. 39
		Operation in Salt Water Areas...........................................................................178
		Operation at High Altitudes............................................................................. 40
Inspection, Maintenance and Adjustment..........................................................................179
	Preventive Maintenance......................................................................................179
		Product Identification Number (P. I. N.) Location.......................................................180
		Component Serial Numbers................................................................................180
		Safety Precautions......................................................................................181
	Preliminary Work Machine Setup for Maintenance..............................................................182
	Table of Recommended Lubricants.............................................................................184
	Fluid Capacities............................................................................................186
	Lubrication and Service Chart...............................................................................186
	Maintenance Intervals.......................................................................................190
	10 Hour / Daily Service.....................................................................................192
		Grease Boom, Arm and Front Attachment Pins (for first 100 hours)........................................192
		Check Engine Oil Level..................................................................................192
		Check Level of Hydraulic Oil Tank.......................................................................193
		Check for Leaks in Hydraulic System.....................................................................194
		Check Fuel Level........................................................................................194
		Check for Leaks in Fuel System..........................................................................195
		Check Fuel Prefilter and Drain Water As Required........................................................195
		Check Oil Level of Swing Reduction Device...............................................................197
		Clean Dust Net in Front of Oil Cooler and Intercooler...................................................198
		Check Cooling System and Refill As Required.............................................................199
		Check Level of Window Washer Liquid.....................................................................199
		Inspect the Bucket Teeth and Side Cutters for Signs of Wear.............................................200
		Inspect Engine Fan Blade................................................................................200
		Check Air Intake System.................................................................................200
		Inspect Seat Belt for Proper Operation..................................................................201
		Inspect the Structure for Cracks and Faulty Welds.......................................................201
		Check the Operation of All Switches.....................................................................201
		Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights.......201
		Start Engine, Check Starting Ability, and Observe Exhaust Color at Startup and at Normal Operati.......202
		Check Operation of All Controls.........................................................................202
	50 Hour / Weekly Service....................................................................................203
		Perform All Daily Service Checks........................................................................203
		Grease Arm and Front Attachment Pins....................................................................203
		Grease Swing Bearing....................................................................................204
		Drain Water and Sediment from Fuel Tank.................................................................205
		Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours).......................205
		Change Engine Oil and Filter (After First 50 Hours).....................................................205
		Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, R.......205
	250 Hour / Monthly Service..................................................................................206
		Perform All Daily and 50 Hour Service Checks............................................................206
		Change Swing Reduction Device Oil (Drain and Refill After First 250 Hours)..............................206
		Grease Arm and Front Attachment Pins....................................................................207
		Check Engine Fan Belt Tension...........................................................................209
		Check Engine Fan Belt Wear..............................................................................209
		Check Oil Level in Travel Reduction Device (One on Each Side of Unit)...................................210
		Change Breaker Filter Element (Optional)................................................................211
		Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 250 Hours)................211
		Replace Hydraulic Oil Return Filter (After First 250 Hours).............................................211
		Change Pilot Filter (After First 250 Hours).............................................................211
		Inspect Pins and Bushings of the Front End Attachments for Signs of Wear................................212
		Check Fluid Levels in Batteries and Battery Charge Levels...............................................212
		Inspect for Any Loose or Missing Nuts and Bolts.........................................................212
		Inspect Fuel System Hose Clamps.........................................................................212
	500 Hour / 3 Month Service..................................................................................213
		Perform All Daily, 50 and 250 Hour Service Checks.......................................................213
		Grease Swing Gear and Pinion............................................................................213
		Change Engine Oil and Filter............................................................................214
		Clean AirConditioning Outer Filter.....................................................................215
		Check and Clean AirConditioning Inner Filter...........................................................216
		Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Core.................217
		Clean Outer Filter of Air Cleaner.......................................................................218
		Change of Fuel Prefilter................................................................................219
		Change Fuel Filter......................................................................................220
	1,000 Hour / 6 Month Service................................................................................222
		Perform All Daily, 50, 250 and 500 Hour Service Checks..................................................222
		Grease Swing Reduction Device...........................................................................222
		Change Pilot Filter.....................................................................................224
		Change Oil in Travel Reduction Device (One on Each Side of Unit)........................................225
		Change AirConditioning Outer Filter....................................................................226
		Check Air Conditioner Refrigerant.......................................................................227
		Check and Adjust Engine **..............................................................................228
	2,000 Hour / Yearly Service.................................................................................229
		Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks...........................................229
		Change Swing Reduction Device Oil.......................................................................229
		Replace Outer and Inner Air Cleaner Elements............................................................230
		Change Radiator Coolant.................................................................................231
		Hydraulic Oil Exchange and Suction Strainer Cleaning....................................................232
		Check Alternator and Starter**..........................................................................234
		Check All Rubber Antivibration Shock Mounts.............................................................234
		Perform and Record the Results of the Cycle Time Tests..................................................234
		Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage.........................234
		Check, Adjust Valve Clearance **........................................................................234
		Check Head Bolt Torques.................................................................................234
	4,000 Hour / Biennial Service...............................................................................235
		Major Parts  Periodic Replacement......................................................................235
	12,000 Hour / Six Year Service..............................................................................236
		Hose Inservice Lifetime Limit (European Standard ISO8331 and EN982CEN)...............................236
	AirConditioning System.....................................................................................237
		Check Control Panel.....................................................................................237
		Check Air Conditioner Hoses.............................................................................237
		Check Condenser.........................................................................................237
		Check Magnetic Clutch...................................................................................237
		Check Belt Tension......................................................................................237
	Bolt and Nut Inspection.....................................................................................238
	Bucket......................................................................................................248
		Bucket Tooth Replacement................................................................................248
		Bucket Oring Replacement...............................................................................249
	Bucket Shimming Procedures..................................................................................251
		New Bucket Installation.................................................................................251
		Shimming Procedures for Installed Bucket................................................................251
	Electrical System...........................................................................................252
		Battery.................................................................................................252
		Fuses...................................................................................................253
	Engine Cooling System.......................................................................................256
		General.................................................................................................256
		Measuring the Concentration of Coolant..................................................................257
		Antifreeze Concentration Tables.........................................................................259
	Fuel Transfer Pump (Option).................................................................................260
	Handling of Accumulator.....................................................................................263
	Track Tension...............................................................................................264
	Venting and Priming Hydraulic System........................................................................266
		Main System Pump........................................................................................266
		Hydraulic Cylinders.....................................................................................266
		Swing Motor.............................................................................................267
		Travel Motor............................................................................................267
		General Venting.........................................................................................267
	Long Term Storage...........................................................................................268
	Maintenance in Special Conditions...........................................................................269
Transportation..................................................................................................271
	Extension and Retraction of Track Frames....................................................................271
		Track Width Adjustment..................................................................................271
		Frame Retraction........................................................................................272
		Frame Extension.........................................................................................273
	Loading and Unloading.......................................................................................135
		Warning for Counterweight and Front Attachment Removal..................................................274
	Lifting With Sling..........................................................................................277
	Disassembly and Assembly Before and after Transportation....................................................278
		Personnel and Equipment.................................................................................278
		Time Required...........................................................................................278
Troubleshooting.................................................................................................279
	Electrical System...........................................................................................279
	Engine......................................................................................................280
	Hydraulic System............................................................................................281
	Swing System................................................................................................282
	Travel System...............................................................................................283
Specification...................................................................................................285
	DX480LC.....................................................................................................285
		Standard Specification..................................................................................285
		Overall Dimensions......................................................................................286
		Working Range...........................................................................................287
	DX520LC.....................................................................................................288
		Standard Specification..................................................................................288
		Overall Dimensions......................................................................................289
		Working Range...........................................................................................290
	Approximate Weight of Workload Materials....................................................................291

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