Doosan DX490LC-3 DX530LC-3 Excavator Operation & Maintenance Manual 950106-00258ANA – PDF DOWNLOAD
DESCRIPTION:
Doosan DX490LC-3 DX530LC-3 Excavator Operation & Maintenance Manual 950106-00258ANA – PDF DOWNLOAD
Serial Number 10001 and Up
950106-00258ANA
Foreword:
- This Operation and 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 and Maintenance Manual, or Shop Manual. Do not remove, alter, or render inoperative, any emission control system.
- Foreword DX490LC-3/DX530LC-3 0-II 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 Rollover Protective Structure (ROPS) and can result in death or serious injury. Contact your DOOSAN distributor for further information.
TABLE OF CONTENTS:
Doosan DX490LC-3 DX530LC-3 Excavator Operation & Maintenance Manual 950106-00258ANA – PDF DOWNLOAD
DX490LC-3/DX530LC-3............................................................................................................................................. 0 Table of Contents........................................................................................................................................... 5 Foreword.................................................................................................................................................... 9 Intended Use............................................................................................................................................ 9 Engine and Emission Control System Maintenance.......................................................................................................... 9 Safety Messages......................................................................................................................................... 11 AEM Safety Manual (North America Only).................................................................................................................. 12 Non-Road Diesel Engine Emission Control System Warranty Statement....................................................................................... 13 Emission Related System Defect Warranty............................................................................................................. 13 Limitations and Responsibilities.................................................................................................................... 15 Off-Road Compression- Ignition Engines.................................................................................................................. 17 California Emission Control Warranty Statement Your Warranty Rights and Obligations................................................................. 17 Safety...................................................................................................................................................... 19 Safety Decals........................................................................................................................................... 20 Safety Decals With Text............................................................................................................................. 20 Safety Decals Without Text (No-Text)................................................................................................................ 21 Information and Location for Safety Decals.......................................................................................................... 22 Information and Location for Safety Decals (Continued).............................................................................................. 23 General................................................................................................................................................. 33 Safe Operation is Operator's Responsibility......................................................................................................... 33 Know Your Machine................................................................................................................................... 33 Proper Work Tools and Attachments................................................................................................................... 34 Pressurized Fluids.................................................................................................................................. 34 Flying or Falling Objects........................................................................................................................... 35 Personal Protective Equipment (PPE)................................................................................................................. 36 Correction of Machine Problems...................................................................................................................... 36 Crushing and Cutting................................................................................................................................ 36 Hot Coolant and Oils - Burn Prevention.............................................................................................................. 37 Fire and Explosion Prevention....................................................................................................................... 38 Maintenance..................................................................................................................................... 38 Operation....................................................................................................................................... 38 Electrical...................................................................................................................................... 39 Hydraulic System................................................................................................................................ 39 Fueling......................................................................................................................................... 40 Never Use Ether Starting Aids................................................................................................................... 40 Welding and Grinding............................................................................................................................ 40 If a Fire Occurs................................................................................................................................ 41 Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)......................................................................................... 41 Electrical System and Electrical Shock.............................................................................................................. 42 Rollover Protective Structure (ROPS)................................................................................................................ 42 ROPS Certification.............................................................................................................................. 43 Protecting Cabin from Flying or Falling Objects (Optional)...................................................................................... 44 Emergency Exit from Operator's Station.......................................................................................................... 45 Transportation.......................................................................................................................................... 46 Obey State and Local Over-the-Road Regulations...................................................................................................... 46 Loading and Unloading............................................................................................................................... 46 Transporting Machine................................................................................................................................ 47 Operation............................................................................................................................................... 48 Before Engine Starting.............................................................................................................................. 48 Machine Condition............................................................................................................................... 48 Work Site........................................................................................................................................... 49 Mounting/Dismounting................................................................................................................................ 50 Cleaning............................................................................................................................................ 51 Operator Station.................................................................................................................................... 51 Seat Belt........................................................................................................................................... 52 Visibility Information.............................................................................................................................. 53 Work Site Rules................................................................................................................................. 53 Boost Starting or Charging Engine Batteries......................................................................................................... 54 Swinging or Traveling............................................................................................................................... 56 Lifting and Digging................................................................................................................................. 58 Operation on Slopes................................................................................................................................. 59 Towing.............................................................................................................................................. 60 Attachment.......................................................................................................................................... 61 Equipment Lowering with Engine Stopped.............................................................................................................. 61 Engine Stop......................................................................................................................................... 61 Parking Machine..................................................................................................................................... 62 Preservation/Storing Machine........................................................................................................................ 63 Check After Long-term Parking................................................................................................................... 64 Maintenance............................................................................................................................................. 65 Cleaning............................................................................................................................................ 68 Proper Tools and Clothing........................................................................................................................... 68 Disassembling Precautions........................................................................................................................... 68 Use of Lighting..................................................................................................................................... 69 Fire and Explosion Prevention....................................................................................................................... 69 Burn Prevention..................................................................................................................................... 70 Rubber That Contains Fluorides...................................................................................................................... 71 Rubber and Plastics................................................................................................................................. 72 Waste Hazardous to the Environment.............................................................................................................. 72 Check List After Fire........................................................................................................................... 72 Welding Repairs..................................................................................................................................... 73 Preparation for Electrical Welding On Body Structure............................................................................................ 74 Warning for Counterweight and Front Attachment Removal.............................................................................................. 74 Lock Inspection Covers.............................................................................................................................. 75 Working on Machine.................................................................................................................................. 75 Accumulator......................................................................................................................................... 76 Compressed Air...................................................................................................................................... 76 Track Tension Adjustments........................................................................................................................... 77 Supports and Blocking for Work Equipment............................................................................................................ 77 High-pressure Lines, Tubes and Hoses................................................................................................................ 78 Battery............................................................................................................................................. 79 Battery Hazard Prevention....................................................................................................................... 79 Environment and Circumstances........................................................................................................................... 81 Work Site Areas Requiring Extra Caution............................................................................................................. 81 Digging Under an Overhang....................................................................................................................... 81 Deep Digging.................................................................................................................................... 81 Drop-off or Edge................................................................................................................................ 82 Poor Visibility................................................................................................................................. 82 Loose or Soft Ground............................................................................................................................ 82 High-voltage Cables................................................................................................................................. 83 Underground Operation............................................................................................................................... 84 Working in Water.................................................................................................................................... 84 Working in Contaminated Environment................................................................................................................. 84 Operation in Extreme Conditions..................................................................................................................... 85 Operation In Extreme Cold....................................................................................................................... 85 Operation in Extreme Heat....................................................................................................................... 86 Operation In Dusty and Sandy Areas.............................................................................................................. 87 Operation in Rainy or Humid Conditions.......................................................................................................... 87 Operation in Saltwater Areas.................................................................................................................... 88 Operation at High Altitudes..................................................................................................................... 88 Operation During Electrical Storms.............................................................................................................. 88 Exhaust Ventilation................................................................................................................................. 89 Ventilation for Enclosed Area................................................................................................................... 89 Asbestos Information................................................................................................................................ 89 Silica Dust Information............................................................................................................................. 90 Disposal of Hazardous Materials..................................................................................................................... 90 Sound............................................................................................................................................... 91 Vibration........................................................................................................................................... 91 Operating Controls.......................................................................................................................................... 93 Component Locations..................................................................................................................................... 94 Operator's Area......................................................................................................................................... 96 Operational Controls and Panels......................................................................................................................... 98 1. Starter Switch...................................................................................................................................100 2. Heater and Air Conditioner Control Panel.........................................................................................................100 3. Power Socket for 12 Volt.........................................................................................................................101 4. Cigarette Lighter................................................................................................................................101 5. Engine Emergency Stop Switch.....................................................................................................................101 6. Engine Speed Control Dial........................................................................................................................102 7. Travel Speed Selector Switch.....................................................................................................................102 8. Light Switch.....................................................................................................................................102 9. Intelligent Floating Boom Switch (Optional)......................................................................................................103 10. Cabin Work Light Switch (Optional)..............................................................................................................103 11. Audio Control Panel.............................................................................................................................103 12. Wiper Control Panel.............................................................................................................................105 13. Quick Coupler Switch (Optional).................................................................................................................106 14. Warning Light Switch (Optional).................................................................................................................106 15. Lower Wiper Switch (Optional)...................................................................................................................106 16. Travel/Swing Alarm Switch (Optional)............................................................................................................107 17. Cooling Fan Reverse Rotation Switch (Only DX420/490/530LC-3)....................................................................................107 18. Fuel Heater Switch (Optional)...................................................................................................................108 19. Overload Warning Switch (Optional)..............................................................................................................108 20. Power Socket for 12 Volt (Optional).............................................................................................................108 21. Horn Button (Left-hand Work Lever)..............................................................................................................109 22. Breaker/Booster Button (Right-hand Work Lever)..................................................................................................109 23. Rotating Switch.................................................................................................................................109 24. Shear Switch....................................................................................................................................110 25. Display Monitor.................................................................................................................................110 26. Photo Sensor....................................................................................................................................110 27. Safety Lever....................................................................................................................................111 28. Auxiliary Mode Switch...........................................................................................................................111 29. Diesel Particulate Filter (DPF) Switch..........................................................................................................112 30. Hour Meter......................................................................................................................................115 31. One Touch Deceleration Button...................................................................................................................115 32. Intelligent Floating Boom Temporary Reset Button................................................................................................116 33. Jog Switch Control Panel........................................................................................................................116 34. Jack Assembly...................................................................................................................................118 35. Micro Phone (Optional)..........................................................................................................................118 Display Monitor.........................................................................................................................................119 Functional Check....................................................................................................................................119 Password Activated..................................................................................................................................120 1. Fuel Gauge.......................................................................................................................................120 2. Engine Coolant Temperature Gauge.................................................................................................................120 3. Hydraulic Oil Temperature Gauge..................................................................................................................121 4. Multifunction Gauge and Graphic Information Area.................................................................................................121 5. ECO Gauge........................................................................................................................................123 6. Digital Clock....................................................................................................................................123 7. Display Warning Symbols..........................................................................................................................124 9. Function Buttons.................................................................................................................................131 10. Mode Selector Buttons...........................................................................................................................133 11. Selector Function Display.......................................................................................................................134 12. Jog Switch......................................................................................................................................134 13. Camera Mode Selector/ESC Button.................................................................................................................134 14. Multimedia Selector Button......................................................................................................................135 Warning Pop-up Window...............................................................................................................................135 User Menu............................................................................................................................................... 0 Switch Operation Indication.........................................................................................................................166 Heater and Air Conditioner Control Panel................................................................................................................169 Location of Controls and Vents......................................................................................................................169 Control Panel.......................................................................................................................................170 Memory Function.....................................................................................................................................174 Additional Operating Instructions...................................................................................................................174 Miscellaneous Electrical Devices........................................................................................................................176 Cabin Light.........................................................................................................................................176 Battery Disconnect Switch...........................................................................................................................176 Pilot Cutoff Switch.................................................................................................................................177 Circuit Breaker.....................................................................................................................................177 Fusible Link........................................................................................................................................177 Fuse Boxes..........................................................................................................................................178 Seat Adjustment......................................................................................................................................... 0 7. Storage Compartment..............................................................................................................................181 8. Left and Right Control Stand Adjustment..........................................................................................................181 Cabin Storage Compartments..............................................................................................................................187 Sunglass Case...........................................................................................................................................187 Miscellaneous Access Covers and Doors...................................................................................................................190 Side Door...........................................................................................................................................190 Storage Box Door....................................................................................................................................190 Engine Cover........................................................................................................................................190 Operation...................................................................................................................................................191 To Operate a New Excavator..............................................................................................................................191 Lubrication and Filters.............................................................................................................................192 Starting and Stopping Engine............................................................................................................................192 Inspection Before Starting Engine...................................................................................................................192 Walk Around Checks..............................................................................................................................192 Checks Before Starting Engine...................................................................................................................193 Operational Checks Before Starting Engine...........................................................................................................194 Engine Start........................................................................................................................................196 Cold Weather Starting...............................................................................................................................198 Engine Coolant Heater (Optional)....................................................................................................................200 Starting Engine With a Booster Cable................................................................................................................202 Connecting Booster Batteries....................................................................................................................202 Disconnecting Booster Batteries.................................................................................................................203 Hydraulic System Warm-up............................................................................................................................203 Hydraulic System Warm-up - Cold Weather.............................................................................................................204 Stopping Engine.....................................................................................................................................206 Checks and Maintenance After Stopping Engine........................................................................................................207 Safety Lever............................................................................................................................................207 Travel..................................................................................................................................................208 Automatic Travel Speed Control......................................................................................................................208 Travel Control Lever Operation......................................................................................................................209 General Travel Instructions.........................................................................................................................210 Straight Travel Pedal (Optional)....................................................................................................................212 Operating.......................................................................................................................................213 Locking Pedal...................................................................................................................................213 Operating Instructions..................................................................................................................................214 Engine Speed Control................................................................................................................................214 Engine Exhaust Emission Control System..............................................................................................................214 Regeneration of Diesel Particulate Filter (DPF).................................................................................................215 Diesel Particulate Filter (DPF) Regeneration Light and Switch...................................................................................215 Passive Regeneration............................................................................................................................218 Active Regeneration.............................................................................................................................218 Manual (Forced) Regeneration....................................................................................................................219 DPF Cleaning (Removing Ash in DPF)..............................................................................................................221 Removal and Installation of the DPF Assembly....................................................................................................222 Mode Selection......................................................................................................................................223 Power Mode......................................................................................................................................223 Work Mode.......................................................................................................................................224 Auto Idle Mode..................................................................................................................................224 Boost Mode......................................................................................................................................225 Work Levers (Joysticks) (ISO Pattern)...............................................................................................................226 Left-hand Work Lever (Joystick) (Figure 61 and Figure 62).......................................................................................226 Right-hand Work Lever (Joystick) (Figure 61 and Figure 64)......................................................................................226 Work Levers (Joysticks) (BHL Pattern)...............................................................................................................228 Left-hand Work Lever (Joystick) (Figure 65 and Figure 68).......................................................................................228 Right-hand Work Lever (Joystick) (Figure 65 and Figure 69)......................................................................................228 Intelligent Floating Boom Control (Optional)........................................................................................................229 Intelligent Floating Boom Mode..................................................................................................................229 Operating a Breaker.............................................................................................................................230 Truck Loading...................................................................................................................................230 Operating Precautions...................................................................................................................................232 Working in Water....................................................................................................................................238 Escaping From Mud...................................................................................................................................238 Track On One Side Stuck.........................................................................................................................238 Tracks On Both Sides Stuck......................................................................................................................238 Parking Excavator.......................................................................................................................................239 Towing Procedure........................................................................................................................................240 Attachments.............................................................................................................................................241 Bucket Replacement and Reversal.....................................................................................................................241 Replacement.........................................................................................................................................242 Reversal (If Applicable)............................................................................................................................243 Hydraulic Attachments (Optional)........................................................................................................................244 Breaker Operation...................................................................................................................................244 Selection of Hydraulic Breaker..................................................................................................................244 Hydraulic Hoses and Tubing for Breaker..........................................................................................................244 Breaker Operating Precautions...................................................................................................................245 To Activate Breaker.............................................................................................................................247 Hydraulic Oil and Filter Service Intervals......................................................................................................248 Shear Operation (Optional)..........................................................................................................................249 To Activate Shear...............................................................................................................................250 Rotating Operation (Optional).......................................................................................................................252 Quick Coupler Operation (Optional)..................................................................................................................253 Securing Work Tool..............................................................................................................................253 Attaching Quick Coupler to Excavator............................................................................................................253 Releasing the Work Tool.........................................................................................................................255 Lifting Objects.........................................................................................................................................256 Lifting Unknown Weight..............................................................................................................................257 Lifting Known Weight................................................................................................................................257 Pick and Carry......................................................................................................................................257 Operation Under Abnormal Conditions.....................................................................................................................258 Operation in Extreme Cold...........................................................................................................................258 Operation in Extreme Heat...........................................................................................................................259 Operation in Dusty and Sandy Areas..................................................................................................................260 Operation in Rainy or Humid Conditions..............................................................................................................261 Operation in Saltwater Areas........................................................................................................................261 Operation at High Altitudes.........................................................................................................................261 Operation During Electrical Storms..................................................................................................................262 Equipment Lowering with Engine Stopped..............................................................................................................262 Machine Without a Boom Lowering Control Valve...................................................................................................262 Machine With a Boom Lowering Control Valve......................................................................................................264 Long Term Storage.......................................................................................................................................265 Before Storage......................................................................................................................................265 During Storage......................................................................................................................................266 After Storage.......................................................................................................................................266 Inspection, Maintenance and Adjustment......................................................................................................................267 Maintenance Information.................................................................................................................................267 Operational Hour Meter Reading......................................................................................................................267 DOOSAN Genuine Replacement Parts....................................................................................................................267 DOOSAN Genuine Lubricants...........................................................................................................................267 Windshield Washer Fluid.............................................................................................................................267 Fresh and Clean Lubricants..........................................................................................................................267 Check Drained Oil and Used Filter...................................................................................................................267 Fuel Strainer.......................................................................................................................................267 Welding Instructions................................................................................................................................268 Do Not Drop Things Inside Machine...................................................................................................................268 Dusty Work Site.....................................................................................................................................268 Avoid Mixing Lubricants.............................................................................................................................268 Locking Inspection Covers...........................................................................................................................268 Hydraulic System - Air Bleeding.....................................................................................................................269 Hydraulic Hose Installation.........................................................................................................................269 Checks After Inspection and Maintenance Works.......................................................................................................269 Safety Precautions..................................................................................................................................270 Machine Setup Position for Maintenance..................................................................................................................271 Maintenance Handling Access.............................................................................................................................273 Entering/Leaving/Climbing On Machine................................................................................................................273 Handling Oil, Fuel, Coolant.............................................................................................................................274 Oil.................................................................................................................................................274 Fuel................................................................................................................................................274 Engine Oil..........................................................................................................................................276 Grease..............................................................................................................................................276 Coolant and Water for Dilution......................................................................................................................277 Filters.............................................................................................................................................278 Electrical System Maintenance...........................................................................................................................279 Recommend Fuel, Coolant, and Lubricant..................................................................................................................280 Lubrication.........................................................................................................................................280 Symbols for "Lubrication and Service Chart".........................................................................................................281 Fluid Capacities........................................................................................................................................284 Table of Recommended Lubricants.........................................................................................................................285 Maintenance Intervals...................................................................................................................................287 10 Hour / Daily Service.................................................................................................................................290 Grease Boom, Arm and Front Attachment Pins (for first 100 hours)....................................................................................290 Check Engine Oil Level..............................................................................................................................290 Check Level of Hydraulic Oil Tank...................................................................................................................291 Check for Leaks in Hydraulic System.................................................................................................................292 Check Fuel Level....................................................................................................................................292 Check for Leaks in Fuel System......................................................................................................................293 Check Fuel Prefilter and Drain Water As Required....................................................................................................294 Check Oil Level of Swing Reduction Device...........................................................................................................295 Clean Dust Net In Front of Oil Cooler and Radiator..................................................................................................296 Oil Cooler......................................................................................................................................296 Radiator........................................................................................................................................296 Check Cooling System and Refill As Required.........................................................................................................297 Check Level of Window Washer Liquid.................................................................................................................297 Inspect Bucket Teeth and Side Cutters for Signs of Wear.............................................................................................298 Inspect Cooling Fan Blade...........................................................................................................................298 Check Air Intake System and Emission Control System Components......................................................................................299 Inspect Seat Belt for Proper Operation..............................................................................................................299 Inspect Rear View Camera for Proper Operation (If Equipped).........................................................................................299 Inspect Mirrors for Damage and Adjust and Clean as Required.........................................................................................300 Inspect Structure for Cracks and Faulty Welds.......................................................................................................300 Check Operation of All Switches and Travel Alarm (If Equipped)......................................................................................300 Check the Operation of Pilot Cutoff Switch..........................................................................................................300 Inspection and Maintenance of the Pilot Cutoff Switch...........................................................................................300 Check Operation of All Exterior Lights, Horn and Control Console Indicator and Display Monitor......................................................301 Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds.....301 Check Operation of All Controls and Linkages........................................................................................................302 50 Hour / Weekly Service................................................................................................................................303 Perform All Daily Service Checks....................................................................................................................303 Grease Arm and Bucket Joint Pins....................................................................................................................303 Grease Swing Bearing................................................................................................................................304 Drain Water and Sediment from Fuel Tank.............................................................................................................305 Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)...................................................................305 Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers)....................................305 250 Hour / Monthly Service..............................................................................................................................306 Perform All Daily and 50 Hour Service Checks........................................................................................................306 Grease Boom and Arm Joint Pins......................................................................................................................306 Check Engine Fan and Alternator Belts Wear..........................................................................................................309 Change Breaker Filter (Optional)....................................................................................................................310 Check Oil Bath Precleaner (Optional)................................................................................................................310 Clean Oil Bath Precleaner (Optional)................................................................................................................311 Replace Hydraulic Oil Return Filter (After First 250 Hours).........................................................................................313 Change Pilot Filter (After First 250 Hours).........................................................................................................313 Inspect Pins and Bushings of the Front End Attachments for Signs of Wear............................................................................313 Check Fluid Levels in Batteries.....................................................................................................................313 Inspect for Any Loose or Missing Nuts and Bolts.....................................................................................................313 Inspect Fuel System Hose Clamps.....................................................................................................................313 500 Hour / 3 Month Service..............................................................................................................................314 Perform All Daily, 50 and 250 Hour Service Checks...................................................................................................314 Grease Swing Gear and Pinion........................................................................................................................314 Change Engine Oil and Filter........................................................................................................................315 Clean Air-conditioning Outer Filter.................................................................................................................316 Check and Clean Air-conditioning Inner Filter.......................................................................................................317 Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Cores............................................................318 Clean Primary Element of Air Cleaner................................................................................................................319 Change of Fuel Prefilter............................................................................................................................321 Change Fuel Filter..................................................................................................................................322 Fuel System Priming.............................................................................................................................323 Check Oil Level in Travel Reduction Device (One on Each Side of Unit)...............................................................................324 Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 500 Hours)............................................................324 Change Swing Reduction Device Oil (Drain and Refill After First 500 Hours)..........................................................................324 1,000 Hour / 6 Month Service............................................................................................................................325 Perform All Daily, 50, 250 and 500 Hour Service Checks..............................................................................................325 Grease Swing Reduction Device.......................................................................................................................325 Change Hydraulic Oil Tank Breather Filter...........................................................................................................325 Change Pilot Filter.................................................................................................................................327 Change Swing Reduction Device Oil...................................................................................................................328 Change Air-conditioning Outer Filter................................................................................................................329 Change Air-conditioning Inner Filter................................................................................................................329 Check Air Conditioner Refrigerant...................................................................................................................330 Change Fuel Cap Filter..............................................................................................................................331 Check and Adjust Engine**...........................................................................................................................332 2,000 Hour / Yearly Service.............................................................................................................................333 Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks.......................................................................................333 Change Primary and Secondary Air Cleaner Filters....................................................................................................333 Change Radiator Coolant.............................................................................................................................334 Hydraulic Oil Exchange and Suction Strainer Cleaning................................................................................................336 Change Oil in Travel Reduction Device (One on Each Side of Unit)....................................................................................338 Check Alternator and Starter**......................................................................................................................339 Check All Rubber Antivibration Shock Mounts.........................................................................................................339 Perform and Record Results of Cycle Time Tests......................................................................................................339 Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage.....................................................................339 Check, Adjust Valve Clearance**.....................................................................................................................339 Check Head Bolt Torques.............................................................................................................................339 4,000 Hour / Biennial Service...........................................................................................................................340 Major Parts - Periodic Replacement..................................................................................................................340 4,500 Hour / Biennial Service...........................................................................................................................341 Clean Diesel Particulate Filter (DPF)...............................................................................................................341 12,000 Hour / 6 Year Service............................................................................................................................342 Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 (CEN)).........................................................................342 Air-conditioning System.................................................................................................................................343 Check Control Panel.................................................................................................................................343 Check Air Conditioner Hoses.........................................................................................................................343 Check Condenser.....................................................................................................................................343 Check Magnetic Clutch...............................................................................................................................343 Check Belt Tension..................................................................................................................................343 Bolt and Nut Inspection.................................................................................................................................344 Bucket..................................................................................................................................................352 Bucket Tooth Replacement............................................................................................................................352 Bucket O-ring Replacement...........................................................................................................................353 Electrical System.......................................................................................................................................354 Battery.............................................................................................................................................354 Batteries in Cold Weather.......................................................................................................................354 Inspection of Battery Electrolyte Level.........................................................................................................355 Check Charging State............................................................................................................................355 Check Battery Terminals.........................................................................................................................355 Battery Replacement.............................................................................................................................355 Fuses...............................................................................................................................................356 Fuse Boxes......................................................................................................................................356 Fuse Identification.............................................................................................................................357 Engine Cooling System...................................................................................................................................358 General.............................................................................................................................................358 Types of Antifreeze.............................................................................................................................359 Antifreeze Concentration Tables.....................................................................................................................360 Table of Standards for Allowed Tap Water............................................................................................................360 Fuel Transfer Pump (Optional)...........................................................................................................................361 Handling of Accumulator.................................................................................................................................364 Track Tension...........................................................................................................................................365 Venting and Priming Hydraulic System....................................................................................................................367 Main System Pump....................................................................................................................................367 Hydraulic Cylinders.................................................................................................................................367 Swing Motor.........................................................................................................................................368 Travel Motor........................................................................................................................................368 General Venting.....................................................................................................................................368 Maintenance in Special Conditions.......................................................................................................................369 Transportation..............................................................................................................................................371 Loading and Unloading...................................................................................................................................371 Warning for Counterweight and Front Attachment Removal..............................................................................................371 Track Frame Extension and Retraction................................................................................................................374 Lifting Machine.........................................................................................................................................380 Troubleshooting.............................................................................................................................................381 Electrical System.......................................................................................................................................381 Engine..................................................................................................................................................382 Variable Geometry Turbocharger (VGT)....................................................................................................................386 Lubrication System......................................................................................................................................387 Hydraulic System........................................................................................................................................388 Air Compressor (Optional)...............................................................................................................................389 Swing System............................................................................................................................................390 Travel System...........................................................................................................................................390 Hydraulic Fan Drive System..............................................................................................................................391 Specification...............................................................................................................................................393 Standard Specification..................................................................................................................................393 DX490LC-3...........................................................................................................................................393 Standard Specification..................................................................................................................................394 DX530LC-3...........................................................................................................................................394 Overall Dimensions......................................................................................................................................395 Variable Track......................................................................................................................................395 Fixed Track.........................................................................................................................................396 Disassembled Parts, Dimension and Weight................................................................................................................397 Components..........................................................................................................................................397 Ground Pressure.........................................................................................................................................400 Digging Force...........................................................................................................................................401 Working Range...........................................................................................................................................402 Fixed Track.........................................................................................................................................403 Excavator Rated Lift Capacity Tables....................................................................................................................404 Approximate Weight of Workload Materials................................................................................................................488 Index.......................................................................................................................................................491
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R.D
Cameron K –
Good options. Just need to be more detailed since the options seem alike.