Doosan DX225LC-3 Excavator Operation & Maintenance Manual 950106-00365ANA – PDF DOWNLOAD
DESCRIPTION:
Serial Number 50001 and Up (Europe Only)
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.
TABLE OF CONTENTS:
Doosan DX225LC-3 Excavator Operation & Maintenance Manual 950106-00365ANA – PDF DOWNLOAD
DX225LC-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
Federal Emission Control Systems………………………………………………………………………………………………………… 13
Limited Warranty for Non-road Engines (CI)……………………………………………………………………………………………. 13
Owner’s Warranty Rights and Obligations………………………………………………………………………………………………. 13
Manufacturer’s Warranty Coverage…………………………………………………………………………………………………….. 14
Owner’s Warranty Responsibilities……………………………………………………………………………………………………. 14
Safety…………………………………………………………………………………………………………………………………… 15
Safety Decals…………………………………………………………………………………………………………………………. 16
Safety Decals With Text…………………………………………………………………………………………………………….. 16
Safety Decals Without Text (No-Text)…………………………………………………………………………………………………. 17
Information and Location for Safety Decals……………………………………………………………………………………………. 18
Information and Location for Safety Decals (Continued)…………………………………………………………………………………. 19
General………………………………………………………………………………………………………………………………. 30
Safe Operation is Operator’s Responsibility…………………………………………………………………………………………… 30
Know Your Machine………………………………………………………………………………………………………………….. 30
Proper Work Tools and Attachments……………………………………………………………………………………………………. 31
Pressurized Fluids…………………………………………………………………………………………………………………. 31
Flying or Falling Objects…………………………………………………………………………………………………………… 32
Personal Protective Equipment (PPE)………………………………………………………………………………………………….. 33
Correction of Machine Problems………………………………………………………………………………………………………. 33
Crushing and Cutting……………………………………………………………………………………………………………….. 33
Hot Coolant and Oils – Burn Prevention……………………………………………………………………………………………….. 34
Fire and Explosion Prevention……………………………………………………………………………………………………….. 35
Maintenance……………………………………………………………………………………………………………………. 35
Operation……………………………………………………………………………………………………………………… 35
Electrical…………………………………………………………………………………………………………………….. 36
Hydraulic System……………………………………………………………………………………………………………….. 36
Fueling……………………………………………………………………………………………………………………….. 37
Never Use Ether Starting Aids……………………………………………………………………………………………………. 37
Welding and Grinding……………………………………………………………………………………………………………. 37
If a Fire Occurs……………………………………………………………………………………………………………….. 38
Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)…………………………………………………………………………….. 38
Electrical System and Electrical Shock……………………………………………………………………………………………….. 39
Rollover Protective Structure (ROPS)…………………………………………………………………………………………………. 39
ROPS Certification……………………………………………………………………………………………………………… 40
Protecting Cabin from Flying or Falling Objects (Optional)………………………………………………………………………….. 41
Emergency Exit from Operator’s Station……………………………………………………………………………………………. 42
Transportation………………………………………………………………………………………………………………………… 43
Obey State and Local Over-the-Road Regulations………………………………………………………………………………………… 43
Loading and Unloading………………………………………………………………………………………………………………. 43
Transporting Machine……………………………………………………………………………………………………………….. 44
Operation…………………………………………………………………………………………………………………………….. 45
Before Engine Starting……………………………………………………………………………………………………………… 45
Machine Condition………………………………………………………………………………………………………………. 45
Work Site…………………………………………………………………………………………………………………………. 46
Mounting/Dismounting……………………………………………………………………………………………………………….. 47
Cleaning………………………………………………………………………………………………………………………….. 48
Operator Station…………………………………………………………………………………………………………………… 48
Seat Belt…………………………………………………………………………………………………………………………. 49
Visibility Information……………………………………………………………………………………………………………… 50
Work Site Rules………………………………………………………………………………………………………………… 50
Boost Starting or Charging Engine Batteries…………………………………………………………………………………………… 51
Swinging or Traveling………………………………………………………………………………………………………………. 53
Lifting and Digging………………………………………………………………………………………………………………… 55
Operation on Slopes………………………………………………………………………………………………………………… 56
Towing……………………………………………………………………………………………………………………………. 57
Attachment………………………………………………………………………………………………………………………… 58
Equipment Lowering with Engine Stopped……………………………………………………………………………………………….. 58
Engine Stop……………………………………………………………………………………………………………………….. 58
Parking Machine……………………………………………………………………………………………………………………. 59
Preservation/Storing Machine………………………………………………………………………………………………………… 60
Check After Long-term Parking……………………………………………………………………………………………………. 61
Maintenance…………………………………………………………………………………………………………………………… 62
Cleaning………………………………………………………………………………………………………………………….. 65
Proper Tools and Clothing…………………………………………………………………………………………………………… 65
Disassembling Precautions…………………………………………………………………………………………………………… 65
Use of Lighting……………………………………………………………………………………………………………………. 66
Fire and Explosion Prevention……………………………………………………………………………………………………….. 66
Burn Prevention……………………………………………………………………………………………………………………. 67
Rubber That Contains Fluorides………………………………………………………………………………………………………. 68
Rubber and Plastics………………………………………………………………………………………………………………… 69
Waste Hazardous to the Environment……………………………………………………………………………………………….. 69
Check List After Fire…………………………………………………………………………………………………………… 69
Welding Repairs……………………………………………………………………………………………………………………. 70
Preparation for Electrical Welding On Body Structure……………………………………………………………………………….. 71
Warning for Counterweight and Front Attachment Removal…………………………………………………………………………………. 71
Lock Inspection Covers……………………………………………………………………………………………………………… 72
Working on Machine…………………………………………………………………………………………………………………. 72
Accumulator……………………………………………………………………………………………………………………….. 73
Compressed Air…………………………………………………………………………………………………………………….. 73
Track Tension Adjustments…………………………………………………………………………………………………………… 74
Supports and Blocking for Work Equipment……………………………………………………………………………………………… 74
High-pressure Lines, Tubes and Hoses…………………………………………………………………………………………………. 75
Battery…………………………………………………………………………………………………………………………… 76
Battery Hazard Prevention……………………………………………………………………………………………………….. 76
Environment and Circumstances…………………………………………………………………………………………………………… 78
Work Site Areas Requiring Extra Caution………………………………………………………………………………………………. 78
Digging Under an Overhang……………………………………………………………………………………………………….. 78
Deep Digging…………………………………………………………………………………………………………………… 78
Drop-off or Edge……………………………………………………………………………………………………………….. 79
Poor Visibility………………………………………………………………………………………………………………… 79
Loose or Soft Ground……………………………………………………………………………………………………………. 79
High-voltage Cables………………………………………………………………………………………………………………… 80
Underground Operation………………………………………………………………………………………………………………. 81
Working in Water…………………………………………………………………………………………………………………… 81
Working in Contaminated Environment………………………………………………………………………………………………….. 81
Operation in Extreme Conditions……………………………………………………………………………………………………… 82
Operation In Extreme Cold……………………………………………………………………………………………………….. 82
Operation in Extreme Heat……………………………………………………………………………………………………….. 83
Operation In Dusty and Sandy Areas……………………………………………………………………………………………….. 84
Operation in Rainy or Humid Conditions……………………………………………………………………………………………. 85
Operation in Saltwater Areas…………………………………………………………………………………………………….. 85
Operation at High Altitudes……………………………………………………………………………………………………… 86
Operation During Electrical Storms……………………………………………………………………………………………….. 86
Exhaust Ventilation………………………………………………………………………………………………………………… 86
Ventilation for Enclosed Area……………………………………………………………………………………………………. 86
Asbestos Information……………………………………………………………………………………………………………….. 87
Silica Dust Information…………………………………………………………………………………………………………….. 87
Disposal of Hazardous Materials……………………………………………………………………………………………………… 88
Sound…………………………………………………………………………………………………………………………….. 88
Vibration…………………………………………………………………………………………………………………………. 89
Operating Controls………………………………………………………………………………………………………………………… 91
Component Locations……………………………………………………………………………………………………………………. 92
Operator’s Area……………………………………………………………………………………………………………………….. 94
Operational Controls and Panels…………………………………………………………………………………………………………. 96
1. Starter Switch………………………………………………………………………………………………………………….. 98
2. Heater and Air Conditioner Control Panel…………………………………………………………………………………………… 98
3. Power Socket for 12 Volt…………………………………………………………………………………………………………. 99
4. Cigarette Lighter……………………………………………………………………………………………………………….. 99
5. Engine Emergency Stop Switch……………………………………………………………………………………………………… 99
6. Engine Speed Control Dial…………………………………………………………………………………………………………100
7. Travel Speed Selector Switch………………………………………………………………………………………………………100
8. Light Switch…………………………………………………………………………………………………………………….100
9. Intelligent Floating Boom Switch (Optional)…………………………………………………………………………………………101
10. Cabin Work Light Switch (Optional)………………………………………………………………………………………………..101
11. Audio Control Panel……………………………………………………………………………………………………………..101
12. Wiper Control Panel……………………………………………………………………………………………………………..103
13. Quick Coupler Switch (Optional)…………………………………………………………………………………………………..104
14. Air Compressor Switch (Optional)………………………………………………………………………………………………….104
15. Warning Light Switch (Optional)…………………………………………………………………………………………………..105
16. Lower Wiper Switch (Optional)…………………………………………………………………………………………………….105
17. Travel/Swing Alarm Switch (Optional)………………………………………………………………………………………………105
18. Fuel Heater Switch (Optional)…………………………………………………………………………………………………….106
19. Overload Warning Switch (Optional)………………………………………………………………………………………………..106
20. Power Socket for 12 Volt (Optional)……………………………………………………………………………………………….106
21. Horn Button (Left-hand Work Lever)………………………………………………………………………………………………..107
22. Breaker/Booster Button (Right-hand Work Lever)……………………………………………………………………………………..107
23. Rotating Switch…………………………………………………………………………………………………………………107
24. Shear Switch……………………………………………………………………………………………………………………108
25. Display Monitor…………………………………………………………………………………………………………………108
26. Photo Sensor……………………………………………………………………………………………………………………108
27. Safety Lever……………………………………………………………………………………………………………………109
28. Auxiliary Mode Switch……………………………………………………………………………………………………………109
29. Hour Meter……………………………………………………………………………………………………………………..109
30. Diesel Particulate Filter (DPF) Switch…………………………………………………………………………………………….110
31. One Touch Deceleration Button…………………………………………………………………………………………………….110
32. Intelligent Floating Boom Temporary Reset Button……………………………………………………………………………………111
33. Jog Switch Control Panel…………………………………………………………………………………………………………111
34. Jack Assembly…………………………………………………………………………………………………………………..113
35. Micro Phone (Optional)…………………………………………………………………………………………………………..113
Display Monitor………………………………………………………………………………………………………………………..114
Functional Check……………………………………………………………………………………………………………………114
Password Activated………………………………………………………………………………………………………………….115
1. Fuel Gauge………………………………………………………………………………………………………………………115
2. Engine Coolant Temperature Gauge…………………………………………………………………………………………………..115
3. Hydraulic Oil Temperature Gauge……………………………………………………………………………………………………116
4. Multifunction Gauge and Graphic Information Area…………………………………………………………………………………….116
5. ECO Gauge……………………………………………………………………………………………………………………….118
6. Digital Clock……………………………………………………………………………………………………………………118
7. Display Warning Symbols…………………………………………………………………………………………………………..119
9. Function Buttons…………………………………………………………………………………………………………………126
10. Mode Selector Buttons……………………………………………………………………………………………………………128
11. Selector Function Display………………………………………………………………………………………………………..129
12. Jog Switch……………………………………………………………………………………………………………………..129
13. Camera Mode Selector/ESC Button…………………………………………………………………………………………………..129
14. Multimedia Selector Button……………………………………………………………………………………………………….130
Warning Pop-up Window……………………………………………………………………………………………………………….130
User Menu…………………………………………………………………………………………………………………………….. 0
Switch Operation Indication………………………………………………………………………………………………………….161
Heater and Air Conditioner Control Panel………………………………………………………………………………………………….164
Location of Controls and Vents……………………………………………………………………………………………………….164
Control Panel………………………………………………………………………………………………………………………165
Memory Function…………………………………………………………………………………………………………………….169
Additional Operating Instructions…………………………………………………………………………………………………….169
Miscellaneous Electrical Devices…………………………………………………………………………………………………………171
Cabin Light………………………………………………………………………………………………………………………..171
Pilot Cutoff Switch…………………………………………………………………………………………………………………171
Circuit Breaker…………………………………………………………………………………………………………………….171
Fusible Link……………………………………………………………………………………………………………………….172
Fuse Boxes…………………………………………………………………………………………………………………………172
Seat Adjustment……………………………………………………………………………………………………………………….. 0
7. Storage Compartment………………………………………………………………………………………………………………175
8. Left and Right Control Stand Adjustment…………………………………………………………………………………………….175
Cabin Storage Compartments………………………………………………………………………………………………………………181
Sunglass Case………………………………………………………………………………………………………………………….181
Miscellaneous Access Covers and Doors…………………………………………………………………………………………………….184
Side Door………………………………………………………………………………………………………………………….184
Battery Box Door……………………………………………………………………………………………………………………184
Engine Cover……………………………………………………………………………………………………………………….184
Air Gun and Compressor (Optional)………………………………………………………………………………………………………..185
Air Gun (Optional)………………………………………………………………………………………………………………….185
How to Use Air Compressor……………………………………………………………………………………………………………185
Operation…………………………………………………………………………………………………………………………………189
To Operate a New Excavator………………………………………………………………………………………………………………189
Lubrication and Filters……………………………………………………………………………………………………………..190
Starting and Stopping Engine…………………………………………………………………………………………………………….190
Inspection Before Starting Engine…………………………………………………………………………………………………….190
Walk Around Checks………………………………………………………………………………………………………………190
Checks Before Starting Engine…………………………………………………………………………………………………….191
Operational Checks Before Starting Engine……………………………………………………………………………………………..192
Engine Start……………………………………………………………………………………………………………………….193
Cold Weather Starting……………………………………………………………………………………………………………….195
Engine Coolant Heater (Optional)……………………………………………………………………………………………………..197
Starting Engine With a Booster Cable………………………………………………………………………………………………….199
Connecting Booster Batteries……………………………………………………………………………………………………..199
Disconnecting Booster Batteries…………………………………………………………………………………………………..200
Hydraulic System Warm-up…………………………………………………………………………………………………………….200
Hydraulic System Warm-up – Cold Weather……………………………………………………………………………………………….201
Stopping Engine…………………………………………………………………………………………………………………….203
Checks and Maintenance After Stopping Engine…………………………………………………………………………………………..204
Safety Lever…………………………………………………………………………………………………………………………..204
Travel………………………………………………………………………………………………………………………………..205
Automatic Travel Speed Control……………………………………………………………………………………………………….205
Travel Control Lever Operation……………………………………………………………………………………………………….206
General Travel Instructions………………………………………………………………………………………………………….207
Straight Travel Pedal (Optional)……………………………………………………………………………………………………..209
Operating………………………………………………………………………………………………………………………210
Locking Pedal…………………………………………………………………………………………………………………..210
Operating Instructions………………………………………………………………………………………………………………….211
Engine Speed Control………………………………………………………………………………………………………………..211
Engine Exhaust Emission Control System………………………………………………………………………………………………..211
Regeneration of Diesel Particulate Filter (DPF)…………………………………………………………………………………….212
Diesel Particulate Filter (DPF) Regeneration Light and Switch………………………………………………………………………..212
Passive Regeneration…………………………………………………………………………………………………………….215
Active Regeneration……………………………………………………………………………………………………………..215
Manual (Forced) Regeneration……………………………………………………………………………………………………..216
DPF Cleaning (Removing Ash in DPF)………………………………………………………………………………………………..218
Removal and Installation of the DPF Assembly……………………………………………………………………………………….219
Mode Selection……………………………………………………………………………………………………………………..220
Power Mode……………………………………………………………………………………………………………………..220
Work Mode………………………………………………………………………………………………………………………221
Auto Idle Mode………………………………………………………………………………………………………………….221
Boost Mode……………………………………………………………………………………………………………………..222
Work Levers (Joysticks) (ISO Pattern)…………………………………………………………………………………………………223
Left-hand Work Lever (Joystick) (Figure 62 and Figure 63)……………………………………………………………………………223
Right-hand Work Lever (Joystick) (Figure 62 and Figure 65)…………………………………………………………………………..223
Work Levers (Joysticks) (BHL Pattern)…………………………………………………………………………………………………225
Left-hand Work Lever (Joystick) (Figure 66 and Figure 68)……………………………………………………………………………225
Right-hand Work Lever (Joystick) (Figure 66 and Figure 69)…………………………………………………………………………..225
Intelligent Floating Boom Control (Optional)…………………………………………………………………………………………..226
Intelligent Floating Boom Mode……………………………………………………………………………………………………226
Operating a Breaker……………………………………………………………………………………………………………..227
Truck Loading…………………………………………………………………………………………………………………..227
Operating Precautions…………………………………………………………………………………………………………………..230
Working in Water……………………………………………………………………………………………………………………237
Escaping From Mud…………………………………………………………………………………………………………………..237
Track On One Side Stuck………………………………………………………………………………………………………….237
Tracks On Both Sides Stuck……………………………………………………………………………………………………….237
Parking Excavator………………………………………………………………………………………………………………………238
Towing Procedure……………………………………………………………………………………………………………………….239
Attachments……………………………………………………………………………………………………………………………240
Bucket Replacement and Reversal………………………………………………………………………………………………………240
Replacement………………………………………………………………………………………………………………………..241
Reversal (If Applicable)…………………………………………………………………………………………………………….242
Hydraulic Attachments (Optional)…………………………………………………………………………………………………………243
Breaker Operation…………………………………………………………………………………………………………………..243
Selection of Hydraulic Breaker……………………………………………………………………………………………………243
Hydraulic Hoses and Tubing for Breaker…………………………………………………………………………………………….243
Breaker Operating Precautions…………………………………………………………………………………………………….244
To Activate Breaker……………………………………………………………………………………………………………..246
Hydraulic Oil and Filter Service Intervals…………………………………………………………………………………………247
Shear Operation (Optional)…………………………………………………………………………………………………………..248
To Activate Shear……………………………………………………………………………………………………………….249
Rotating Operation (Optional)………………………………………………………………………………………………………..251
Quick Coupler Operation (Optional)……………………………………………………………………………………………………252
Securing Work Tool………………………………………………………………………………………………………………252
Attaching Quick Coupler to Excavator………………………………………………………………………………………………252
Releasing the Work Tool………………………………………………………………………………………………………….254
Lifting Objects………………………………………………………………………………………………………………………..255
Lifting Unknown Weight………………………………………………………………………………………………………………256
Lifting Known Weight………………………………………………………………………………………………………………..256
Pick and Carry……………………………………………………………………………………………………………………..256
Operation Under Abnormal Conditions………………………………………………………………………………………………………257
Operation in Extreme Cold……………………………………………………………………………………………………………257
Operation in Extreme Heat……………………………………………………………………………………………………………258
Operation in Dusty and Sandy Areas……………………………………………………………………………………………………260
Operation in Rainy or Humid Conditions………………………………………………………………………………………………..260
Operation in Saltwater Areas…………………………………………………………………………………………………………261
Operation During Electrical Storms……………………………………………………………………………………………………261
Operation at High Altitudes………………………………………………………………………………………………………….261
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 Intercooler…………………………………………………………………………………..296
Check Cooling System and Refill As Required……………………………………………………………………………………………296
Check Level of Window Washer Liquid…………………………………………………………………………………………………..297
Inspect Bucket Teeth and Side Cutters for Signs of Wear…………………………………………………………………………………297
Inspect Cooling Fan Blade……………………………………………………………………………………………………………297
Check Air Intake System and Emission Control System Components…………………………………………………………………………..298
Inspect Seat Belt for Proper Operation………………………………………………………………………………………………..298
Inspect Rear View Camera for Proper Operation (If Equipped)……………………………………………………………………………..298
Inspect Mirrors for Damage and Adjust and Clean as Required……………………………………………………………………………..299
Inspect Structure for Cracks and Faulty Welds………………………………………………………………………………………….299
Check Operation of All Switches and Travel Alarm (If Equipped)…………………………………………………………………………..299
Check the Operation of Pilot Cutoff Switch…………………………………………………………………………………………….299
Inspection and Maintenance of the Pilot Cutoff Switch……………………………………………………………………………….299
Check Operation of All Exterior Lights, Horn and Control Console Indicator and Display Monitor………………………………………………300
Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds…..300
Check Operation of All Controls and Linkages…………………………………………………………………………………………..301
50 Hour / Weekly Service………………………………………………………………………………………………………………..302
Perform All Daily Service Checks……………………………………………………………………………………………………..302
Grease Arm and Bucket Joint Pins……………………………………………………………………………………………………..302
Grease Swing Bearing………………………………………………………………………………………………………………..303
Grease Leveling Blade Pins (Optional)…………………………………………………………………………………………………304
Drain Water and Sediment from Fuel Tank……………………………………………………………………………………………….304
Check Air Compressor and Drain Water as Required……………………………………………………………………………………….304
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
Replace Hydraulic Oil Return Filter (After First 250 Hours)……………………………………………………………………………..311
Change Pilot Filter (After First 250 Hours)……………………………………………………………………………………………311
Inspect Pins and Bushings of the Front End Attachments for Signs of Wear………………………………………………………………….311
Check Fluid Levels in Batteries………………………………………………………………………………………………………311
Inspect for Any Loose or Missing Nuts and Bolts………………………………………………………………………………………..311
Inspect Fuel System Hose Clamps………………………………………………………………………………………………………311
500 Hour / 3 Month Service………………………………………………………………………………………………………………312
Perform All Daily, 50 and 250 Hour Service Checks………………………………………………………………………………………312
Grease Swing Gear and Pinion…………………………………………………………………………………………………………312
Change Engine Oil and Filter…………………………………………………………………………………………………………313
Clean Air-conditioning Outer Filter…………………………………………………………………………………………………..314
Check and Clean Air-conditioning Inner Filter………………………………………………………………………………………….315
Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Cores……………………………………………………316
Clean Outer Filter of Air Cleaner…………………………………………………………………………………………………….317
Change of Fuel Prefilter…………………………………………………………………………………………………………….319
Change Fuel Filter………………………………………………………………………………………………………………….320
Fuel System Priming……………………………………………………………………………………………………………..320
Check Oil Level in Travel Reduction Device (One on Each Side of Unit)…………………………………………………………………….322
Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 500 Hours)……………………………………………………322
Change Swing Reduction Device Oil (Drain and Refill After First 500 Hours)………………………………………………………………..322
1,000 Hour / 6 Month Service…………………………………………………………………………………………………………….323
Perform All Daily, 50, 250 and 500 Hour Service Checks………………………………………………………………………………….323
Grease Swing Reduction Device………………………………………………………………………………………………………..323
Change Hydraulic Oil Tank Breather Filter……………………………………………………………………………………………..323
Change Pilot Filter…………………………………………………………………………………………………………………325
Change Oil in Travel Reduction Device (One on Each Side of Unit)…………………………………………………………………………326
Change Swing Reduction Device Oil…………………………………………………………………………………………………….327
Change Air-conditioning Outer Filter………………………………………………………………………………………………….328
Change Air-conditioning Inner Filter………………………………………………………………………………………………….328
Check Air Conditioner Refrigerant…………………………………………………………………………………………………….329
Change Fuel Cap Filter………………………………………………………………………………………………………………330
Check and Adjust Engine**……………………………………………………………………………………………………………331
2,000 Hour / Yearly Service…………………………………………………………………………………………………………….. 0
Change Radiator Coolant……………………………………………………………………………………………………………..334
Hydraulic Oil Exchange and Suction Strainer Cleaning……………………………………………………………………………………336
Check Alternator and Starter**……………………………………………………………………………………………………….338
Check All Rubber Antivibration Shock Mounts……………………………………………………………………………………………338
Perform and Record Results of Cycle Time Tests…………………………………………………………………………………………338
Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage……………………………………………………………338
Check, Adjust Valve Clearance**………………………………………………………………………………………………………338
Check Head Bolt Torques……………………………………………………………………………………………………………..338
4,000 Hour / Biennial Service……………………………………………………………………………………………………………339
Major Parts – Periodic Replacement……………………………………………………………………………………………………339
4,500 Hour / Biennial Service……………………………………………………………………………………………………………340
Clean Diesel Particulate Filter (DPF)…………………………………………………………………………………………………340
12,000 Hour / 6 Year Service…………………………………………………………………………………………………………….341
Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 (CEN))……………………………………………………………….341
Air-conditioning System…………………………………………………………………………………………………………………342
Check Control Panel…………………………………………………………………………………………………………………342
Check Air Conditioner Hoses………………………………………………………………………………………………………….342
Check Condenser…………………………………………………………………………………………………………………….342
Check Magnetic Clutch……………………………………………………………………………………………………………….342
Check Belt Tension………………………………………………………………………………………………………………….342
Bolt and Nut Inspection…………………………………………………………………………………………………………………343
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
Electric Viscous Fan Clutch………………………………………………………………………………………………………….361
Removal and Installation of the Cooling Fan Assembly………………………………………………………………………………..361
Fuel Transfer Pump (Optional)……………………………………………………………………………………………………………362
Handling of Accumulator…………………………………………………………………………………………………………………365
Track Tension………………………………………………………………………………………………………………………….366
Venting and Priming Hydraulic System……………………………………………………………………………………………………..368
Main System Pump……………………………………………………………………………………………………………………368
Hydraulic Cylinders…………………………………………………………………………………………………………………368
Swing Motor………………………………………………………………………………………………………………………..369
Travel Motor……………………………………………………………………………………………………………………….369
General Venting…………………………………………………………………………………………………………………….369
Maintenance in Special Conditions………………………………………………………………………………………………………..370
Transportation…………………………………………………………………………………………………………………………….371
Loading and Unloading…………………………………………………………………………………………………………………..371
Warning for Counterweight and Front Attachment Removal………………………………………………………………………………….371
Lifting Machine………………………………………………………………………………………………………………………..378
Troubleshooting……………………………………………………………………………………………………………………………379
Electrical System………………………………………………………………………………………………………………………379
Engine………………………………………………………………………………………………………………………………..380
Turbocharger…………………………………………………………………………………………………………………………..384
Cooling Fan……………………………………………………………………………………………………………………………385
Lubrication System……………………………………………………………………………………………………………………..385
Hydraulic System……………………………………………………………………………………………………………………….386
Air Compressor (Optional)……………………………………………………………………………………………………………….387
Swing System…………………………………………………………………………………………………………………………..388
Travel System………………………………………………………………………………………………………………………….388
Specification……………………………………………………………………………………………………………………………..389
Standard Specification………………………………………………………………………………………………………………….389
Overall Dimensions……………………………………………………………………………………………………………………..390
One – Piece Boom……………………………………………………………………………………………………………………390
Two – Piece Boom……………………………………………………………………………………………………………………391
Disassembled Parts, Dimension and Weight………………………………………………………………………………………………….392
Components…………………………………………………………………………………………………………………………392
Ground Pressure………………………………………………………………………………………………………………………..394
Digging Force………………………………………………………………………………………………………………………….395
Working Range………………………………………………………………………………………………………………………….396
One – Piece Boom……………………………………………………………………………………………………………………396
Two – Piece Boom……………………………………………………………………………………………………………………397
Excavator Rated Lift Capacity Tables……………………………………………………………………………………………………..398
Approximate Weight of Workload Materials………………………………………………………………………………………………….418
Index…………………………………………………………………………………………………………………………………….421
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