Doosan DX255LC-3 Excavator Operation & Maintenance Manual 950106-00375ANA – PDF DOWNLOAD
DESCRIPTION:
Doosan DX255LC-3 Excavator Operation & Maintenance Manual 950106-00375ANA – PDF DOWNLOAD
Serial Number 50001 and Up
- 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.
- 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 DX255LC-3 Excavator Operation & Maintenance Manual 950106-00375ANA – PDF DOWNLOAD
DX255LC-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………………………………………………………………………………………………………………………………. 29
Safe Operation is Operator’s Responsibility…………………………………………………………………………………………… 29
Know Your Machine………………………………………………………………………………………………………………….. 29
Proper Work Tools and Attachments……………………………………………………………………………………………………. 30
Pressurized Fluids…………………………………………………………………………………………………………………. 30
Flying or Falling Objects…………………………………………………………………………………………………………… 31
Personal Protective Equipment (PPE)………………………………………………………………………………………………….. 32
Correction of Machine Problems………………………………………………………………………………………………………. 32
Crushing and Cutting……………………………………………………………………………………………………………….. 32
Hot Coolant and Oils – Burn Prevention……………………………………………………………………………………………….. 33
Fire and Explosion Prevention……………………………………………………………………………………………………….. 34
Maintenance……………………………………………………………………………………………………………………. 34
Operation……………………………………………………………………………………………………………………… 34
Electrical…………………………………………………………………………………………………………………….. 35
Hydraulic System……………………………………………………………………………………………………………….. 35
Fueling……………………………………………………………………………………………………………………….. 36
Never Use Ether Starting Aids……………………………………………………………………………………………………. 36
Welding and Grinding……………………………………………………………………………………………………………. 36
If a Fire Occurs……………………………………………………………………………………………………………….. 37
Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)…………………………………………………………………………….. 37
Electrical System and Electrical Shock……………………………………………………………………………………………….. 38
Rollover Protective Structure (ROPS)…………………………………………………………………………………………………. 38
ROPS Certification……………………………………………………………………………………………………………… 39
Protecting Cabin from Flying or Falling Objects (Optional)………………………………………………………………………….. 40
Emergency Exit from Operator’s Station……………………………………………………………………………………………. 41
Transportation………………………………………………………………………………………………………………………… 42
Obey State and Local Over-the-Road Regulations………………………………………………………………………………………… 42
Loading and Unloading………………………………………………………………………………………………………………. 42
Transporting Machine……………………………………………………………………………………………………………….. 43
Operation…………………………………………………………………………………………………………………………….. 44
Before Engine Starting……………………………………………………………………………………………………………… 44
Machine Condition………………………………………………………………………………………………………………. 44
Work Site…………………………………………………………………………………………………………………………. 45
Mounting/Dismounting……………………………………………………………………………………………………………….. 46
Cleaning………………………………………………………………………………………………………………………….. 47
Operator Station…………………………………………………………………………………………………………………… 47
Seat Belt…………………………………………………………………………………………………………………………. 48
Visibility Information……………………………………………………………………………………………………………… 49
Work Site Rules………………………………………………………………………………………………………………… 49
Boost Starting or Charging Engine Batteries…………………………………………………………………………………………… 50
Swinging or Traveling………………………………………………………………………………………………………………. 52
Lifting and Digging………………………………………………………………………………………………………………… 54
Operation on Slopes………………………………………………………………………………………………………………… 55
Towing……………………………………………………………………………………………………………………………. 56
Attachment………………………………………………………………………………………………………………………… 57
Equipment Lowering with Engine Stopped……………………………………………………………………………………………….. 57
Engine Stop……………………………………………………………………………………………………………………….. 57
Parking Machine……………………………………………………………………………………………………………………. 58
Preservation/Storing Machine………………………………………………………………………………………………………… 59
Check After Long-term Parking……………………………………………………………………………………………………. 60
Maintenance…………………………………………………………………………………………………………………………… 61
Cleaning………………………………………………………………………………………………………………………….. 64
Proper Tools and Clothing…………………………………………………………………………………………………………… 64
Disassembling Precautions…………………………………………………………………………………………………………… 64
Use of Lighting……………………………………………………………………………………………………………………. 65
Fire and Explosion Prevention……………………………………………………………………………………………………….. 65
Burn Prevention……………………………………………………………………………………………………………………. 66
Rubber That Contains Fluorides………………………………………………………………………………………………………. 67
Rubber and Plastics………………………………………………………………………………………………………………… 68
Waste Hazardous to the Environment……………………………………………………………………………………………….. 68
Check List After Fire…………………………………………………………………………………………………………… 68
Welding Repairs……………………………………………………………………………………………………………………. 69
Preparation for Electrical Welding On Body Structure……………………………………………………………………………….. 70
Warning for Counterweight and Front Attachment Removal…………………………………………………………………………………. 70
Lock Inspection Covers……………………………………………………………………………………………………………… 71
Working on Machine…………………………………………………………………………………………………………………. 71
Accumulator……………………………………………………………………………………………………………………….. 72
Compressed Air…………………………………………………………………………………………………………………….. 72
Track Tension Adjustments…………………………………………………………………………………………………………… 73
Supports and Blocking for Work Equipment……………………………………………………………………………………………… 73
High-pressure Lines, Tubes and Hoses…………………………………………………………………………………………………. 74
Battery…………………………………………………………………………………………………………………………… 75
Battery Hazard Prevention……………………………………………………………………………………………………….. 75
Environment and Circumstances…………………………………………………………………………………………………………… 77
Work Site Areas Requiring Extra Caution………………………………………………………………………………………………. 77
Digging Under an Overhang……………………………………………………………………………………………………….. 77
Deep Digging…………………………………………………………………………………………………………………… 77
Drop-off or Edge……………………………………………………………………………………………………………….. 78
Poor Visibility………………………………………………………………………………………………………………… 78
Loose or Soft Ground……………………………………………………………………………………………………………. 78
High-voltage Cables………………………………………………………………………………………………………………… 79
Underground Operation………………………………………………………………………………………………………………. 80
Working in Water…………………………………………………………………………………………………………………… 80
Working in Contaminated Environment………………………………………………………………………………………………….. 80
Operation in Extreme Conditions……………………………………………………………………………………………………… 81
Operation In Extreme Cold……………………………………………………………………………………………………….. 81
Operation in Extreme Heat……………………………………………………………………………………………………….. 82
Operation In Dusty and Sandy Areas……………………………………………………………………………………………….. 83
Operation in Rainy or Humid Conditions……………………………………………………………………………………………. 84
Operation in Saltwater Areas…………………………………………………………………………………………………….. 84
Operation at High Altitudes……………………………………………………………………………………………………… 85
Operation During Electrical Storms……………………………………………………………………………………………….. 85
Exhaust Ventilation………………………………………………………………………………………………………………… 85
Ventilation for Enclosed Area……………………………………………………………………………………………………. 85
Asbestos Information……………………………………………………………………………………………………………….. 86
Silica Dust Information…………………………………………………………………………………………………………….. 86
Disposal of Hazardous Materials……………………………………………………………………………………………………… 87
Sound…………………………………………………………………………………………………………………………….. 87
Vibration…………………………………………………………………………………………………………………………. 88
Operating Controls………………………………………………………………………………………………………………………… 89
Component Locations……………………………………………………………………………………………………………………. 90
Operator’s Area……………………………………………………………………………………………………………………….. 92
Operational Controls and Panels…………………………………………………………………………………………………………. 94
1. Starter Switch………………………………………………………………………………………………………………….. 96
2. Heater and Air Conditioner Control Panel…………………………………………………………………………………………… 96
3. Power Socket for 12 Volt…………………………………………………………………………………………………………. 97
4. Cigarette Lighter……………………………………………………………………………………………………………….. 97
5. Engine Emergency Stop Switch……………………………………………………………………………………………………… 97
6. Engine Speed Control Dial………………………………………………………………………………………………………… 98
7. Travel Speed Selector Switch……………………………………………………………………………………………………… 98
8. Light Switch……………………………………………………………………………………………………………………. 98
9. Intelligent Floating Boom Switch (Optional)………………………………………………………………………………………… 99
10. Cabin Work Light Switch (Optional)……………………………………………………………………………………………….. 99
11. Audio Control Panel…………………………………………………………………………………………………………….. 99
12. Wiper Control Panel……………………………………………………………………………………………………………..101
13. Quick Coupler Switch (Optional)…………………………………………………………………………………………………..102
14. Air Compressor Switch (Optional)………………………………………………………………………………………………….102
15. Warning Light Switch (Optional)…………………………………………………………………………………………………..103
16. Lower Wiper Switch (Optional)…………………………………………………………………………………………………….103
17. Travel/Swing Alarm Switch (Optional)………………………………………………………………………………………………103
18. Fuel Heater Switch (Optional)…………………………………………………………………………………………………….104
19. Overload Warning Switch (Optional)………………………………………………………………………………………………..104
20. Power Socket for 12 Volt (Optional)……………………………………………………………………………………………….104
21. Horn Button (Left-hand Work Lever)………………………………………………………………………………………………..105
22. Breaker/Booster Button (Right-hand Work Lever)……………………………………………………………………………………..105
23. Rotating Switch…………………………………………………………………………………………………………………105
24. Shear Switch……………………………………………………………………………………………………………………106
25. Display Monitor…………………………………………………………………………………………………………………106
26. Photo Sensor……………………………………………………………………………………………………………………106
27. Safety Lever……………………………………………………………………………………………………………………107
28. Auxiliary Mode Switch……………………………………………………………………………………………………………107
29. Hour Meter……………………………………………………………………………………………………………………..107
30. Diesel Particulate Filter (DPF) Switch…………………………………………………………………………………………….108
31. One Touch Deceleration Button…………………………………………………………………………………………………….108
32. Intelligent Floating Boom Temporary Reset Button……………………………………………………………………………………109
33. Jog Switch Control Panel…………………………………………………………………………………………………………109
34. Jack Assembly…………………………………………………………………………………………………………………..111
35. Micro Phone (Optional)…………………………………………………………………………………………………………..111
Display Monitor………………………………………………………………………………………………………………………..112
Functional Check……………………………………………………………………………………………………………………112
Password Activated………………………………………………………………………………………………………………….113
1. Fuel Gauge………………………………………………………………………………………………………………………113
2. Engine Coolant Temperature Gauge…………………………………………………………………………………………………..113
3. Hydraulic Oil Temperature Gauge……………………………………………………………………………………………………114
4. Multifunction Gauge and Graphic Information Area…………………………………………………………………………………….114
5. ECO Gauge……………………………………………………………………………………………………………………….116
6. Digital Clock……………………………………………………………………………………………………………………116
7. Display Warning Symbols…………………………………………………………………………………………………………..117
9. Function Buttons…………………………………………………………………………………………………………………124
10. Mode Selector Buttons……………………………………………………………………………………………………………126
11. Selector Function Display………………………………………………………………………………………………………..127
12. Jog Switch……………………………………………………………………………………………………………………..127
13. Camera Mode Selector/ESC Button…………………………………………………………………………………………………..127
14. Multimedia Selector Button……………………………………………………………………………………………………….128
Warning Pop-up Window……………………………………………………………………………………………………………….128
User Menu…………………………………………………………………………………………………………………………….. 0
Switch Operation Indication………………………………………………………………………………………………………….159
Heater and Air Conditioner Control Panel………………………………………………………………………………………………….162
Location of Controls and Vents……………………………………………………………………………………………………….162
Control Panel………………………………………………………………………………………………………………………163
Memory Function…………………………………………………………………………………………………………………….167
Additional Operating Instructions…………………………………………………………………………………………………….167
Miscellaneous Electrical Devices…………………………………………………………………………………………………………169
Cabin Light………………………………………………………………………………………………………………………..169
Pilot Cutoff Switch…………………………………………………………………………………………………………………169
Circuit Breaker…………………………………………………………………………………………………………………….169
Fusible Link……………………………………………………………………………………………………………………….170
Fuse Boxes…………………………………………………………………………………………………………………………170
Seat Adjustment……………………………………………………………………………………………………………………….. 0
7. Storage Compartment………………………………………………………………………………………………………………173
8. Left and Right Control Stand Adjustment…………………………………………………………………………………………….173
Cabin Storage Compartments………………………………………………………………………………………………………………179
Sunglass Case………………………………………………………………………………………………………………………….179
Miscellaneous Access Covers and Doors…………………………………………………………………………………………………….182
Side Door………………………………………………………………………………………………………………………….182
Battery Box Door……………………………………………………………………………………………………………………182
Engine Cover……………………………………………………………………………………………………………………….182
Air Gun and Compressor (Optional)………………………………………………………………………………………………………..183
Air Gun (Optional)………………………………………………………………………………………………………………….183
How to Use Air Compressor……………………………………………………………………………………………………………183
Operation…………………………………………………………………………………………………………………………………187
To Operate a New Excavator………………………………………………………………………………………………………………187
Lubrication and Filters……………………………………………………………………………………………………………..188
Starting and Stopping Engine…………………………………………………………………………………………………………….188
Inspection Before Starting Engine…………………………………………………………………………………………………….188
Walk Around Checks………………………………………………………………………………………………………………188
Checks Before Starting Engine…………………………………………………………………………………………………….189
Operational Checks Before Starting Engine……………………………………………………………………………………………..190
Engine Start……………………………………………………………………………………………………………………….191
Cold Weather Starting……………………………………………………………………………………………………………….193
Engine Coolant Heater (Optional)……………………………………………………………………………………………………..195
Starting Engine With a Booster Cable………………………………………………………………………………………………….197
Connecting Booster Batteries……………………………………………………………………………………………………..197
Disconnecting Booster Batteries…………………………………………………………………………………………………..198
Hydraulic System Warm-up…………………………………………………………………………………………………………….198
Hydraulic System Warm-up – Cold Weather……………………………………………………………………………………………….199
Stopping Engine…………………………………………………………………………………………………………………….201
Checks and Maintenance After Stopping Engine…………………………………………………………………………………………..202
Safety Lever…………………………………………………………………………………………………………………………..202
Travel………………………………………………………………………………………………………………………………..203
Automatic Travel Speed Control……………………………………………………………………………………………………….203
Travel Control Lever Operation……………………………………………………………………………………………………….204
General Travel Instructions………………………………………………………………………………………………………….205
Straight Travel Pedal (Optional)……………………………………………………………………………………………………..207
Operating………………………………………………………………………………………………………………………208
Locking Pedal…………………………………………………………………………………………………………………..208
Operating Instructions………………………………………………………………………………………………………………….209
Engine Speed Control………………………………………………………………………………………………………………..209
Engine Exhaust Emission Control System………………………………………………………………………………………………..209
Regeneration of Diesel Particulate Filter (DPF)…………………………………………………………………………………….210
Diesel Particulate Filter (DPF) Regeneration Light and Switch………………………………………………………………………..210
Passive Regeneration…………………………………………………………………………………………………………….213
Active Regeneration……………………………………………………………………………………………………………..213
Manual (Forced) Regeneration……………………………………………………………………………………………………..214
DPF Cleaning (Removing Ash in DPF)………………………………………………………………………………………………..216
Removal and Installation of the DPF Assembly……………………………………………………………………………………….217
Mode Selection……………………………………………………………………………………………………………………..218
Power Mode……………………………………………………………………………………………………………………..218
Work Mode………………………………………………………………………………………………………………………219
Auto Idle Mode………………………………………………………………………………………………………………….219
Boost Mode……………………………………………………………………………………………………………………..220
Work Levers (Joysticks) (ISO Pattern)…………………………………………………………………………………………………221
Left-hand Work Lever (Joystick) (Figure 61 and Figure 62)……………………………………………………………………………221
Right-hand Work Lever (Joystick) (Figure 61 and Figure 64)…………………………………………………………………………..221
Work Levers (Joysticks) (BHL Pattern)…………………………………………………………………………………………………223
Left-hand Work Lever (Joystick) (Figure 65 and Figure 67)……………………………………………………………………………223
Right-hand Work Lever (Joystick) (Figure 65 and Figure 68)…………………………………………………………………………..223
Intelligent Floating Boom Control (Optional)…………………………………………………………………………………………..224
Intelligent Floating Boom Mode……………………………………………………………………………………………………224
Operating a Breaker……………………………………………………………………………………………………………..225
Truck Loading…………………………………………………………………………………………………………………..225
Operating Precautions…………………………………………………………………………………………………………………..227
Working in Water……………………………………………………………………………………………………………………233
Escaping From Mud…………………………………………………………………………………………………………………..233
Track On One Side Stuck………………………………………………………………………………………………………….233
Tracks On Both Sides Stuck……………………………………………………………………………………………………….233
Parking Excavator………………………………………………………………………………………………………………………234
Towing Procedure……………………………………………………………………………………………………………………….235
Attachments……………………………………………………………………………………………………………………………236
Bucket Replacement and Reversal………………………………………………………………………………………………………236
Replacement………………………………………………………………………………………………………………………..237
Reversal (If Applicable)…………………………………………………………………………………………………………….238
Hydraulic Attachments (Optional)…………………………………………………………………………………………………………239
Breaker Operation…………………………………………………………………………………………………………………..239
Selection of Hydraulic Breaker……………………………………………………………………………………………………239
Hydraulic Hoses and Tubing for Breaker…………………………………………………………………………………………….239
Breaker Operating Precautions…………………………………………………………………………………………………….240
To Activate Breaker……………………………………………………………………………………………………………..242
Hydraulic Oil and Filter Service Intervals…………………………………………………………………………………………243
Shear Operation (Optional)…………………………………………………………………………………………………………..244
To Activate Shear……………………………………………………………………………………………………………….245
Rotating Operation (Optional)………………………………………………………………………………………………………..247
Quick Coupler Operation (Optional)……………………………………………………………………………………………………248
Securing Work Tool………………………………………………………………………………………………………………248
Attaching Quick Coupler to Excavator………………………………………………………………………………………………248
Releasing the Work Tool………………………………………………………………………………………………………….250
Lifting Objects………………………………………………………………………………………………………………………..251
Lifting Unknown Weight………………………………………………………………………………………………………………252
Lifting Known Weight………………………………………………………………………………………………………………..252
Pick and Carry……………………………………………………………………………………………………………………..252
Operation Under Abnormal Conditions………………………………………………………………………………………………………253
Operation in Extreme Cold……………………………………………………………………………………………………………253
Operation in Extreme Heat……………………………………………………………………………………………………………254
Operation in Dusty and Sandy Areas……………………………………………………………………………………………………256
Operation in Rainy or Humid Conditions………………………………………………………………………………………………..256
Operation in Saltwater Areas…………………………………………………………………………………………………………257
Operation at High Altitudes………………………………………………………………………………………………………….257
Operation During Electrical Storms……………………………………………………………………………………………………257
Equipment Lowering with Engine Stopped………………………………………………………………………………………………..258
Machine Without a Boom Lowering Control Valve………………………………………………………………………………………258
Machine With a Boom Lowering Control Valve…………………………………………………………………………………………260
Long Term Storage………………………………………………………………………………………………………………………261
Before Storage……………………………………………………………………………………………………………………..261
During Storage……………………………………………………………………………………………………………………..262
After Storage………………………………………………………………………………………………………………………262
Inspection, Maintenance and Adjustment……………………………………………………………………………………………………….263
Maintenance Information…………………………………………………………………………………………………………………263
Operational Hour Meter Reading……………………………………………………………………………………………………….263
DOOSAN Genuine Replacement Parts……………………………………………………………………………………………………..263
DOOSAN Genuine Lubricants……………………………………………………………………………………………………………263
Windshield Washer Fluid……………………………………………………………………………………………………………..263
Fresh and Clean Lubricants…………………………………………………………………………………………………………..263
Check Drained Oil and Used Filter…………………………………………………………………………………………………….263
Fuel Strainer………………………………………………………………………………………………………………………263
Welding Instructions………………………………………………………………………………………………………………..264
Do Not Drop Things Inside Machine…………………………………………………………………………………………………….264
Dusty Work Site…………………………………………………………………………………………………………………….264
Avoid Mixing Lubricants……………………………………………………………………………………………………………..264
Locking Inspection Covers……………………………………………………………………………………………………………264
Hydraulic System – Air Bleeding………………………………………………………………………………………………………265
Hydraulic Hose Installation………………………………………………………………………………………………………….265
Checks After Inspection and Maintenance Works………………………………………………………………………………………….265
Safety Precautions………………………………………………………………………………………………………………….266
Machine Setup Position for Maintenance……………………………………………………………………………………………………267
Maintenance Handling Access……………………………………………………………………………………………………………..269
Entering/Leaving/Climbing On Machine………………………………………………………………………………………………….269
Handling Oil, Fuel, Coolant……………………………………………………………………………………………………………..270
Oil……………………………………………………………………………………………………………………………….270
Fuel………………………………………………………………………………………………………………………………270
Engine Oil…………………………………………………………………………………………………………………………272
Grease…………………………………………………………………………………………………………………………….272
Coolant and Water for Dilution……………………………………………………………………………………………………….273
Filters……………………………………………………………………………………………………………………………274
Electrical System Maintenance……………………………………………………………………………………………………………275
Recommend Fuel, Coolant, and Lubricant……………………………………………………………………………………………………276
Lubrication………………………………………………………………………………………………………………………..276
Symbols for “Lubrication and Service Chart”……………………………………………………………………………………………277
Fluid Capacities……………………………………………………………………………………………………………………….280
Table of Recommended Lubricants………………………………………………………………………………………………………….281
Maintenance Intervals…………………………………………………………………………………………………………………..283
10 Hour / Daily Service…………………………………………………………………………………………………………………286
Grease Boom, Arm and Front Attachment Pins (for first 100 hours)…………………………………………………………………………286
Check Engine Oil Level………………………………………………………………………………………………………………286
Check Level of Hydraulic Oil Tank…………………………………………………………………………………………………….287
Check for Leaks in Hydraulic System…………………………………………………………………………………………………..288
Check Fuel Level……………………………………………………………………………………………………………………288
Check for Leaks in Fuel System……………………………………………………………………………………………………….289
Check Fuel Prefilter and Drain Water As Required……………………………………………………………………………………….290
Check Oil Level of Swing Reduction Device……………………………………………………………………………………………..291
Clean Dust Net in Front of Oil Cooler and Intercooler…………………………………………………………………………………..292
Check Cooling System and Refill As Required……………………………………………………………………………………………292
Check Level of Window Washer Liquid…………………………………………………………………………………………………..293
Inspect Bucket Teeth and Side Cutters for Signs of Wear…………………………………………………………………………………293
Inspect Cooling Fan Blade……………………………………………………………………………………………………………293
Check Air Intake System and Emission Control System Components…………………………………………………………………………..294
Inspect Seat Belt for Proper Operation………………………………………………………………………………………………..294
Inspect Rear View Camera for Proper Operation (If Equipped)……………………………………………………………………………..294
Inspect Mirrors for Damage and Adjust and Clean as Required……………………………………………………………………………..295
Inspect Structure for Cracks and Faulty Welds………………………………………………………………………………………….295
Check Operation of All Switches and Travel Alarm (If Equipped)…………………………………………………………………………..295
Check the Operation of Pilot Cutoff Switch…………………………………………………………………………………………….295
Inspection and Maintenance of the Pilot Cutoff Switch……………………………………………………………………………….295
Check Operation of All Exterior Lights, Horn and Control Console Indicator and Display Monitor………………………………………………296
Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds…..296
Check Operation of All Controls and Linkages…………………………………………………………………………………………..297
50 Hour / Weekly Service………………………………………………………………………………………………………………..298
Perform All Daily Service Checks……………………………………………………………………………………………………..298
Grease Arm and Bucket Joint Pins……………………………………………………………………………………………………..298
Grease Swing Bearing………………………………………………………………………………………………………………..299
Drain Water and Sediment from Fuel Tank……………………………………………………………………………………………….300
Check Air Compressor and Drain Water as Required……………………………………………………………………………………….300
Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)………………………………………………………….301
Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers)………………………………301
250 Hour / Monthly Service………………………………………………………………………………………………………………302
Perform All Daily and 50 Hour Service Checks…………………………………………………………………………………………..302
Grease Boom and Arm Joint Pins……………………………………………………………………………………………………….302
Check Engine Fan and Alternator Belts Wear…………………………………………………………………………………………….305
Change Breaker Filter (Optional)……………………………………………………………………………………………………..306
Replace Hydraulic Oil Return Filter (After First 250 Hours)……………………………………………………………………………..307
Change Pilot Filter (After First 250 Hours)……………………………………………………………………………………………307
Inspect Pins and Bushings of the Front End Attachments for Signs of Wear………………………………………………………………….307
Check Fluid Levels in Batteries………………………………………………………………………………………………………307
Inspect for Any Loose or Missing Nuts and Bolts………………………………………………………………………………………..307
Inspect Fuel System Hose Clamps………………………………………………………………………………………………………307
500 Hour / 3 Month Service………………………………………………………………………………………………………………308
Perform All Daily, 50 and 250 Hour Service Checks………………………………………………………………………………………308
Grease Swing Gear and Pinion…………………………………………………………………………………………………………308
Change Engine Oil and Filter…………………………………………………………………………………………………………309
Clean Air-conditioning Outer Filter…………………………………………………………………………………………………..310
Check and Clean Air-conditioning Inner Filter………………………………………………………………………………………….311
Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Cores……………………………………………………312
Clean Outer Filter of Air Cleaner…………………………………………………………………………………………………….313
Change of Fuel Prefilter…………………………………………………………………………………………………………….315
Change Fuel Filter………………………………………………………………………………………………………………….316
Fuel System Priming……………………………………………………………………………………………………………..316
Check Oil Level in Travel Reduction Device (One on Each Side of Unit)…………………………………………………………………….318
Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 500 Hours)……………………………………………………318
Change Swing Reduction Device Oil (Drain and Refill After First 500 Hours)………………………………………………………………..318
1,000 Hour / 6 Month Service…………………………………………………………………………………………………………….319
Perform All Daily, 50, 250 and 500 Hour Service Checks………………………………………………………………………………….319
Grease Swing Reduction Device………………………………………………………………………………………………………..319
Change Hydraulic Oil Tank Breather Filter……………………………………………………………………………………………..319
Change Pilot Filter…………………………………………………………………………………………………………………321
Change Oil in Travel Reduction Device (One on Each Side of Unit)…………………………………………………………………………322
Change Swing Reduction Device Oil…………………………………………………………………………………………………….323
Change Air-conditioning Outer Filter………………………………………………………………………………………………….324
Change Air-conditioning Inner Filter………………………………………………………………………………………………….324
Check Air Conditioner Refrigerant…………………………………………………………………………………………………….325
Change Fuel Cap Filter………………………………………………………………………………………………………………326
Check and Adjust Engine**……………………………………………………………………………………………………………327
2,000 Hour / Yearly Service…………………………………………………………………………………………………………….. 0
Change Radiator Coolant……………………………………………………………………………………………………………..330
Hydraulic Oil Exchange and Suction Strainer Cleaning……………………………………………………………………………………332
Check Alternator and Starter**……………………………………………………………………………………………………….334
Check All Rubber Antivibration Shock Mounts……………………………………………………………………………………………334
Perform and Record Results of Cycle Time Tests…………………………………………………………………………………………334
Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage……………………………………………………………334
Check, Adjust Valve Clearance**………………………………………………………………………………………………………334
Check Head Bolt Torques……………………………………………………………………………………………………………..334
4,000 Hour / Biennial Service……………………………………………………………………………………………………………335
Major Parts – Periodic Replacement……………………………………………………………………………………………………335
4,500 Hour / Biennial Service……………………………………………………………………………………………………………336
Clean Diesel Particulate Filter (DPF)…………………………………………………………………………………………………336
12,000 Hour / 6 Year Service…………………………………………………………………………………………………………….337
Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 (CEN))……………………………………………………………….337
Air-conditioning System…………………………………………………………………………………………………………………338
Check Control Panel…………………………………………………………………………………………………………………338
Check Air Conditioner Hoses………………………………………………………………………………………………………….338
Check Condenser…………………………………………………………………………………………………………………….338
Check Magnetic Clutch……………………………………………………………………………………………………………….338
Check Belt Tension………………………………………………………………………………………………………………….338
Bolt and Nut Inspection…………………………………………………………………………………………………………………339
Bucket………………………………………………………………………………………………………………………………..348
Bucket Tooth Replacement…………………………………………………………………………………………………………….348
Bucket O-ring Replacement……………………………………………………………………………………………………………349
Electrical System………………………………………………………………………………………………………………………350
Battery……………………………………………………………………………………………………………………………350
Batteries in Cold Weather………………………………………………………………………………………………………..350
Inspection of Battery Electrolyte Level……………………………………………………………………………………………351
Check Charging State…………………………………………………………………………………………………………….351
Check Battery Terminals………………………………………………………………………………………………………….351
Battery Replacement……………………………………………………………………………………………………………..351
Fuses……………………………………………………………………………………………………………………………..352
Fuse Boxes……………………………………………………………………………………………………………………..352
Fuse Identification……………………………………………………………………………………………………………..353
Engine Cooling System…………………………………………………………………………………………………………………..354
General……………………………………………………………………………………………………………………………354
Types of Antifreeze……………………………………………………………………………………………………………..355
Antifreeze Concentration Tables………………………………………………………………………………………………………356
Table of Standards for Allowed Tap Water………………………………………………………………………………………………356
Electric Viscous Fan Clutch………………………………………………………………………………………………………….357
Removal and Installation of the Cooling Fan Assembly………………………………………………………………………………..357
Fuel Transfer Pump (Optional)……………………………………………………………………………………………………………358
Handling of Accumulator…………………………………………………………………………………………………………………361
Track Tension………………………………………………………………………………………………………………………….362
Venting and Priming Hydraulic System……………………………………………………………………………………………………..364
Main System Pump……………………………………………………………………………………………………………………364
Hydraulic Cylinders…………………………………………………………………………………………………………………364
Swing Motor………………………………………………………………………………………………………………………..365
Travel Motor……………………………………………………………………………………………………………………….365
General Venting…………………………………………………………………………………………………………………….365
Maintenance in Special Conditions………………………………………………………………………………………………………..366
Transportation…………………………………………………………………………………………………………………………….367
Loading and Unloading…………………………………………………………………………………………………………………..367
Warning for Counterweight and Front Attachment Removal………………………………………………………………………………….367
Lifting Machine………………………………………………………………………………………………………………………..374
Troubleshooting……………………………………………………………………………………………………………………………375
Electrical System………………………………………………………………………………………………………………………375
Engine………………………………………………………………………………………………………………………………..376
Turbocharger…………………………………………………………………………………………………………………………..380
Cooling Fan……………………………………………………………………………………………………………………………381
Lubrication System……………………………………………………………………………………………………………………..381
Hydraulic System……………………………………………………………………………………………………………………….382
Air Compressor (Optional)……………………………………………………………………………………………………………….383
Swing System…………………………………………………………………………………………………………………………..384
Travel System………………………………………………………………………………………………………………………….384
Specification……………………………………………………………………………………………………………………………..385
Standard Specification………………………………………………………………………………………………………………….385
Overall Dimensions……………………………………………………………………………………………………………………..386
One – Piece Boom……………………………………………………………………………………………………………………386
Two – Piece Boom……………………………………………………………………………………………………………………387
Disassembled Parts, Dimension and Weight………………………………………………………………………………………………….388
Components…………………………………………………………………………………………………………………………388
Ground Pressure………………………………………………………………………………………………………………………..390
Digging Force………………………………………………………………………………………………………………………….391
Working Range………………………………………………………………………………………………………………………….392
One – Piece Boom……………………………………………………………………………………………………………………392
Two – Piece Boom……………………………………………………………………………………………………………………393
Excavator Rated Lift Capacity Tables……………………………………………………………………………………………………..394
Approximate Weight of Workload Materials………………………………………………………………………………………………….411
Index…………………………………………………………………………………………………………………………………….413
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