Doosan DX300LC-3 Excavator Operation & Maintenance Manual 950106-00214DNA – PDF DOWNLOAD
DESCRIPTION:
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.
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.
TABLE OF CONTENTS:
Doosan DX300LC-3 Excavator Operation & Maintenance Manual 950106-00214DNA – PDF DOWNLOAD
DX300LC-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……………………………………………………………………………………………………………………….. 58
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 Radiator……………………………………………………………………………………..292
Oil Cooler……………………………………………………………………………………………………………………..292
Radiator……………………………………………………………………………………………………………………….292
Check Cooling System and Refill As Required……………………………………………………………………………………………293
Check Level of Window Washer Liquid…………………………………………………………………………………………………..293
Inspect Bucket Teeth and Side Cutters for Signs of Wear…………………………………………………………………………………294
Inspect Cooling Fan Blade……………………………………………………………………………………………………………294
Check Air Intake System and Emission Control System Components…………………………………………………………………………..295
Inspect Seat Belt for Proper Operation………………………………………………………………………………………………..295
Inspect Rear View Camera for Proper Operation (If Equipped)……………………………………………………………………………..295
Inspect Mirrors for Damage and Adjust and Clean as Required……………………………………………………………………………..296
Inspect Structure for Cracks and Faulty Welds………………………………………………………………………………………….296
Check Operation of All Switches and Travel Alarm (If Equipped)…………………………………………………………………………..296
Check the Operation of Pilot Cutoff Switch…………………………………………………………………………………………….296
Inspection and Maintenance of the Pilot Cutoff Switch……………………………………………………………………………….296
Check Operation of All Exterior Lights, Horn and Control Console Indicator and Display Monitor………………………………………………297
Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds…..297
Check Operation of All Controls and Linkages…………………………………………………………………………………………..298
50 Hour / Weekly Service………………………………………………………………………………………………………………..299
Perform All Daily Service Checks……………………………………………………………………………………………………..299
Grease Arm and Bucket Joint Pins……………………………………………………………………………………………………..299
Grease Swing Bearing………………………………………………………………………………………………………………..300
Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)………………………………………………………….302
Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers)………………………………302
250 Hour / Monthly Service………………………………………………………………………………………………………………303
Perform All Daily and 50 Hour Service Checks…………………………………………………………………………………………..303
Grease Boom and Arm Joint Pins……………………………………………………………………………………………………….303
Check Engine Fan and Alternator Belts Wear…………………………………………………………………………………………….306
Change Breaker Filter (Optional)……………………………………………………………………………………………………..307
Check Oil Bath Precleaner (Optional)………………………………………………………………………………………………….307
Clean Oil Bath Precleaner (Optional)………………………………………………………………………………………………….308
Replace Hydraulic Oil Return Filter (After First 250 Hours)……………………………………………………………………………..310
Change Pilot Filter (After First 250 Hours)……………………………………………………………………………………………310
Inspect Pins and Bushings of the Front End Attachments for Signs of Wear………………………………………………………………….310
Check Fluid Levels in Batteries………………………………………………………………………………………………………310
Inspect for Any Loose or Missing Nuts and Bolts………………………………………………………………………………………..310
Inspect Fuel System Hose Clamps………………………………………………………………………………………………………310
500 Hour / 3 Month Service………………………………………………………………………………………………………………311
Perform All Daily, 50 and 250 Hour Service Checks………………………………………………………………………………………311
Grease Swing Gear and Pinion…………………………………………………………………………………………………………311
Change Engine Oil and Filter…………………………………………………………………………………………………………312
Clean Air-conditioning Outer Filter…………………………………………………………………………………………………..313
Check and Clean Air-conditioning Inner Filter………………………………………………………………………………………….314
Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Cores……………………………………………………315
Clean Outer Filter of Air Cleaner…………………………………………………………………………………………………….316
Change of Fuel Prefilter…………………………………………………………………………………………………………….318
Change Fuel Filter………………………………………………………………………………………………………………….319
Fuel System Priming……………………………………………………………………………………………………………..319
Check Oil Level in Travel Reduction Device (One on Each Side of Unit)…………………………………………………………………….321
Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 500 Hours)……………………………………………………321
Change Swing Reduction Device Oil (Drain and Refill After First 500 Hours)………………………………………………………………..321
1,000 Hour / 6 Month Service…………………………………………………………………………………………………………….322
Perform All Daily, 50, 250 and 500 Hour Service Checks………………………………………………………………………………….322
Grease Swing Reduction Device………………………………………………………………………………………………………..322
Change Hydraulic Oil Tank Breather Filter……………………………………………………………………………………………..322
Change Pilot Filter…………………………………………………………………………………………………………………324
Change Oil in Travel Reduction Device (One on Each Side of Unit)…………………………………………………………………………325
Change Swing Reduction Device Oil…………………………………………………………………………………………………….326
Change Air-conditioning Outer Filter………………………………………………………………………………………………….327
Change Air-conditioning Inner Filter………………………………………………………………………………………………….327
Check Air Conditioner Refrigerant…………………………………………………………………………………………………….328
Change Fuel Cap Filter………………………………………………………………………………………………………………329
Check and Adjust Engine**……………………………………………………………………………………………………………330
2,000 Hour / Yearly Service…………………………………………………………………………………………………………….. 0
Change Radiator Coolant……………………………………………………………………………………………………………..333
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
Bucket Shimming Procedures……………………………………………………………………………………………………………… 0
Shimming Procedures for Installed Bucket………………………………………………………………………………………………355
Electrical System………………………………………………………………………………………………………………………356
Battery……………………………………………………………………………………………………………………………356
Batteries in Cold Weather………………………………………………………………………………………………………..356
Inspection of Battery Electrolyte Level……………………………………………………………………………………………357
Check Charging State…………………………………………………………………………………………………………….357
Check Battery Terminals………………………………………………………………………………………………………….357
Battery Replacement……………………………………………………………………………………………………………..357
Fuses……………………………………………………………………………………………………………………………..358
Fuse Boxes……………………………………………………………………………………………………………………..358
Fuse Identification……………………………………………………………………………………………………………..359
Engine Cooling System…………………………………………………………………………………………………………………..360
General……………………………………………………………………………………………………………………………360
Types of Antifreeze……………………………………………………………………………………………………………..361
Antifreeze Concentration Tables………………………………………………………………………………………………………362
Table of Standards for Allowed Tap Water………………………………………………………………………………………………362
Fuel Transfer Pump (Optional)……………………………………………………………………………………………………………363
Handling of Accumulator…………………………………………………………………………………………………………………366
Track Tension………………………………………………………………………………………………………………………….367
Venting and Priming Hydraulic System……………………………………………………………………………………………………..369
Main System Pump……………………………………………………………………………………………………………………369
Hydraulic Cylinders…………………………………………………………………………………………………………………369
Swing Motor………………………………………………………………………………………………………………………..370
Travel Motor……………………………………………………………………………………………………………………….370
General Venting…………………………………………………………………………………………………………………….370
Maintenance in Special Conditions………………………………………………………………………………………………………..371
Transportation…………………………………………………………………………………………………………………………….373
Loading and Unloading…………………………………………………………………………………………………………………..373
Warning for Counterweight and Front Attachment Removal………………………………………………………………………………….373
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
Overall Dimensions……………………………………………………………………………………………………………………..394
One – Piece Boom……………………………………………………………………………………………………………………394
Two – Piece Boom……………………………………………………………………………………………………………………395
Disassembled Parts, Dimension and Weight………………………………………………………………………………………………….396
Components…………………………………………………………………………………………………………………………396
Ground Pressure………………………………………………………………………………………………………………………..398
Digging Force………………………………………………………………………………………………………………………….399
Working Range………………………………………………………………………………………………………………………….400
One – Piece Boom……………………………………………………………………………………………………………………400
Two – Piece Boom……………………………………………………………………………………………………………………401
Excavator Rated Lift Capacity Tables……………………………………………………………………………………………………..402
Approximate Weight of Workload Materials………………………………………………………………………………………………….434
Index…………………………………………………………………………………………………………………………………….437
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
R.D
Murphy Manuel –
Worked great