Doosan DX350LC-3 Excavator Operation & Maintenance Manual 950106-00224BNA – PDF DOWNLOAD
DESCRIPTION:
Doosan DX350LC-3 Excavator Operation & Maintenance Manual 950106-00224BNA – PDF DOWNLOAD
Serial Number 10001 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 DX350LC-3 Excavator Operation & Maintenance Manual 950106-00224BNA – PDF DOWNLOAD
DX350LC-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 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
36. Swing Brake Release Switch (Only DX340/380LC-3)…………………………………………………………………………………….114
37. Travel/Work Auxiliary Mode Selector Switch (Only DX340/380LC-3)………………………………………………………………………114
Display Monitor………………………………………………………………………………………………………………………..115
Functional Check……………………………………………………………………………………………………………………115
Password Activated………………………………………………………………………………………………………………….116
1. Fuel Gauge………………………………………………………………………………………………………………………116
2. Engine Coolant Temperature Gauge…………………………………………………………………………………………………..116
3. Hydraulic Oil Temperature Gauge……………………………………………………………………………………………………117
4. Multifunction Gauge and Graphic Information Area…………………………………………………………………………………….117
5. ECO Gauge……………………………………………………………………………………………………………………….119
6. Digital Clock……………………………………………………………………………………………………………………119
7. Display Warning Symbols…………………………………………………………………………………………………………..120
9. Function Buttons…………………………………………………………………………………………………………………127
10. Mode Selector Buttons……………………………………………………………………………………………………………129
11. Selector Function Display………………………………………………………………………………………………………..130
12. Jog Switch……………………………………………………………………………………………………………………..130
13. Camera Mode Selector/ESC Button…………………………………………………………………………………………………..130
14. Multimedia Selector Button……………………………………………………………………………………………………….131
Warning Pop-up Window……………………………………………………………………………………………………………….131
User Menu…………………………………………………………………………………………………………………………….. 0
Switch Operation Indication………………………………………………………………………………………………………….162
Heater and Air Conditioner Control Panel………………………………………………………………………………………………….165
Location of Controls and Vents……………………………………………………………………………………………………….165
Control Panel………………………………………………………………………………………………………………………166
Memory Function…………………………………………………………………………………………………………………….170
Additional Operating Instructions…………………………………………………………………………………………………….170
Miscellaneous Electrical Devices…………………………………………………………………………………………………………172
Cabin Light………………………………………………………………………………………………………………………..172
Pilot Cutoff Switch…………………………………………………………………………………………………………………172
Circuit Breaker…………………………………………………………………………………………………………………….172
Fusible Link……………………………………………………………………………………………………………………….173
Fuse Boxes…………………………………………………………………………………………………………………………173
Seat Adjustment……………………………………………………………………………………………………………………….. 0
7. Storage Compartment………………………………………………………………………………………………………………176
8. Left and Right Control Stand Adjustment…………………………………………………………………………………………….176
Cabin Storage Compartments………………………………………………………………………………………………………………182
Sunglass Case………………………………………………………………………………………………………………………….182
Miscellaneous Access Covers and Doors…………………………………………………………………………………………………….185
Side Door………………………………………………………………………………………………………………………….185
Battery Box Door……………………………………………………………………………………………………………………185
Engine Cover……………………………………………………………………………………………………………………….185
Air Gun and Compressor (Optional)………………………………………………………………………………………………………..186
Air Gun (Optional)………………………………………………………………………………………………………………….186
How to Use Air Compressor……………………………………………………………………………………………………………186
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 61 and Figure 62)……………………………………………………………………………223
Right-hand Work Lever (Joystick) (Figure 61 and Figure 64)…………………………………………………………………………..223
Work Levers (Joysticks) (BHL Pattern)…………………………………………………………………………………………………225
Left-hand Work Lever (Joystick) (Figure 65 and Figure 67)……………………………………………………………………………225
Right-hand Work Lever (Joystick) (Figure 65 and Figure 68)…………………………………………………………………………..225
Intelligent Floating Boom Control (Optional)…………………………………………………………………………………………..226
Intelligent Floating Boom Mode……………………………………………………………………………………………………226
Operating a Breaker……………………………………………………………………………………………………………..227
Truck Loading…………………………………………………………………………………………………………………..227
Operating Precautions…………………………………………………………………………………………………………………..229
Working in Water……………………………………………………………………………………………………………………235
Escaping From Mud…………………………………………………………………………………………………………………..235
Track On One Side Stuck………………………………………………………………………………………………………….235
Tracks On Both Sides Stuck……………………………………………………………………………………………………….235
Parking Excavator………………………………………………………………………………………………………………………236
Towing Procedure……………………………………………………………………………………………………………………….237
Attachments……………………………………………………………………………………………………………………………238
Bucket Replacement and Reversal………………………………………………………………………………………………………238
Replacement………………………………………………………………………………………………………………………..239
Reversal (If Applicable)…………………………………………………………………………………………………………….240
Hydraulic Attachments (Optional)…………………………………………………………………………………………………………241
Breaker Operation…………………………………………………………………………………………………………………..241
Selection of Hydraulic Breaker……………………………………………………………………………………………………241
Hydraulic Hoses and Tubing for Breaker…………………………………………………………………………………………….241
Breaker Operating Precautions…………………………………………………………………………………………………….242
To Activate Breaker……………………………………………………………………………………………………………..244
Hydraulic Oil and Filter Service Intervals…………………………………………………………………………………………245
Shear Operation (Optional)…………………………………………………………………………………………………………..246
To Activate Shear……………………………………………………………………………………………………………….247
Rotating Operation (Optional)………………………………………………………………………………………………………..249
Quick Coupler Operation (Optional)……………………………………………………………………………………………………250
Securing Work Tool………………………………………………………………………………………………………………250
Attaching Quick Coupler to Excavator………………………………………………………………………………………………250
Releasing the Work Tool………………………………………………………………………………………………………….251
Lifting Objects………………………………………………………………………………………………………………………..253
Lifting Unknown Weight………………………………………………………………………………………………………………254
Lifting Known Weight………………………………………………………………………………………………………………..254
Pick and Carry……………………………………………………………………………………………………………………..254
Operation Under Abnormal Conditions………………………………………………………………………………………………………255
Operation in Extreme Cold……………………………………………………………………………………………………………255
Operation in Extreme Heat……………………………………………………………………………………………………………256
Operation in Dusty and Sandy Areas……………………………………………………………………………………………………258
Operation in Rainy or Humid Conditions………………………………………………………………………………………………..258
Operation in Saltwater Areas…………………………………………………………………………………………………………259
Operation at High Altitudes………………………………………………………………………………………………………….259
Operation During Electrical Storms……………………………………………………………………………………………………259
Equipment Lowering with Engine Stopped………………………………………………………………………………………………..260
Machine without a Boom Lowering Control Valve………………………………………………………………………………………260
Machine with a Boom Lowering Control Valve…………………………………………………………………………………………262
Long Term Storage………………………………………………………………………………………………………………………263
Before Storage……………………………………………………………………………………………………………………..263
During Storage……………………………………………………………………………………………………………………..264
After Storage………………………………………………………………………………………………………………………264
Inspection, Maintenance and Adjustment……………………………………………………………………………………………………….265
Maintenance Information…………………………………………………………………………………………………………………265
Operational Hour Meter Reading……………………………………………………………………………………………………….265
DOOSAN Genuine Replacement Parts……………………………………………………………………………………………………..265
DOOSAN Genuine Lubricants……………………………………………………………………………………………………………265
Windshield Washer Fluid……………………………………………………………………………………………………………..265
Fresh and Clean Lubricants…………………………………………………………………………………………………………..265
Check Drained Oil and Used Filter…………………………………………………………………………………………………….265
Fuel Strainer………………………………………………………………………………………………………………………265
Welding Instructions………………………………………………………………………………………………………………..266
Do Not Drop Things Inside Machine…………………………………………………………………………………………………….266
Dusty Work Site…………………………………………………………………………………………………………………….266
Avoid Mixing Lubricants……………………………………………………………………………………………………………..266
Locking Inspection Covers……………………………………………………………………………………………………………266
Hydraulic System – Air Bleeding………………………………………………………………………………………………………267
Hydraulic Hose Installation………………………………………………………………………………………………………….267
Checks After Inspection and Maintenance Works………………………………………………………………………………………….267
Safety Precautions………………………………………………………………………………………………………………….268
Machine Setup Position for Maintenance……………………………………………………………………………………………………269
Maintenance Handling Access……………………………………………………………………………………………………………..271
Entering/Leaving/Climbing On Machine………………………………………………………………………………………………….271
Handling Oil, Fuel, Coolant……………………………………………………………………………………………………………..272
Oil……………………………………………………………………………………………………………………………….272
Fuel………………………………………………………………………………………………………………………………272
Engine Oil…………………………………………………………………………………………………………………………274
Grease…………………………………………………………………………………………………………………………….274
Coolant and Water for Dilution……………………………………………………………………………………………………….275
Filters……………………………………………………………………………………………………………………………276
Electrical System Maintenance……………………………………………………………………………………………………………277
Recommend Fuel, Coolant, and Lubricant……………………………………………………………………………………………………278
Lubrication………………………………………………………………………………………………………………………..278
Symbols for “Lubrication and Service Chart”……………………………………………………………………………………………279
Fluid Capacities……………………………………………………………………………………………………………………….282
Table of Recommended Lubricants………………………………………………………………………………………………………….283
Maintenance Intervals…………………………………………………………………………………………………………………..285
10 Hour / Daily Service…………………………………………………………………………………………………………………288
Grease Boom, Arm and Front Attachment Pins (for first 100 hours)…………………………………………………………………………288
Check Engine Oil Level………………………………………………………………………………………………………………288
Check Level of Hydraulic Oil Tank…………………………………………………………………………………………………….289
Check for Leaks in Hydraulic System…………………………………………………………………………………………………..290
Check Fuel Level……………………………………………………………………………………………………………………290
Check for Leaks in Fuel System……………………………………………………………………………………………………….291
Check Fuel Prefilter and Drain Water As Required……………………………………………………………………………………….292
Check Oil Level of Swing Reduction Device……………………………………………………………………………………………..293
Clean Dust Net in Front of Oil Cooler and Radiator……………………………………………………………………………………..294
Oil Cooler……………………………………………………………………………………………………………………..294
Radiator……………………………………………………………………………………………………………………….294
Check Cooling System and Refill As Required……………………………………………………………………………………………294
Check Level of Window Washer Liquid…………………………………………………………………………………………………..295
Inspect Bucket Teeth and Side Cutters for Signs of Wear…………………………………………………………………………………295
Inspect Cooling Fan Blade……………………………………………………………………………………………………………296
Check Air Intake System and Emission Control System Components…………………………………………………………………………..296
Inspect Seat Belt for Proper Operation………………………………………………………………………………………………..297
Inspect Rear View Camera for Proper Operation (If Equipped)……………………………………………………………………………..297
Inspect Mirrors for Damage and Adjust and Clean as Required……………………………………………………………………………..297
Inspect Structure for Cracks and Faulty Welds………………………………………………………………………………………….297
Check Operation of All Switches and Travel Alarm (If Equipped)…………………………………………………………………………..297
Check the Operation of Pilot Cutoff Switch…………………………………………………………………………………………….297
Inspection and Maintenance of the Pilot Cutoff Switch……………………………………………………………………………….298
Check Operation of All Exterior Lights, Horn and Control Console Indicator and Display Monitor………………………………………………299
Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds…..299
Check Operation of All Controls and Linkages…………………………………………………………………………………………..299
50 Hour / Weekly Service………………………………………………………………………………………………………………..300
Perform All Daily Service Checks……………………………………………………………………………………………………..300
Grease Arm and Bucket Joint Pins……………………………………………………………………………………………………..300
Grease Swing Bearing………………………………………………………………………………………………………………..301
Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)………………………………………………………….303
Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers)………………………………303
250 Hour / Monthly Service………………………………………………………………………………………………………………304
Perform All Daily and 50 Hour Service Checks…………………………………………………………………………………………..304
Grease Boom and Arm Joint Pins……………………………………………………………………………………………………….304
Check Engine Fan and Alternator Belts Wear…………………………………………………………………………………………….307
Change Breaker Filter (Optional)……………………………………………………………………………………………………..308
Check Oil Bath Precleaner (Optional)………………………………………………………………………………………………….308
Clean Oil Bath Precleaner (Optional)………………………………………………………………………………………………….309
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……………………………………………………………………………………337
Check Alternator and Starter**……………………………………………………………………………………………………….339
Check All Rubber Antivibration Shock Mounts……………………………………………………………………………………………339
Perform and Record Results of Cycle Time Tests…………………………………………………………………………………………339
Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage……………………………………………………………339
Check, Adjust Valve Clearance**………………………………………………………………………………………………………339
Check Head Bolt Torques……………………………………………………………………………………………………………..339
4,000 Hour / Biennial Service……………………………………………………………………………………………………………340
Major Parts – Periodic Replacement……………………………………………………………………………………………………340
4,500 Hour / Biennial Service……………………………………………………………………………………………………………341
Clean Diesel Particulate Filter (DPF)…………………………………………………………………………………………………341
12,000 Hour / 6 Year Service…………………………………………………………………………………………………………….342
Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 (CEN))……………………………………………………………….342
Air-conditioning System…………………………………………………………………………………………………………………343
Check Control Panel…………………………………………………………………………………………………………………343
Check Air Conditioner Hoses………………………………………………………………………………………………………….343
Check Condenser…………………………………………………………………………………………………………………….343
Check Magnetic Clutch……………………………………………………………………………………………………………….343
Check Belt Tension………………………………………………………………………………………………………………….343
Bolt and Nut Inspection…………………………………………………………………………………………………………………344
Bucket………………………………………………………………………………………………………………………………..353
Bucket Tooth Replacement…………………………………………………………………………………………………………….353
Bucket O-ring Replacement……………………………………………………………………………………………………………354
Bucket Shimming Procedures……………………………………………………………………………………………………………… 0
Shimming Procedures for Installed Bucket………………………………………………………………………………………………356
Electrical System………………………………………………………………………………………………………………………357
Battery……………………………………………………………………………………………………………………………357
Batteries in Cold Weather………………………………………………………………………………………………………..357
Inspection of Battery Electrolyte Level……………………………………………………………………………………………358
Check Charging State…………………………………………………………………………………………………………….358
Check Battery Terminals………………………………………………………………………………………………………….358
Battery Replacement……………………………………………………………………………………………………………..358
Fuses……………………………………………………………………………………………………………………………..359
Fuse Boxes……………………………………………………………………………………………………………………..359
Fuse Identification……………………………………………………………………………………………………………..360
Engine Cooling System…………………………………………………………………………………………………………………..361
General……………………………………………………………………………………………………………………………361
Types of Antifreeze……………………………………………………………………………………………………………..362
Antifreeze Concentration Tables………………………………………………………………………………………………………363
Table of Standards for Allowed Tap Water………………………………………………………………………………………………363
Fuel Transfer Pump (Optional)……………………………………………………………………………………………………………364
Handling of Accumulator…………………………………………………………………………………………………………………367
Track Tension………………………………………………………………………………………………………………………….368
Venting and Priming Hydraulic System……………………………………………………………………………………………………..370
Main System Pump……………………………………………………………………………………………………………………370
Hydraulic Cylinders…………………………………………………………………………………………………………………370
Swing Motor………………………………………………………………………………………………………………………..371
Travel Motor……………………………………………………………………………………………………………………….371
General Venting…………………………………………………………………………………………………………………….371
Maintenance in Special Conditions………………………………………………………………………………………………………..372
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………………………………………………………………………………………………….430
Index…………………………………………………………………………………………………………………………………….433
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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