Doosan DX350LC-5 Excavator Operation & Maintenance Manual 950106-01000NA-1 – PDF DOWNLOAD
DESCRIPTION:
Doosan DX350LC-5 Excavator Operation & Maintenance Manual 950106-01000NA-1 – PDF DOWNLOAD
Serial Number 10001
950106-01000NA-
Foreword:
- This Operation & Maintenance Manual was written to give owner or operator instructions on safe operation and maintenance of DOOSAN equipment.
- READ AND UNDERSTAND THIS OPERATION AND MAINTENANCE MANUAL BEFORE OPERATING YOUR DOOSAN EQUIPMENT.
- Keep this manual in the cabin so it is always available. If it is lost, order another one from your DOOSAN distributor.
- If there are any questions, contact your DOOSAN distributor. This manual may illustrate options and accessories not installed on your equipment.
- Any modification made without written authorization or approval from DOOSAN can create a safety hazard. Always replace parts with genuine DOOSAN parts or DOOSAN authorized replacement parts.
Intended Use:
- The machine is intended to be used under normal conditions for applications described in this manual.
- If it is used for other purposes, or in potentially hazardous environments, special precautions must be followed and the machine must be equipped for such use.
- Examples include, but are not limited to, are: falling object guards, work lights, etc. Do not engage in prohibited uses as described in this manual.
- Contact your DOOSAN distributor for further information.
Engine and Emission Control System Maintenance:
- Proper inspection, maintenance and repair is essential to keeping engine and machine systems properly operating.
- This includes proper inspection and maintenance of the machine’s emission control system.
- This could include machine and engine components, such as an EGR (Exhaust Gas Recirculation) system, fuel system, turbocharger, electrical system, air intake system and/or cooling system. As a heavy-duty off-road diesel engine owner, you are responsible for performing required maintenance.
- The required maintenance procedures are outlined in this Operation & Maintenance Manual, or Shop Manual.
- Do not remove, alter, or render inoperative, any emission control system.
Machine Capacity:
- Do not exceed machine capacity by modifying machine or using unapproved attachments.
- Exceeding machine capacity can adversely affect machine performance characteristics such as: stability, system certifications such as brakes and steering, the Roll-over Protective Structure (ROPS) and can result in death or serious injury.
- Contact your DOOSAN distributor for further information.
Attachments:
- These and other attachments are approved for use on this machine.
- Do not use unapproved attachments.
- Attachments not manufactured by DOOSAN may not be approved. See your DOOSAN distributor for information about approved attachments and attachment manuals.
• Buckets
• Hydraulic Breakers
• Grapples
• Plate Compactors
• Quick Couplers
• Hydraulic Breakers
• Grapples
• Plate Compactors
• Quick Couplers
TABLE OF CONTENTS:
Doosan DX350LC-5 Excavator Operation & Maintenance Manual 950106-01000NA-1 – PDF DOWNLOAD
DX350LC-5....................................................................................................................................................... 0 Table of Contents........................................................................................................................................... 5 Foreword.................................................................................................................................................... 9 Intended Use............................................................................................................................................ 9 Engine and Emission Control System Maintenance.......................................................................................................... 9 Machine Capacity........................................................................................................................................ 10 Attachments............................................................................................................................................. 10 Engine Identification................................................................................................................................... 12 Your Machine Serial Numbers............................................................................................................................. 12 Safety Messages......................................................................................................................................... 12 AEM Safety Manual (North America Only).................................................................................................................. 14 Federal Emission Control Systems........................................................................................................................ 15 Emission Control System Warranty Statement.......................................................................................................... 15 California Emission Control Warranty Statement...................................................................................................... 20 Your Warranty Rights and Obligations................................................................................................................ 20 Manufacturer's Warranty Coverage.................................................................................................................... 20 Owner's Warranty Responsibilities................................................................................................................... 21 Catalytic Converter................................................................................................................................. 21 Safety...................................................................................................................................................... 25 Safety Decals........................................................................................................................................... 26 Safety Decals With Text............................................................................................................................. 26 Safety Decals Without Text (No-Text)................................................................................................................ 27 Information and Location for Safety Decals.......................................................................................................... 28 Information and Location for Safety Decals (Continued).............................................................................................. 29 25. Do Not Lift (950205-03570).................................................................................................................. 39 26. DEF (AdBlue) (950205-01489A)................................................................................................................ 39 General................................................................................................................................................. 40 Safe Operation is Operator's Responsibility......................................................................................................... 40 Know Your Machine................................................................................................................................... 40 Proper Work Tools and Attachments................................................................................................................... 41 Pressurized Fluids.................................................................................................................................. 41 Flying or Falling Objects........................................................................................................................... 42 Personal Protective Equipment (PPE)................................................................................................................. 43 Correction of Machine Problems...................................................................................................................... 43 Crushing and Cutting................................................................................................................................ 43 Hot Coolant and Oils - Burn Prevention.............................................................................................................. 44 Fire and Explosion Prevention....................................................................................................................... 45 Maintenance..................................................................................................................................... 45 Operation....................................................................................................................................... 45 Electrical...................................................................................................................................... 46 Hydraulic System................................................................................................................................ 46 Fueling......................................................................................................................................... 47 Never Use Ether Starting Aids................................................................................................................... 47 Welding and Grinding............................................................................................................................ 47 If a Fire Occurs................................................................................................................................ 48 Fire Extinguisher and First-aid Kit (Emergency Medical Kit)......................................................................................... 48 Electrical System and Electrical Shock.............................................................................................................. 49 Roll-over Protective Structure (ROPS)............................................................................................................... 49 ROPS Certification.............................................................................................................................. 50 Protecting Cabin from Flying or Falling Objects (Optional)...................................................................................... 51 Emergency Exit from Operator's Station.......................................................................................................... 52 Transportation.......................................................................................................................................... 53 Obey State and Local Over-the-Road Regulations...................................................................................................... 53 Loading and Unloading............................................................................................................................... 53 Transporting Machine................................................................................................................................ 54 Operation............................................................................................................................................... 55 Before Engine Starting.............................................................................................................................. 55 Machine Condition............................................................................................................................... 55 Work Site........................................................................................................................................... 56 Mounting/Dismounting................................................................................................................................ 57 Cleaning............................................................................................................................................ 58 Operator Station.................................................................................................................................... 58 Seat Belt........................................................................................................................................... 59 Visibility Information.............................................................................................................................. 60 Work Site Rules................................................................................................................................. 60 Boost Starting or Charging Engine Batteries......................................................................................................... 61 Swinging or Traveling............................................................................................................................... 63 Lifting and Digging................................................................................................................................. 65 Operation on Slopes................................................................................................................................. 66 Towing.............................................................................................................................................. 67 Attachment.......................................................................................................................................... 68 Equipment Lowering with Engine Stopped.............................................................................................................. 68 Engine Stop......................................................................................................................................... 69 Parking Machine..................................................................................................................................... 69 Preservation/Storing Machine........................................................................................................................ 70 Check After Long-term Parking................................................................................................................... 71 Maintenance............................................................................................................................................. 72 Cleaning............................................................................................................................................ 75 Proper Tools and Clothing........................................................................................................................... 75 Disassembling Precautions........................................................................................................................... 75 Use of Lighting..................................................................................................................................... 75 Fire and Explosion Prevention....................................................................................................................... 76 Burn Prevention..................................................................................................................................... 77 Rubber That Contains Fluorides...................................................................................................................... 78 Rubber and Plastics................................................................................................................................. 79 Waste Hazardous to the Environment.............................................................................................................. 79 Check List After Fire........................................................................................................................... 79 Welding Repairs..................................................................................................................................... 80 Preparation for Electrical Welding on Body Structure............................................................................................ 80 Warning for Counterweight and Front Attachment Removal.............................................................................................. 81 Lock Inspection Covers.............................................................................................................................. 82 Working on Machine.................................................................................................................................. 82 Accumulator......................................................................................................................................... 83 Compressed Air...................................................................................................................................... 83 Track Tension Adjustments........................................................................................................................... 84 Supports and Blocking for Work Equipment............................................................................................................ 84 High-pressure Lines, Tubes and Hoses................................................................................................................ 85 Battery............................................................................................................................................. 86 Battery Hazard Prevention....................................................................................................................... 86 Environment and Circumstances........................................................................................................................... 88 Work Site Areas Requiring Extra Caution............................................................................................................. 88 Digging Under an Overhang....................................................................................................................... 88 Deep Digging.................................................................................................................................... 88 Drop-off or Edge................................................................................................................................ 89 Poor Visibility................................................................................................................................. 89 Loose or Soft Ground............................................................................................................................ 89 High-voltage Cables................................................................................................................................. 90 Underground Operation............................................................................................................................... 91 Working in Water.................................................................................................................................... 91 Working in Contaminated Environment................................................................................................................. 91 Operation in Extreme Conditions..................................................................................................................... 92 Operation In Extreme Cold....................................................................................................................... 92 Operation in Extreme Heat....................................................................................................................... 93 Operation In Dusty and Sandy Areas.............................................................................................................. 94 Operation in Rainy or Humid Conditions.......................................................................................................... 95 Operation in Saltwater Areas.................................................................................................................... 95 Operation at High Altitudes..................................................................................................................... 96 Operation During Electrical Storms.............................................................................................................. 96 Exhaust Ventilation................................................................................................................................. 96 Ventilation for Enclosed Area................................................................................................................... 96 Asbestos Information................................................................................................................................ 97 Silica Dust Information............................................................................................................................. 97 Disposal of Hazardous Materials..................................................................................................................... 98 Sound............................................................................................................................................... 98 Vibration Information............................................................................................................................... 99 Hand/Arm Vibration Level........................................................................................................................ 99 Whole Body Vibration Level...................................................................................................................... 99 Guidelines for Use and Working Conditions of Earth-moving Machinery to Reduce Vibration Levels (ISO/TR 25398 Annex E)........................... 99 Operating Controls..........................................................................................................................................101 Component Locations.....................................................................................................................................102 Operator's Area.........................................................................................................................................106 Operational Controls and Panels.........................................................................................................................108 1. Starter Switch...................................................................................................................................110 2. Heater and Air Conditioner Control Panel.........................................................................................................111 3. Power Socket for 12 Volt.........................................................................................................................111 4. Cigarette Lighter................................................................................................................................111 5. Smart Power Control Switch.......................................................................................................................112 6. Engine Speed Control Dial........................................................................................................................112 7. Travel Speed Selector Switch.....................................................................................................................112 8. Light Switch.....................................................................................................................................113 9. Intelligent Floating Boom Switch (Optional)......................................................................................................113 10. Cabin Work Light Switch (Optional)..............................................................................................................113 11. Audio Control Panel.............................................................................................................................114 12. Wiper Control Panel.............................................................................................................................115 13. Quick Coupler Switch (Optional).................................................................................................................116 14. Air Compressor Switch (Optional)................................................................................................................117 15. Warning Light Switch (Optional).................................................................................................................117 16. Lower Wiper Switch (Optional)...................................................................................................................117 17. Travel/Swing Alarm Switch (Optional)............................................................................................................118 18. Overload Warning Switch (Optional)..............................................................................................................118 19. Power Socket for 12 Volt (Optional).............................................................................................................119 20. Horn Button (Left-hand Work Lever)..............................................................................................................119 21. Breaker/Booster Button (Right-hand Work Lever)..................................................................................................119 22. Rotating Switch.................................................................................................................................120 23. Shear Switch....................................................................................................................................120 24. Display Monitor.................................................................................................................................121 25. Photo Sensor....................................................................................................................................121 26. Safety Lever....................................................................................................................................121 27. Auxiliary Mode Switch...........................................................................................................................122 28. Hour Meter......................................................................................................................................122 29. Emergency Start Mode Switch.....................................................................................................................122 30. One Touch Deceleration Button...................................................................................................................123 31. Intelligent Floating Boom Temporary Reset Button................................................................................................123 32. Selector Switch Control Panel...................................................................................................................123 33. Jack Assembly...................................................................................................................................125 34. Micro Phone (Optional)..........................................................................................................................126 35. Travel/Work Auxiliary Mode Selector Switch (Only DX340/380LC-5).................................................................................126 36. Swing Brake Release Switch (Only DX340/380LC-5).................................................................................................126 Display Monitor.........................................................................................................................................127 Functional Check....................................................................................................................................127 Password Activated..................................................................................................................................128 1. Fuel Gauge.......................................................................................................................................128 2. DEF (AdBlue) Level Gauge.........................................................................................................................128 3. Engine Coolant Temperature Gauge.................................................................................................................129 4. Hydraulic Oil Temperature Gauge..................................................................................................................129 5. Multifunction Gauge and Graphic Information Area.................................................................................................130 6. ECO Gauge........................................................................................................................................131 7. Trip Meter.......................................................................................................................................131 8. Digital Clock....................................................................................................................................132 9. Display Warning Symbols..........................................................................................................................132 10. Warning Light...................................................................................................................................139 11. Function Buttons................................................................................................................................139 12. Mode Selector Buttons...........................................................................................................................141 13. Selector Function Display.......................................................................................................................143 14. Jog Switch......................................................................................................................................143 15. Camera Mode Selector/ESC Button.................................................................................................................143 16. Multimedia Selector Button......................................................................................................................144 Launch Menu.........................................................................................................................................145 Warning Pop-up Window...............................................................................................................................148 User Menu...............................................................................................................................................151 User Menu - Access and Escape Methods...............................................................................................................151 Switch Operation Indication.........................................................................................................................188 Heater and Air Conditioner Control Panel................................................................................................................191 Location of Controls and Vents......................................................................................................................191 Control Panel.......................................................................................................................................192 Memory Function.....................................................................................................................................196 Additional Operating Instructions...................................................................................................................196 Miscellaneous Electrical Devices........................................................................................................................198 Cabin Light.........................................................................................................................................198 Pilot Cutoff Switch.................................................................................................................................198 Circuit Breaker (80 A)..............................................................................................................................198 Circuit Breaker (30 A)..............................................................................................................................199 Fuse Boxes..........................................................................................................................................199 Seat Adjustment......................................................................................................................................... 0 7. Storage Compartment..............................................................................................................................202 8. Left and Right Control Stand Adjustment..........................................................................................................202 Engine Emergency Stop Switch............................................................................................................................204 Emergency Exit Glass Breaking Tool......................................................................................................................204 Miscellaneous Convenience Devices....................................................................................................................... 0 Front Windows.......................................................................................................................................206 Door Side Latch.....................................................................................................................................208 Cabin Storage Compartments..........................................................................................................................209 Sunglasses Case.....................................................................................................................................209 Sun Visor...........................................................................................................................................210 Miscellaneous Access Covers and Doors...................................................................................................................212 Side Door...........................................................................................................................................212 Storage Box Door....................................................................................................................................212 Engine Cover........................................................................................................................................213 Air Gun and Compressor (Optional).......................................................................................................................214 Air Gun (Optional)..................................................................................................................................214 How to Use Air Compressor...........................................................................................................................214 Operation...................................................................................................................................................217 To Operate a New Excavator..............................................................................................................................217 Lubrication and Filters.............................................................................................................................218 Starting and Stopping Engine............................................................................................................................218 Inspection Before Starting Engine...................................................................................................................218 Walk Around Checks..............................................................................................................................218 Checks Before Starting Engine...................................................................................................................219 Operational Checks Before Starting Engine...........................................................................................................221 Engine Start........................................................................................................................................222 After start limit logic.........................................................................................................................224 Cold Weather Starting...............................................................................................................................224 Engine Pre-heater...............................................................................................................................224 Engine Coolant Heater (Optional)....................................................................................................................227 Plug Heater (Optional)..............................................................................................................................229 Starting Engine with a Booster Cable................................................................................................................230 Connecting Booster Batteries....................................................................................................................230 Disconnecting Booster Batteries.................................................................................................................231 Hydraulic System Warm-up............................................................................................................................231 Hydraulic System Warm-up - Cold Weather.............................................................................................................232 Stopping Engine.....................................................................................................................................234 Checks and Maintenance After Stopping Engine........................................................................................................235 Safety Lever............................................................................................................................................235 Travel..................................................................................................................................................236 Automatic Travel Speed Control......................................................................................................................236 Travel Control Lever Operation......................................................................................................................237 General Travel Instructions.........................................................................................................................238 Straight Travel Pedal (Optional)....................................................................................................................240 Operating.......................................................................................................................................241 Locking Pedal...................................................................................................................................241 Operating Instructions..................................................................................................................................242 Engine Speed Control................................................................................................................................242 Emission Control System.............................................................................................................................242 Reaction at Low Reductant Level.................................................................................................................242 Reaction to Faults in SCR System (Only EPA).....................................................................................................243 Mode Selection......................................................................................................................................244 Power Mode......................................................................................................................................244 Work Mode.......................................................................................................................................245 Auto Idle Mode..................................................................................................................................245 Boost Mode......................................................................................................................................246 Work Levers (Joysticks) (ISO Pattern)...............................................................................................................247 Left-hand Work Lever (Joystick) (Figure 59 and Figure 60).......................................................................................247 Right-hand Work Lever (Joystick) (Figure 59 and Figure 62)......................................................................................247 Work Levers (Joysticks) (BHL Pattern)...............................................................................................................249 Left-hand Work Lever (Joystick) (Figure 63 and Figure 65).......................................................................................249 Right-hand Work Lever (Joystick) (Figure 63 and Figure 66)......................................................................................249 Intelligent Floating Boom Control (Optional)........................................................................................................250 Intelligent Floating Boom Mode..................................................................................................................250 Operating a Breaker.............................................................................................................................250 Truck Loading...................................................................................................................................251 Operating Precautions...................................................................................................................................253 Working in Water....................................................................................................................................259 Escaping From Mud...................................................................................................................................259 Track On One Side Stuck.........................................................................................................................259 Tracks On Both Sides Stuck......................................................................................................................259 Parking Excavator.......................................................................................................................................260 Towing Procedure........................................................................................................................................261 Attachments.............................................................................................................................................262 Bucket Replacement and Reversal.....................................................................................................................262 Replacement.........................................................................................................................................262 Reversal (If Applicable)............................................................................................................................264 Hydraulic Attachments (Optional)........................................................................................................................265 Breaker Operation...................................................................................................................................265 Selection of Hydraulic Breaker..................................................................................................................265 Hydraulic Hoses and Tubing for Breaker..........................................................................................................265 Breaker Operating Precautions...................................................................................................................266 To Activate Breaker.............................................................................................................................268 Hydraulic Oil and Filter Service Intervals......................................................................................................269 Shear Operation.....................................................................................................................................270 To Activate Shear...............................................................................................................................271 Rotating Operation..................................................................................................................................274 Quick Coupler Operation.............................................................................................................................275 To Engage Attachment............................................................................................................................275 To Release Attachment...........................................................................................................................279 Lifting Objects.........................................................................................................................................280 Lifting Unknown Weight..............................................................................................................................281 Lifting Known Weight................................................................................................................................281 Pick and Carry......................................................................................................................................281 Lifting Objects with Quick Coupler......................................................................................................................282 Operation Under Abnormal Conditions.....................................................................................................................284 Operation In Extreme Cold...........................................................................................................................284 Operation in Extreme Heat...........................................................................................................................285 Operation In Dusty and Sandy Areas..................................................................................................................287 Operation in Rainy or Humid Conditions..............................................................................................................287 Operation in Saltwater Areas........................................................................................................................288 Operation at High Altitudes.........................................................................................................................288 Operation During Electrical Storms..................................................................................................................288 Equipment Lowering with Engine Stopped..............................................................................................................289 Machine without a Boom Lock Valve...............................................................................................................289 Machine with a Boom Lock Valve..................................................................................................................291 Long Term Storage.......................................................................................................................................292 Before Storage......................................................................................................................................292 During Storage......................................................................................................................................293 After Storage.......................................................................................................................................293 Inspection, Maintenance and Adjustment......................................................................................................................295 Maintenance Information.................................................................................................................................295 Operational Hour Meter Reading......................................................................................................................295 DOOSAN Genuine Replacement Parts....................................................................................................................295 DOOSAN Genuine Lubricants...........................................................................................................................295 Windshield Washer Fluid.............................................................................................................................295 Fresh and Clean Lubricants..........................................................................................................................295 Check Drained Oil and Used Filter...................................................................................................................295 Fuel Strainer.......................................................................................................................................295 Welding Instructions................................................................................................................................296 Do Not Drop Things Inside Machine...................................................................................................................296 Dusty Work Site.....................................................................................................................................296 Avoid Mixing Lubricants.............................................................................................................................296 Locking Inspection Covers...........................................................................................................................296 Hydraulic System - Air Bleeding.....................................................................................................................297 Hydraulic Hose Installation.........................................................................................................................297 Checks After Inspection and Maintenance Works.......................................................................................................297 Safety Precautions..................................................................................................................................298 Machine Setup Position for Maintenance..................................................................................................................299 Maintenance Handling Access.............................................................................................................................301 Entering/Leaving/Climbing On Machine................................................................................................................301 Handling Oil, Fuel, DEF (AdBlue), Coolant...............................................................................................................302 Oil.................................................................................................................................................302 Fuel................................................................................................................................................302 DEF (AdBlue)........................................................................................................................................304 Grease..............................................................................................................................................305 Coolant and Water for Dilution......................................................................................................................305 Filters.............................................................................................................................................306 Electrical System Maintenance...........................................................................................................................307 Recommend Fuel, Coolant, and Lubricant..................................................................................................................308 Lubrication.........................................................................................................................................308 Symbols for "Lubrication and Service Chart".........................................................................................................309 Fluid Capacities........................................................................................................................................313 Table of Recommended Lubricants.........................................................................................................................314 Maintenance Intervals...................................................................................................................................316 10 Hour / Daily Service.................................................................................................................................319 Grease Boom, Arm and Front Attachment Pins (for first 100 hours)....................................................................................319 Check Engine Oil Level..............................................................................................................................319 Check for Leaks in Hydraulic System.................................................................................................................319 Check Level of Hydraulic Oil Tank...................................................................................................................320 Check for Leaks in Fuel System......................................................................................................................321 Check Fuel Level....................................................................................................................................321 Check DEF (AdBlue) Tank.............................................................................................................................323 Check Water Separator & Pre Fuel Filter (Fuel Prefilter) and Drain Water As Required................................................................324 Check Oil Level of Swing Reduction Gear.............................................................................................................325 Clean Dust Net in Front of Oil Cooler and Radiator..................................................................................................326 Oil Cooler......................................................................................................................................326 Radiator........................................................................................................................................326 Check Cooling System and Refill As Required.........................................................................................................327 Check Level of Window Washer Liquid.................................................................................................................327 Inspect Bucket Teeth and Side Cutters for Signs of Wear.............................................................................................328 Inspect Cooling Fan Blade...........................................................................................................................328 Check Air Intake System and Emission Control System Components......................................................................................329 Inspect Seat Belt for Proper Operation..............................................................................................................329 Inspect Rear View Camera for Proper Operation (If Equipped).........................................................................................329 Inspect Mirrors for Damage and Adjust and Clean as Required.........................................................................................330 Inspect Structure for Cracks and Faulty Welds.......................................................................................................330 Check Operation of All Switches and Travel Alarm (If Equipped)......................................................................................330 Check the Operation of Pilot Cutoff Switch..........................................................................................................330 Inspection and Maintenance of the Pilot Cutoff Switch...........................................................................................330 Check Operation of All Exterior Lights, Horn and Control Console Indicator and Display Monitor......................................................331 Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds.....331 Check Operation of All Controls and Linkages........................................................................................................332 50 Hour / Weekly Service................................................................................................................................333 Perform All Daily Service Checks....................................................................................................................333 Grease Arm and Bucket Joint Pins....................................................................................................................333 Grease Swing Bearing................................................................................................................................334 Drain Water and Sediment from Fuel Tank.............................................................................................................335 Check Air Compressor and Drain Water as Required....................................................................................................335 Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)...................................................................336 Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers)....................................336 250 Hour / Monthly Service..............................................................................................................................337 Perform All Daily and 50 Hour Service Checks........................................................................................................337 Grease Boom and Arm Joint Pins......................................................................................................................337 Change Breaker Filter (Optional)....................................................................................................................339 Check Oil Bath Precleaner (Optional)................................................................................................................339 Clean Oil Bath Precleaner (Optional)................................................................................................................340 Replace Hydraulic Oil Return Filter (After First 250 Hours).........................................................................................342 Change Pilot Filter (After First 250 Hours).........................................................................................................342 Inspect Pins and Bushings of the Front End Attachments for Signs of Wear............................................................................342 Check Fluid Levels in Batteries.....................................................................................................................342 Inspect for Any Loose or Missing Nuts and Bolts.....................................................................................................342 Inspect Fuel System Hose Clamps.....................................................................................................................342 500 Hour / 3 Month Service..............................................................................................................................343 Perform All Daily, 50 and 250 Hour Service Checks...................................................................................................343 Grease Swing Gear and Pinion........................................................................................................................343 Change Engine Oil and Filter........................................................................................................................344 Clean Air-conditioning Outer Filter.................................................................................................................346 Check and Clean Air-conditioning Inner Filter.......................................................................................................347 Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Cores............................................................348 Clean Outer Filter of Air Cleaner...................................................................................................................349 Change of Water Separator & Pre Fuel Filter (Fuel Prefilter)........................................................................................351 Change Main Fuel Filter.............................................................................................................................352 Bleeding Fuel System............................................................................................................................354 Check Oil Level in Travel Reduction Gear (One on Each Side of Unit).................................................................................356 Change Oil in Travel Reduction Gear (One on Each Side of Unit) (After First 500 Hours)..............................................................356 Change Oil in Swing Reduction Gear (Drain and Refill After First 500 Hours).........................................................................356 1,000 Hour / 6 Month Service............................................................................................................................357 Perform All Daily, 50, 250 and 500 Hour Service Checks..............................................................................................357 Grease Swing Reduction Gear.........................................................................................................................357 Change Hydraulic Oil Tank Breather Filter...........................................................................................................357 Change Pilot Filter.................................................................................................................................359 Change DEF (AdBlue) Filter..........................................................................................................................360 Change DEF(AdBlue) Breather Filter..................................................................................................................360 Change Oil in Travel Reduction Gear (One on Each Side of Unit)......................................................................................361 Change Oil in Swing Reduction Gear..................................................................................................................362 Change Air-conditioning Outer Filter................................................................................................................363 Change Air-conditioning Inner Filter................................................................................................................364 Check Drive Belt....................................................................................................................................364 Check Air Conditioner Refrigerant...................................................................................................................366 Change Fuel Cap Filter..............................................................................................................................367 Check and Adjust Engine**...........................................................................................................................368 2,000 Hour / Yearly Service............................................................................................................................. 0 Check and Adjust Valve Clearance....................................................................................................................371 Clean Centrifugal Oil Cleaner.......................................................................................................................372 Change Radiator Coolant.............................................................................................................................374 Hydraulic Oil Exchange and Suction Strainer Cleaning................................................................................................376 Check Alternator and Starter**......................................................................................................................378 Check All Rubber Antivibration Shock Mounts.........................................................................................................378 Perform and Record Results of Cycle Time Tests......................................................................................................378 Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage.....................................................................378 Check, Adjust Valve Clearance**.....................................................................................................................378 Check Head Bolt Torques.............................................................................................................................378 4,000 Hour / Biennial Service...........................................................................................................................379 Major Parts - Periodic Replacement..................................................................................................................379 12,000 Hour / 6 Year Service............................................................................................................................380 Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 (CEN)).........................................................................380 Air-conditioning System.................................................................................................................................381 Check Control Panel.................................................................................................................................381 Check Air Conditioner Hoses.........................................................................................................................381 Check Condenser.....................................................................................................................................381 Check Magnetic Clutch...............................................................................................................................381 Check Belt Tension..................................................................................................................................381 Bolt and Nut Inspection.................................................................................................................................382 Bucket..................................................................................................................................................391 Bucket Tooth Replacement............................................................................................................................391 Bucket O-ring Replacement...........................................................................................................................392 Bucket Shimming Procedures.............................................................................................................................. 0 Shimming Procedures for Installed Bucket............................................................................................................394 Electrical System.......................................................................................................................................395 Battery.............................................................................................................................................395 Batteries in Cold Weather.......................................................................................................................395 Inspection of Battery Electrolyte Level.........................................................................................................396 Check Charging State............................................................................................................................396 Check Battery Terminals.........................................................................................................................396 Battery Replacement.............................................................................................................................396 Fuses...............................................................................................................................................397 Fuse Boxes......................................................................................................................................397 Fuse Identification.............................................................................................................................398 Engine Cooling System...................................................................................................................................399 General.............................................................................................................................................399 Types of Antifreeze.............................................................................................................................400 Antifreeze Concentration Tables.....................................................................................................................401 Table of Standards for Allowed Tap Water............................................................................................................401 Fuel Transfer Pump (Optional)...........................................................................................................................402 Handling of Accumulator.................................................................................................................................405 Track Tension...........................................................................................................................................406 Venting and Priming Hydraulic System....................................................................................................................408 Main System Pump....................................................................................................................................408 Hydraulic Cylinders.................................................................................................................................408 Swing Motor.........................................................................................................................................409 Travel Motor........................................................................................................................................409 General Venting.....................................................................................................................................409 Maintenance in Special Conditions.......................................................................................................................410 Transportation..............................................................................................................................................411 Lifting Machine.........................................................................................................................................419 Troubleshooting.............................................................................................................................................421 Electrical System.......................................................................................................................................421 Engine..................................................................................................................................................422 Variable Geometry turbocharger (VGT)....................................................................................................................426 Lubrication System......................................................................................................................................427 Hydraulic System........................................................................................................................................428 Air Compressor (Optional)...............................................................................................................................429 Swing System............................................................................................................................................430 Travel System...........................................................................................................................................430 Hydraulic Fan Drive System..............................................................................................................................431 Specification...............................................................................................................................................433 Standard Specification..................................................................................................................................433 Overall Dimensions......................................................................................................................................434 One - Piece Boom....................................................................................................................................434 Two - Piece Boom....................................................................................................................................435 Disassembled Parts, Dimension and Weight................................................................................................................436 Components..........................................................................................................................................436 Ground Pressure.........................................................................................................................................438 Digging Force...........................................................................................................................................439 Working Range...........................................................................................................................................440 One - Piece Boom....................................................................................................................................440 Two - Piece Boom....................................................................................................................................442 Excavator Rated Lift Capacity Tables....................................................................................................................444 Approximate Weight of Workload Materials................................................................................................................462 Index.......................................................................................................................................................465
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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.
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M.A