Doosan DX380LC-3 Excavator Operation & Maintenance Manual 950106-01350 – PDF DOWNLOAD
DESCRIPTION:
Doosan DX380LC-3 Excavator Operation & Maintenance Manual 950106-01350 – PDF DOWNLOAD
- This Operation and Maintenance Manual was written to give owner or operator instructions on safe operation and maintenance of DOOSAN equipment. READ AND UNDERSTAND THIS OPERATION AND MAINTENANCE MANUAL BEFORE OPERATING YOUR DOOSAN EQUIPMENT.
- Keep this manual in the cabin so it is always available. If it is lost, order another one from your DOOSAN distributor. If there are any questions, contact your DOOSAN distributor. This manual may illustrate options and accessories not installed on your equipment.
- Any modification made without written authorization or approval from DOOSAN can create a safety hazard. Always replace parts with genuine DOOSAN parts or DOOSAN authorized replacement parts.
- The machine is intended to be used under normal conditions for applications described in this manual. If it is used for other purposes, or in potentially hazardous environments, special precautions must be followed and the machine must be equipped for such use.
- Examples include, but are not limited to, are: falling object guards, work lights, etc. Do not engage in prohibited uses as described in this manual. Contact your DOOSAN distributor for further information.
TABLE OF CONTENTS:
Doosan DX380LC-3 Excavator Operation & Maintenance Manual 950106-01350 – PDF DOWNLOAD
DX380LC-3……………………………………………………………………………………………………………………………………. 0
Table of Contents…………………………………………………………………………………………………………………………. 5
Foreword…………………………………………………………………………………………………………………………………. 9
Intended Use………………………………………………………………………………………………………………………….. 9
Engine and Emission Control System Maintenance……………………………………………………………………………………………. 9
Product Identification Number (PIN)……………………………………………………………………………………………………… 0
Component Model and Serial Numbers…………………………………………………………………………………………………… 11
Safety Messages……………………………………………………………………………………………………………………….. 11
Signal Words………………………………………………………………………………………………………………………. 11
Other Signal Words…………………………………………………………………………………………………………………. 12
Safety…………………………………………………………………………………………………………………………………… 13
Safety Decals…………………………………………………………………………………………………………………………. 14
Safety Decals With Text…………………………………………………………………………………………………………….. 14
Safety Decals Without Text (No-Text)…………………………………………………………………………………………………. 15
Information and Location for Safety Decals……………………………………………………………………………………………. 16
Information and Location for Safety Decals (Continued)…………………………………………………………………………………. 17
General………………………………………………………………………………………………………………………………. 27
Safe Operation is Operator’s Responsibility…………………………………………………………………………………………… 27
Know Your Machine………………………………………………………………………………………………………………….. 27
Proper Work Tools and Attachments……………………………………………………………………………………………………. 28
Pressurized Fluids…………………………………………………………………………………………………………………. 28
Flying or Falling Objects…………………………………………………………………………………………………………… 29
Personal Protective Equipment (PPE)………………………………………………………………………………………………….. 30
Correction of Machine Problems………………………………………………………………………………………………………. 30
Crushing and Cutting……………………………………………………………………………………………………………….. 30
Hot Coolant and Oils – Burn Prevention……………………………………………………………………………………………….. 31
Fire and Explosion Prevention……………………………………………………………………………………………………….. 32
Maintenance……………………………………………………………………………………………………………………. 32
Operation……………………………………………………………………………………………………………………… 32
Electrical…………………………………………………………………………………………………………………….. 33
Hydraulic System……………………………………………………………………………………………………………….. 33
Fueling……………………………………………………………………………………………………………………….. 34
Never Use Ether Starting Aids……………………………………………………………………………………………………. 34
Welding and Grinding……………………………………………………………………………………………………………. 34
If a Fire Occurs……………………………………………………………………………………………………………….. 35
Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)…………………………………………………………………………….. 35
Electrical System and Electrical Shock……………………………………………………………………………………………….. 36
Rollover Protective Structure (ROPS)…………………………………………………………………………………………………. 36
ROPS Certification……………………………………………………………………………………………………………… 37
Protecting Cabin from Flying or Falling Objects (Optional)………………………………………………………………………….. 38
Emergency Exit from Operator’s Station……………………………………………………………………………………………. 39
Transportation………………………………………………………………………………………………………………………… 40
Obey State and Local Over-the-Road Regulations………………………………………………………………………………………… 40
Loading and Unloading………………………………………………………………………………………………………………. 40
Transporting Machine……………………………………………………………………………………………………………….. 41
Operation…………………………………………………………………………………………………………………………….. 42
Before Engine Starting……………………………………………………………………………………………………………… 42
Machine Condition………………………………………………………………………………………………………………. 42
Work Site…………………………………………………………………………………………………………………………. 43
Mounting/Dismounting……………………………………………………………………………………………………………….. 44
Cleaning………………………………………………………………………………………………………………………….. 45
Operator Station…………………………………………………………………………………………………………………… 45
Seat Belt…………………………………………………………………………………………………………………………. 46
Visibility Information……………………………………………………………………………………………………………… 47
Work Site Rules………………………………………………………………………………………………………………… 47
Boost Starting or Charging Engine Batteries…………………………………………………………………………………………… 48
Swinging or Traveling………………………………………………………………………………………………………………. 50
Lifting and Digging………………………………………………………………………………………………………………… 52
Operation on Slopes………………………………………………………………………………………………………………… 53
Towing……………………………………………………………………………………………………………………………. 54
Attachment………………………………………………………………………………………………………………………… 55
Equipment Lowering with Engine Stopped……………………………………………………………………………………………….. 55
Engine Stop……………………………………………………………………………………………………………………….. 55
Parking Machine……………………………………………………………………………………………………………………. 56
Preservation/Storing Machine………………………………………………………………………………………………………… 57
Check After Long-term Parking……………………………………………………………………………………………………. 58
Maintenance…………………………………………………………………………………………………………………………… 59
Cleaning………………………………………………………………………………………………………………………….. 62
Proper Tools and Clothing…………………………………………………………………………………………………………… 62
Disassembling Precautions…………………………………………………………………………………………………………… 62
Use of Lighting……………………………………………………………………………………………………………………. 63
Fire and Explosion Prevention……………………………………………………………………………………………………….. 63
Burn Prevention……………………………………………………………………………………………………………………. 64
Rubber That Contains Fluorides………………………………………………………………………………………………………. 65
Rubber and Plastics………………………………………………………………………………………………………………… 66
Waste Hazardous to the Environment……………………………………………………………………………………………….. 66
Check List After Fire…………………………………………………………………………………………………………… 66
Welding Repairs……………………………………………………………………………………………………………………. 67
Preparation for Electrical Welding On Body Structure……………………………………………………………………………….. 68
Warning for Counterweight and Front Attachment Removal…………………………………………………………………………………. 68
Lock Inspection Covers……………………………………………………………………………………………………………… 69
Working on Machine…………………………………………………………………………………………………………………. 69
Accumulator……………………………………………………………………………………………………………………….. 70
Compressed Air…………………………………………………………………………………………………………………….. 70
Track Tension Adjustments…………………………………………………………………………………………………………… 71
Supports and Blocking for Work Equipment……………………………………………………………………………………………… 71
High-pressure Lines, Tubes and Hoses…………………………………………………………………………………………………. 72
Battery…………………………………………………………………………………………………………………………… 73
Battery Hazard Prevention……………………………………………………………………………………………………….. 73
Environment and Circumstances…………………………………………………………………………………………………………… 75
Work Site Areas Requiring Extra Caution………………………………………………………………………………………………. 75
Digging Under an Overhang……………………………………………………………………………………………………….. 75
Deep Digging…………………………………………………………………………………………………………………… 75
Drop-off or Edge……………………………………………………………………………………………………………….. 76
Poor Visibility………………………………………………………………………………………………………………… 76
Loose or Soft Ground……………………………………………………………………………………………………………. 76
High-voltage Cables………………………………………………………………………………………………………………… 77
Underground Operation………………………………………………………………………………………………………………. 78
Working in Water…………………………………………………………………………………………………………………… 78
Working in Contaminated Environment………………………………………………………………………………………………….. 78
Operation in Extreme Conditions……………………………………………………………………………………………………… 79
Operation In Extreme Cold……………………………………………………………………………………………………….. 79
Operation in Extreme Heat……………………………………………………………………………………………………….. 80
Operation in Dusty and Sandy Areas……………………………………………………………………………………………….. 81
Operation in Rainy or Humid Conditions……………………………………………………………………………………………. 82
Operation in Saltwater Areas…………………………………………………………………………………………………….. 82
Operation at High Altitudes……………………………………………………………………………………………………… 83
Operation During Electrical Storms……………………………………………………………………………………………….. 83
Exhaust Ventilation………………………………………………………………………………………………………………… 83
Ventilation for Enclosed Area……………………………………………………………………………………………………. 83
Asbestos Information……………………………………………………………………………………………………………….. 84
Silica Dust Information…………………………………………………………………………………………………………….. 84
Disposal of Hazardous Materials……………………………………………………………………………………………………… 85
Sound…………………………………………………………………………………………………………………………….. 85
Vibration…………………………………………………………………………………………………………………………. 86
Operating Controls………………………………………………………………………………………………………………………… 87
Component Locations……………………………………………………………………………………………………………………. 88
Operator’s Area……………………………………………………………………………………………………………………….. 90
Operational Controls and Panels…………………………………………………………………………………………………………. 92
1. Starter Switch………………………………………………………………………………………………………………….. 94
2. Heater and Air Conditioner Control Panel…………………………………………………………………………………………… 94
3. Power Socket for 12 Volt…………………………………………………………………………………………………………. 95
4. Cigarette Lighter……………………………………………………………………………………………………………….. 95
5. Engine Emergency Stop Switch……………………………………………………………………………………………………… 95
6. Engine Speed Control Dial………………………………………………………………………………………………………… 96
7. Travel Speed Selector Switch……………………………………………………………………………………………………… 96
8. Light Switch……………………………………………………………………………………………………………………. 96
9. Intelligent Floating Boom Switch (Optional)………………………………………………………………………………………… 97
10. Cabin Work Light Switch (Optional)……………………………………………………………………………………………….. 97
11. Audio Control Panel…………………………………………………………………………………………………………….. 97
12. Wiper Control Panel…………………………………………………………………………………………………………….. 99
13. Quick Coupler Switch (Optional)…………………………………………………………………………………………………..100
14. Air Compressor Switch (Optional)………………………………………………………………………………………………….100
15. Warning Light Switch (Optional)…………………………………………………………………………………………………..101
16. Lower Wiper Switch (Optional)…………………………………………………………………………………………………….101
17. Travel/Swing Alarm Switch (Optional)………………………………………………………………………………………………101
18. Fuel Heater Switch (Optional)…………………………………………………………………………………………………….102
19. Overload Warning Switch (Optional)………………………………………………………………………………………………..102
20. Power Socket for 12 Volt (Optional)……………………………………………………………………………………………….102
21. Horn Button (Left-hand Work Lever)………………………………………………………………………………………………..103
22. Breaker/Booster Button (Right-hand Work Lever)……………………………………………………………………………………..103
23. Rotating Switch…………………………………………………………………………………………………………………103
24. Shear Switch……………………………………………………………………………………………………………………104
25. Display Monitor…………………………………………………………………………………………………………………104
26. Photo Sensor……………………………………………………………………………………………………………………104
27. Safety Lever……………………………………………………………………………………………………………………105
28. Auxiliary Mode Switch……………………………………………………………………………………………………………105
29. Hour Meter……………………………………………………………………………………………………………………..105
30. One Touch Deceleration Button…………………………………………………………………………………………………….106
31. Intelligent Floating Boom Temporary Reset Button……………………………………………………………………………………106
32. Jog Switch Control Panel…………………………………………………………………………………………………………106
33. Jack Assembly…………………………………………………………………………………………………………………..108
34. Micro Phone (Optional)…………………………………………………………………………………………………………..109
35. Swing Brake Release Switch……………………………………………………………………………………………………….109
36. Travel/Work Auxiliary Mode Selector Switch…………………………………………………………………………………………109
Display Monitor………………………………………………………………………………………………………………………..110
Functional Check……………………………………………………………………………………………………………………110
Password Activated………………………………………………………………………………………………………………….111
1. Fuel Gauge………………………………………………………………………………………………………………………111
2. Engine Coolant Temperature Gauge…………………………………………………………………………………………………..111
3. Hydraulic Oil Temperature Gauge……………………………………………………………………………………………………112
4. Multifunction Gauge and Graphic Information Area…………………………………………………………………………………….112
5. ECO Gauge……………………………………………………………………………………………………………………….114
6. Digital Clock……………………………………………………………………………………………………………………114
7. Display Warning Symbols…………………………………………………………………………………………………………..115
8. Warning Light……………………………………………………………………………………………………………………120
9. Function Buttons…………………………………………………………………………………………………………………120
10. Mode Selector Buttons……………………………………………………………………………………………………………122
11. Selector Function Display………………………………………………………………………………………………………..123
12. Jog Switch……………………………………………………………………………………………………………………..123
13. Camera Mode Selector/ESC Button…………………………………………………………………………………………………..123
14. Multimedia Selector Button……………………………………………………………………………………………………….124
Warning Pop-up Window……………………………………………………………………………………………………………….124
User Menu…………………………………………………………………………………………………………………………….. 0
Switch Operation Indication………………………………………………………………………………………………………….155
Heater and Air Conditioner Control Panel………………………………………………………………………………………………….158
Location of Controls and Vents……………………………………………………………………………………………………….158
Control Panel………………………………………………………………………………………………………………………159
Memory Function…………………………………………………………………………………………………………………….163
Additional Operating Instructions…………………………………………………………………………………………………….163
Miscellaneous Electrical Devices…………………………………………………………………………………………………………165
Cabin Light………………………………………………………………………………………………………………………..165
Battery Disconnect Switch……………………………………………………………………………………………………………165
Pilot Cutoff Switch…………………………………………………………………………………………………………………166
Circuit Breaker…………………………………………………………………………………………………………………….166
Fusible Link……………………………………………………………………………………………………………………….166
Fuse Boxes…………………………………………………………………………………………………………………………167
Seat Adjustment……………………………………………………………………………………………………………………….. 0
7. Storage Compartment………………………………………………………………………………………………………………170
8. Left and Right Control Stand Adjustment…………………………………………………………………………………………….170
Cabin Storage Compartments………………………………………………………………………………………………………………176
Sunglass Case………………………………………………………………………………………………………………………….176
Miscellaneous Access Covers and Doors…………………………………………………………………………………………………….179
Side Door………………………………………………………………………………………………………………………….179
Storage Box Door……………………………………………………………………………………………………………………179
Engine Cover……………………………………………………………………………………………………………………….179
Air Gun and Compressor (Optional)………………………………………………………………………………………………………..180
Air Gun (Optional)………………………………………………………………………………………………………………….180
How to Use Air Compressor……………………………………………………………………………………………………………180
Operation…………………………………………………………………………………………………………………………………183
To Operate a New Excavator………………………………………………………………………………………………………………183
Lubrication and Filters……………………………………………………………………………………………………………..184
Starting and Stopping Engine…………………………………………………………………………………………………………….184
Inspection Before Starting Engine…………………………………………………………………………………………………….184
Walk Around Checks………………………………………………………………………………………………………………184
Checks Before Starting Engine…………………………………………………………………………………………………….185
Operational Checks Before Starting Engine……………………………………………………………………………………………..186
Engine Start……………………………………………………………………………………………………………………….188
Cold Weather Starting……………………………………………………………………………………………………………….190
Starting Engine With a Booster Cable………………………………………………………………………………………………….192
Connecting Booster Batteries……………………………………………………………………………………………………..192
Disconnecting Booster Batteries…………………………………………………………………………………………………..193
Hydraulic System Warm-up…………………………………………………………………………………………………………….193
Hydraulic System Warm-up – Cold Weather……………………………………………………………………………………………….194
Stopping Engine…………………………………………………………………………………………………………………….196
Checks and Maintenance After Stopping Engine…………………………………………………………………………………………..197
Safety Lever…………………………………………………………………………………………………………………………..197
Travel………………………………………………………………………………………………………………………………..198
Automatic Travel Speed Control……………………………………………………………………………………………………….198
Travel Control Lever Operation……………………………………………………………………………………………………….199
General Travel Instructions………………………………………………………………………………………………………….200
Straight Travel Pedal (Optional)……………………………………………………………………………………………………..202
Operating………………………………………………………………………………………………………………………203
Locking Pedal…………………………………………………………………………………………………………………..203
Operating Instructions………………………………………………………………………………………………………………….204
Engine Speed Control………………………………………………………………………………………………………………..204
Engine Exhaust Emission Control System………………………………………………………………………………………………..204
Mode Selection……………………………………………………………………………………………………………………..205
Power Mode……………………………………………………………………………………………………………………..205
Work Mode………………………………………………………………………………………………………………………206
Auto Idle Mode………………………………………………………………………………………………………………….206
Boost Mode……………………………………………………………………………………………………………………..207
Work Levers (Joysticks) (ISO Pattern)…………………………………………………………………………………………………208
Left-hand Work Lever (Joystick) (Figure 51 and Figure 52)……………………………………………………………………………208
Right-hand Work Lever (Joystick) (Figure 51 and Figure 54)…………………………………………………………………………..208
Work Levers (Joysticks) (BHL Pattern)…………………………………………………………………………………………………210
Left-hand Work Lever (Joystick) (Figure 55 and Figure 58)……………………………………………………………………………210
Right-hand Work Lever (Joystick) (Figure 55 and Figure 59)…………………………………………………………………………..210
Intelligent Floating Boom Control (Optional)…………………………………………………………………………………………..211
Intelligent Floating Boom Mode……………………………………………………………………………………………………211
Operating a Breaker……………………………………………………………………………………………………………..212
Truck Loading…………………………………………………………………………………………………………………..212
Operating Precautions…………………………………………………………………………………………………………………..214
Working in Water……………………………………………………………………………………………………………………220
Escaping From Mud…………………………………………………………………………………………………………………..220
Track On One Side Stuck………………………………………………………………………………………………………….220
Tracks On Both Sides Stuck……………………………………………………………………………………………………….220
Parking Excavator………………………………………………………………………………………………………………………221
Towing Procedure……………………………………………………………………………………………………………………….222
Attachments……………………………………………………………………………………………………………………………223
Bucket Replacement and Reversal………………………………………………………………………………………………………223
Replacement………………………………………………………………………………………………………………………..224
Reversal (If Applicable)…………………………………………………………………………………………………………….225
Hydraulic Attachments (Optional)…………………………………………………………………………………………………………226
Breaker Operation…………………………………………………………………………………………………………………..226
Selection of Hydraulic Breaker……………………………………………………………………………………………………226
Hydraulic Hoses and Tubing for Breaker…………………………………………………………………………………………….226
Breaker Operating Precautions…………………………………………………………………………………………………….227
To Activate Breaker……………………………………………………………………………………………………………..229
Hydraulic Oil and Filter Service Intervals…………………………………………………………………………………………230
Shear Operation (Optional)…………………………………………………………………………………………………………..231
To Activate Shear……………………………………………………………………………………………………………….232
Rotating Operation (Optional)………………………………………………………………………………………………………..234
Quick Coupler Operation (Optional)……………………………………………………………………………………………………235
Securing Work Tool………………………………………………………………………………………………………………235
Attaching Quick Coupler to Excavator………………………………………………………………………………………………235
Releasing the Work Tool………………………………………………………………………………………………………….237
Lifting Objects………………………………………………………………………………………………………………………..238
Lifting Unknown Weight………………………………………………………………………………………………………………239
Lifting Known Weight………………………………………………………………………………………………………………..239
Pick and Carry……………………………………………………………………………………………………………………..239
Operation Under Abnormal Conditions………………………………………………………………………………………………………240
Operation in Extreme Cold……………………………………………………………………………………………………………240
Operation in Extreme Heat……………………………………………………………………………………………………………241
Operation in Dusty and Sandy Areas……………………………………………………………………………………………………243
Operation in Rainy or Humid Conditions………………………………………………………………………………………………..243
Operation in Saltwater Areas…………………………………………………………………………………………………………244
Operation at High Altitudes………………………………………………………………………………………………………….244
Operation During Electrical Storms……………………………………………………………………………………………………244
Equipment Lowering with Engine Stopped………………………………………………………………………………………………..245
Machine without a Boom Lowering Control Valve………………………………………………………………………………………245
Machine with a Boom Lowering Control Valve…………………………………………………………………………………………247
Long Term Storage………………………………………………………………………………………………………………………248
Before Storage……………………………………………………………………………………………………………………..248
During Storage……………………………………………………………………………………………………………………..249
After Storage………………………………………………………………………………………………………………………249
Inspection, Maintenance and Adjustment……………………………………………………………………………………………………….251
Maintenance Information…………………………………………………………………………………………………………………251
Operational Hour Meter Reading……………………………………………………………………………………………………….251
DOOSAN Genuine Replacement Parts……………………………………………………………………………………………………..251
DOOSAN Genuine Lubricants……………………………………………………………………………………………………………251
Windshield Washer Fluid……………………………………………………………………………………………………………..251
Fresh and Clean Lubricants…………………………………………………………………………………………………………..251
Check Drained Oil and Used Filter…………………………………………………………………………………………………….251
Fuel Strainer………………………………………………………………………………………………………………………251
Welding Instructions………………………………………………………………………………………………………………..252
Do Not Drop Things Inside Machine…………………………………………………………………………………………………….252
Dusty Work Site…………………………………………………………………………………………………………………….252
Avoid Mixing Lubricants……………………………………………………………………………………………………………..252
Locking Inspection Covers……………………………………………………………………………………………………………252
Hydraulic System – Air Bleeding………………………………………………………………………………………………………253
Hydraulic Hose Installation………………………………………………………………………………………………………….253
Checks After Inspection and Maintenance Works………………………………………………………………………………………….253
Safety Precautions………………………………………………………………………………………………………………….254
Machine Setup Position for Maintenance……………………………………………………………………………………………………254
Maintenance Handling Access……………………………………………………………………………………………………………..256
Entering/Leaving/Climbing On Machine………………………………………………………………………………………………….256
Handling Oil, Fuel, Coolant……………………………………………………………………………………………………………..257
Oil……………………………………………………………………………………………………………………………….257
Fuel………………………………………………………………………………………………………………………………257
Grease…………………………………………………………………………………………………………………………….258
Coolant and Water for Dilution……………………………………………………………………………………………………….259
Filters……………………………………………………………………………………………………………………………260
Electrical System Maintenance……………………………………………………………………………………………………………261
Recommend Fuel, Coolant, and Lubricant……………………………………………………………………………………………………262
Lubrication………………………………………………………………………………………………………………………..262
Symbols for “Lubrication and Service Chart”……………………………………………………………………………………………263
Fluid Capacities……………………………………………………………………………………………………………………….266
Table of Recommended Lubricants………………………………………………………………………………………………………….267
Maintenance Intervals…………………………………………………………………………………………………………………..269
10 Hour / Daily Service…………………………………………………………………………………………………………………272
Grease Boom, Arm and Front Attachment Pins (for first 100 hours)…………………………………………………………………………272
Check Engine Oil Level………………………………………………………………………………………………………………272
Check Level of Hydraulic Oil Tank…………………………………………………………………………………………………….273
Check for Leaks in Hydraulic System…………………………………………………………………………………………………..274
Check Fuel Level……………………………………………………………………………………………………………………274
Check for Leaks in Fuel System……………………………………………………………………………………………………….275
Check Fuel Prefilter and Drain Water As Required……………………………………………………………………………………….276
Check Oil Level of Swing Reduction Device……………………………………………………………………………………………..277
Clean Dust Net in Front of Oil Cooler and Radiator……………………………………………………………………………………..278
Oil Cooler……………………………………………………………………………………………………………………..278
Radiator……………………………………………………………………………………………………………………….278
Check Level of Window Washer Liquid…………………………………………………………………………………………………..278
Check Cooling System and Refill As Required……………………………………………………………………………………………279
Inspect Bucket Teeth and Side Cutters for Signs of Wear…………………………………………………………………………………279
Inspect Cooling Fan Blade……………………………………………………………………………………………………………280
Check Air Intake System and Emission Control System Components…………………………………………………………………………..280
Inspect Seat Belt for Proper Operation………………………………………………………………………………………………..281
Inspect Rear View Camera for Proper Operation (If Equipped)……………………………………………………………………………..281
Inspect Mirrors for Damage and Adjust and Clean as Required……………………………………………………………………………..281
Inspect Structure for Cracks and Faulty Welds………………………………………………………………………………………….281
Check Operation of All Switches and Travel Alarm (If Equipped)…………………………………………………………………………..281
Check the Operation of Pilot Cutoff Switch…………………………………………………………………………………………….281
Inspection and Maintenance of the Pilot Cutoff Switch……………………………………………………………………………….282
Check Operation of All Exterior Lights, Horn and Control Console Indicator and Display Monitor………………………………………………283
Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds…..283
Check Operation of All Controls and Linkages…………………………………………………………………………………………..283
50 Hour / Weekly Service………………………………………………………………………………………………………………..284
Perform All Daily Service Checks……………………………………………………………………………………………………..284
Grease Arm and Bucket Joint Pins……………………………………………………………………………………………………..284
Grease Swing Bearing………………………………………………………………………………………………………………..285
Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)………………………………………………………….287
Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers)………………………………287
250 Hour / Monthly Service………………………………………………………………………………………………………………288
Perform All Daily and 50 Hour Service Checks…………………………………………………………………………………………..288
Grease Boom and Arm Joint Pins……………………………………………………………………………………………………….288
Check Engine Fan and Alternator Belts Wear…………………………………………………………………………………………….291
Change Breaker Filter (Optional)……………………………………………………………………………………………………..292
Check Oil Bath Precleaner (Optional)………………………………………………………………………………………………….292
Clean Oil Bath Precleaner (Optional)………………………………………………………………………………………………….293
Replace Hydraulic Oil Return Filter (After First 250 Hours)……………………………………………………………………………..295
Change Pilot Filter (After First 250 Hours)……………………………………………………………………………………………295
Inspect Pins and Bushings of the Front End Attachments for Signs of Wear………………………………………………………………….295
Check Fluid Levels in Batteries………………………………………………………………………………………………………295
Inspect for Any Loose or Missing Nuts and Bolts………………………………………………………………………………………..295
Inspect Fuel System Hose Clamps………………………………………………………………………………………………………295
500 Hour / 3 Month Service………………………………………………………………………………………………………………296
Perform All Daily, 50 and 250 Hour Service Checks………………………………………………………………………………………296
Grease Swing Gear and Pinion…………………………………………………………………………………………………………296
Change Engine Oil and Filter…………………………………………………………………………………………………………297
Clean Air-conditioning Outer Filter…………………………………………………………………………………………………..298
Check and Clean Air-conditioning Inner Filter………………………………………………………………………………………….299
Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Cores……………………………………………………300
Clean Outer Filter of Air Cleaner…………………………………………………………………………………………………….301
Change of Fuel Prefilter…………………………………………………………………………………………………………….303
Change Fuel Filter………………………………………………………………………………………………………………….304
Check Oil Level in Travel Reduction Device (One on Each Side of Unit)…………………………………………………………………….306
Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 500 Hours)……………………………………………………306
Change Swing Reduction Device Oil (Drain and Refill After First 500 Hours)………………………………………………………………..306
1,000 Hour / 6 Month Service…………………………………………………………………………………………………………….307
Perform All Daily, 50, 250 and 500 Hour Service Checks………………………………………………………………………………….307
Grease Swing Reduction Device………………………………………………………………………………………………………..307
Change Hydraulic Oil Tank Breather Filter……………………………………………………………………………………………..307
Change Pilot Filter…………………………………………………………………………………………………………………309
Change Oil in Travel Reduction Device (One on Each Side of Unit)…………………………………………………………………………310
Change Swing Reduction Device Oil…………………………………………………………………………………………………….311
Change Air-conditioning Outer Filter………………………………………………………………………………………………….312
Change Air-conditioning Inner Filter………………………………………………………………………………………………….312
Check Air Conditioner Refrigerant…………………………………………………………………………………………………….313
Change Fuel Cap Filter………………………………………………………………………………………………………………314
Check and Adjust Engine**……………………………………………………………………………………………………………315
2,000 Hour / Yearly Service…………………………………………………………………………………………………………….. 0
Change Radiator Coolant……………………………………………………………………………………………………………..318
Hydraulic Oil Exchange and Suction Strainer Cleaning……………………………………………………………………………………321
Check Alternator and Starter**……………………………………………………………………………………………………….323
Check All Rubber Antivibration Shock Mounts……………………………………………………………………………………………323
Perform and Record Results of Cycle Time Tests…………………………………………………………………………………………323
Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage……………………………………………………………323
Check, Adjust Valve Clearance**………………………………………………………………………………………………………323
Check Head Bolt Torques……………………………………………………………………………………………………………..323
4,000 Hour / Biennial Service……………………………………………………………………………………………………………324
Major Parts – Periodic Replacement……………………………………………………………………………………………………324
12,000 Hour / 6 Year Service…………………………………………………………………………………………………………….325
Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 (CEN))……………………………………………………………….325
Air-conditioning System…………………………………………………………………………………………………………………326
Check Control Panel…………………………………………………………………………………………………………………326
Check Air Conditioner Hoses………………………………………………………………………………………………………….326
Check Condenser…………………………………………………………………………………………………………………….326
Check Magnetic Clutch……………………………………………………………………………………………………………….326
Check Belt Tension………………………………………………………………………………………………………………….326
Bolt and Nut Inspection…………………………………………………………………………………………………………………327
Bucket………………………………………………………………………………………………………………………………..336
Bucket Tooth Replacement…………………………………………………………………………………………………………….336
Bucket O-ring Replacement……………………………………………………………………………………………………………337
Bucket Shimming Procedures……………………………………………………………………………………………………………… 0
Shimming Procedures for Installed Bucket………………………………………………………………………………………………339
Electrical System………………………………………………………………………………………………………………………340
Battery……………………………………………………………………………………………………………………………340
Batteries in Cold Weather………………………………………………………………………………………………………..340
Inspection of Battery Electrolyte Level……………………………………………………………………………………………341
Check Charging State…………………………………………………………………………………………………………….341
Check Battery Terminals………………………………………………………………………………………………………….341
Battery Replacement……………………………………………………………………………………………………………..341
Fuses……………………………………………………………………………………………………………………………..342
Fuse Boxes……………………………………………………………………………………………………………………..342
Fuse Identification……………………………………………………………………………………………………………..343
Engine Cooling System…………………………………………………………………………………………………………………..344
General……………………………………………………………………………………………………………………………344
Types of Antifreeze……………………………………………………………………………………………………………..345
Antifreeze Concentration Tables………………………………………………………………………………………………………346
Table of Standards for Allowed Tap Water………………………………………………………………………………………………346
Fuel Transfer Pump (Optional)……………………………………………………………………………………………………………347
Handling of Accumulator…………………………………………………………………………………………………………………349
Track Tension………………………………………………………………………………………………………………………….350
Venting and Priming Hydraulic System……………………………………………………………………………………………………..352
Main System Pump……………………………………………………………………………………………………………………352
Hydraulic Cylinders…………………………………………………………………………………………………………………352
Swing Motor………………………………………………………………………………………………………………………..353
Travel Motor……………………………………………………………………………………………………………………….353
General Venting…………………………………………………………………………………………………………………….353
Maintenance in Special Conditions………………………………………………………………………………………………………..354
Transportation…………………………………………………………………………………………………………………………….355
Loading and Unloading…………………………………………………………………………………………………………………..355
Warning for Counterweight and Front Attachment Removal………………………………………………………………………………….355
Lifting Machine………………………………………………………………………………………………………………………..362
Troubleshooting……………………………………………………………………………………………………………………………363
Electrical System………………………………………………………………………………………………………………………363
Engine………………………………………………………………………………………………………………………………..364
Variable Geometry Turbocharger (VGT)……………………………………………………………………………………………………..368
Lubrication System……………………………………………………………………………………………………………………..369
Hydraulic System……………………………………………………………………………………………………………………….370
Air Compressor (Optional)……………………………………………………………………………………………………………….371
Swing System…………………………………………………………………………………………………………………………..372
Travel System………………………………………………………………………………………………………………………….372
Hydraulic Fan Drive System………………………………………………………………………………………………………………373
Specification……………………………………………………………………………………………………………………………..375
Standard Specification………………………………………………………………………………………………………………….375
Overall Dimensions……………………………………………………………………………………………………………………..376
Disassembled Parts, Dimension and Weight………………………………………………………………………………………………….377
Components…………………………………………………………………………………………………………………………377
Ground Pressure………………………………………………………………………………………………………………………..379
Digging Force………………………………………………………………………………………………………………………….380
Working Range………………………………………………………………………………………………………………………….382
Excavator Rated Lift Capacity Tables……………………………………………………………………………………………………..384
Approximate Weight of Workload Materials………………………………………………………………………………………………….402
Index…………………………………………………………………………………………………………………………………….405
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
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