Doosan DX140W-3 DX160W-3 Excavator Operation & Maintenance Manual 950106-00351BNA-1 – PDF DOWNLOAD
DESCRIPTION:
950106-00351BNA-1
Foreword:
- This Operation and Maintenance Manual was written to give owner or operator instructions on safe operation and maintenance of DOOSAN equipment. READ AND UNDERSTAND THIS OPERATION AND MAINTENANCE MANUAL BEFORE OPERATING YOUR DOOSAN EQUIPMENT. Keep this manual in the cabin so it is always available.
- If it is lost, order another one from your DOOSAN distributor. If there are any questions, contact your DOOSAN distributor. This manual may illustrate options and accessories not installed on your equipment. Any modification made without written authorization or approval from DOOSAN can create a safety hazard.
- Always replace parts with genuine DOOSAN parts or DOOSAN authorized replacement parts.
Intended Use
- The machine is intended to be used under normal conditions for applications described in this manual. If it is used for other purposes, or in potentially hazardous environments, special precautions must be followed and the machine must be equipped for such use.
- Examples include, but are not limited to, are: falling object guards, work lights, etc. Do not engage in prohibited uses as described in this manual. Contact your DOOSAN distributor for further information. Engine and Emission Control System Maintenance Proper inspection, maintenance and repair is essential to keeping engine and machine systems properly operating.
- This includes proper inspection and maintenance of the machine’s emission control system. This could include machine and engine components, such as an EGR (Exhaust Gas Recirculation) system, fuel system, turbocharger, electrical system, air intake system and/or cooling system.
- As a heavy-duty off-road diesel engine owner, you are responsible for performing required maintenance. The required maintenance procedures are outlined in this Operation and Maintenance Manual, or Shop Manual. Do not remove, alter, or render inoperative, any emission control system.
TABLE OF CONTENTS:
Doosan DX140W-3 DX160W-3 Excavator Operation & Maintenance Manual 950106-00351BNA-1 – PDF DOWNLOAD
DX140W-3/DX160W-3…………………………………………………………………………………………………………………………….. 0
Table of Contents…………………………………………………………………………………………………………………………. 5
Foreword…………………………………………………………………………………………………………………………………. 9
Intended Use………………………………………………………………………………………………………………………….. 9
Engine and Emission Control System Maintenance……………………………………………………………………………………………. 9
Safety Messages……………………………………………………………………………………………………………………….. 11
AEM Safety Manual (North America Only)…………………………………………………………………………………………………… 12
Federal Emission Control Systems………………………………………………………………………………………………………… 13
Limited Warranty for Non-road Engines (CI)……………………………………………………………………………………………. 13
Owner’s Warranty Rights and Obligations………………………………………………………………………………………………. 13
Manufacturer’s Warranty Coverage…………………………………………………………………………………………………….. 14
Owner’s Warranty Responsibilities……………………………………………………………………………………………………. 14
Safety…………………………………………………………………………………………………………………………………… 15
Safety Decals…………………………………………………………………………………………………………………………. 16
Safety Decals With Text…………………………………………………………………………………………………………….. 16
Safety Decals Without Text (No-Text)…………………………………………………………………………………………………. 17
Information and Location for Safety Decals……………………………………………………………………………………………. 18
Information and Location for Safety Decals (Continued)…………………………………………………………………………………. 19
General………………………………………………………………………………………………………………………………. 30
Safe Operation is Operator’s Responsibility…………………………………………………………………………………………… 30
Know Your Machine………………………………………………………………………………………………………………….. 30
Proper Work Tools and Attachments……………………………………………………………………………………………………. 31
Pressurized Fluids…………………………………………………………………………………………………………………. 31
Flying or Falling Objects…………………………………………………………………………………………………………… 32
Personal Protective Equipment (PPE)………………………………………………………………………………………………….. 33
Correction of Machine Problems………………………………………………………………………………………………………. 33
Crushing and Cutting……………………………………………………………………………………………………………….. 33
Hot Coolant and Oils – Burn Prevention……………………………………………………………………………………………….. 34
Fire and Explosion Prevention……………………………………………………………………………………………………….. 35
Maintenance……………………………………………………………………………………………………………………. 35
Operation……………………………………………………………………………………………………………………… 35
Electrical…………………………………………………………………………………………………………………….. 36
Hydraulic System……………………………………………………………………………………………………………….. 36
Fueling……………………………………………………………………………………………………………………….. 37
Never Use Ether Starting Aids……………………………………………………………………………………………………. 37
Welding and Grinding……………………………………………………………………………………………………………. 37
If a Fire Occurs……………………………………………………………………………………………………………….. 38
Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)…………………………………………………………………………….. 38
Electrical System and Electrical Shock……………………………………………………………………………………………….. 39
Rollover Protective Structure (ROPS)…………………………………………………………………………………………………. 39
ROPS Certification……………………………………………………………………………………………………………… 40
Protecting Cabin from Flying or Falling Objects (Optional)………………………………………………………………………….. 41
Emergency Exit from Operator’s Station……………………………………………………………………………………………. 42
Transportation………………………………………………………………………………………………………………………… 43
Obey State and Local Over-the-Road Regulations………………………………………………………………………………………… 43
Loading and Unloading………………………………………………………………………………………………………………. 43
Transporting Machine……………………………………………………………………………………………………………….. 44
Operation…………………………………………………………………………………………………………………………….. 45
Before Engine Starting……………………………………………………………………………………………………………… 45
Machine Condition………………………………………………………………………………………………………………. 45
Work Site…………………………………………………………………………………………………………………………. 46
Mounting/Dismounting……………………………………………………………………………………………………………….. 47
Cleaning………………………………………………………………………………………………………………………….. 48
Operator Station…………………………………………………………………………………………………………………… 48
Seat Belt…………………………………………………………………………………………………………………………. 49
Visibility Information……………………………………………………………………………………………………………… 50
Work Site Rules………………………………………………………………………………………………………………… 50
Boost Starting or Charging Engine Batteries…………………………………………………………………………………………… 51
Starting Engine……………………………………………………………………………………………………………………. 52
Swinging or Traveling………………………………………………………………………………………………………………. 53
Lifting and Digging………………………………………………………………………………………………………………… 55
Operation on Slopes………………………………………………………………………………………………………………… 56
Towing……………………………………………………………………………………………………………………………. 57
Attachment………………………………………………………………………………………………………………………… 58
Equipment Lowering with Engine Stopped……………………………………………………………………………………………….. 58
Engine Stop……………………………………………………………………………………………………………………….. 58
Parking Machine……………………………………………………………………………………………………………………. 59
Service Brake……………………………………………………………………………………………………………………… 60
Preservation/Storing Machine………………………………………………………………………………………………………… 61
Check After Long-term Parking……………………………………………………………………………………………………. 62
Maintenance…………………………………………………………………………………………………………………………… 63
Proper Tools and Clothing…………………………………………………………………………………………………………… 67
Disassembling Precautions…………………………………………………………………………………………………………… 67
Use of Lighting……………………………………………………………………………………………………………………. 67
Fire and Explosion Prevention……………………………………………………………………………………………………….. 67
Burn Prevention……………………………………………………………………………………………………………………. 68
Rubber That Contains Fluorides………………………………………………………………………………………………………. 69
Rubber and Plastics………………………………………………………………………………………………………………… 70
Waste Hazardous to the Environment……………………………………………………………………………………………….. 70
Check List After Fire…………………………………………………………………………………………………………… 70
Welding Repairs……………………………………………………………………………………………………………………. 71
Preparation for Electrical Welding On Body Structure……………………………………………………………………………….. 72
Warning for Counterweight and Front Attachment Removal…………………………………………………………………………………. 72
Working on Machine…………………………………………………………………………………………………………………. 73
Lock Inspection Covers……………………………………………………………………………………………………………… 73
Accumulator……………………………………………………………………………………………………………………….. 74
Compressed Air…………………………………………………………………………………………………………………….. 74
Supports and Blocking for Work Equipment……………………………………………………………………………………………… 74
High-pressure Lines, Tubes and Hoses…………………………………………………………………………………………………. 75
Battery…………………………………………………………………………………………………………………………… 76
Battery Hazard Prevention……………………………………………………………………………………………………….. 76
Environment and Circumstances…………………………………………………………………………………………………………… 78
Work Site Areas Requiring Extra Caution………………………………………………………………………………………………. 78
Digging Under an Overhang……………………………………………………………………………………………………….. 78
Deep Digging…………………………………………………………………………………………………………………… 78
Drop-off or Edge……………………………………………………………………………………………………………….. 79
Poor Visibility………………………………………………………………………………………………………………… 79
Loose or Soft Ground……………………………………………………………………………………………………………. 79
High-voltage Cables………………………………………………………………………………………………………………… 80
Underground Operation………………………………………………………………………………………………………………. 81
Working in Water…………………………………………………………………………………………………………………… 81
Working in Contaminated Environment………………………………………………………………………………………………….. 81
Operation in Extreme Conditions……………………………………………………………………………………………………… 82
Operation In Extreme Cold……………………………………………………………………………………………………….. 82
Operation in Extreme Heat……………………………………………………………………………………………………….. 83
Operation In Dusty and Sandy Areas……………………………………………………………………………………………….. 84
Operation in Rainy or Humid Conditions……………………………………………………………………………………………. 85
Operation in Saltwater Areas…………………………………………………………………………………………………….. 85
Operation at High Altitudes……………………………………………………………………………………………………… 86
Operation During Electrical Storms……………………………………………………………………………………………….. 86
Exhaust Ventilation………………………………………………………………………………………………………………… 86
Ventilation for Enclosed Area……………………………………………………………………………………………………. 86
Asbestos Information……………………………………………………………………………………………………………….. 87
Silica Dust Information…………………………………………………………………………………………………………….. 87
Disposal of Hazardous Materials……………………………………………………………………………………………………… 88
Sound…………………………………………………………………………………………………………………………….. 88
Vibration Information………………………………………………………………………………………………………………. 89
Hand/Arm Vibration Level………………………………………………………………………………………………………… 89
Whole Body Vibration Level………………………………………………………………………………………………………. 89
Guidelines for Use and Working Conditions of Earth-moving Machinery to Reduce Vibration Levels (ISO/TR 25398 Annex E)……………………… 89
Operating Controls………………………………………………………………………………………………………………………… 91
Component Locations……………………………………………………………………………………………………………………. 92
Operator’s Area……………………………………………………………………………………………………………………….. 94
Operational Controls and Panels…………………………………………………………………………………………………………. 96
1. Starter Switch………………………………………………………………………………………………………………….. 98
2. Engine Speed Control Dial………………………………………………………………………………………………………… 98
3. Quick Coupler Switch (Optional)…………………………………………………………………………………………………… 99
4. Auxiliary Mode Switch……………………………………………………………………………………………………………. 99
5. Engine Emergency Stop Switch……………………………………………………………………………………………………… 99
6. Audio Control Panel………………………………………………………………………………………………………………100
7. Ram Lock Switch………………………………………………………………………………………………………………….101
8. Light Switch…………………………………………………………………………………………………………………….102
9. Work Light Switch………………………………………………………………………………………………………………..102
10. Intelligent Floating Boom Switch (Optional)………………………………………………………………………………………..102
11. Parking Brake Switch…………………………………………………………………………………………………………….103
12. Cabin Work Light Switch (Optional)………………………………………………………………………………………………..103
13. Travel Alarm Selector Switch……………………………………………………………………………………………………..104
14. Heater and Air Conditioner Control Panel…………………………………………………………………………………………..104
15. Cigarette Lighter……………………………………………………………………………………………………………….104
16. Power Socket for 12 Volt…………………………………………………………………………………………………………105
17. Warning Light Switch (Optional)…………………………………………………………………………………………………..105
18. Overload Warning Switch (Optional)………………………………………………………………………………………………..105
19. Fuel Heater Switch (Optional)…………………………………………………………………………………………………….106
20. Lower Wiper Switch (Optional)…………………………………………………………………………………………………….106
21. Dozer/Outrigger Selector Switch (Independent Optional)………………………………………………………………………………106
22. Steering Console………………………………………………………………………………………………………………..107
23. Horn Button (Left-hand Work Lever)………………………………………………………………………………………………..107
24. Rotating Switch…………………………………………………………………………………………………………………107
28. Safety Lever……………………………………………………………………………………………………………………109
29. Power Socket for 12 Volt (Optional)……………………………………………………………………………………………….109
30. Photo Sensor……………………………………………………………………………………………………………………109
31. Diesel Particulate Filter (DPF) Switch…………………………………………………………………………………………….110
32. One Touch Deceleration Button…………………………………………………………………………………………………….110
33. Intelligent Floating Boom Temporary Reset Button……………………………………………………………………………………111
34. Jog Switch Control Panel…………………………………………………………………………………………………………111
35. Jack Assembly…………………………………………………………………………………………………………………..113
36. Hour Meter……………………………………………………………………………………………………………………..114
37. Micro Phone (Optional)…………………………………………………………………………………………………………..114
38. Travel Speed Selector Switch……………………………………………………………………………………………………..114
39. Cruise Control Switch……………………………………………………………………………………………………………115
40. FNR Selector Switch……………………………………………………………………………………………………………..115
41. Auxiliary Travel Selector Switch………………………………………………………………………………………………….115
42. Auxiliary FNR Switch…………………………………………………………………………………………………………….116
43. Air Compressor Switch (Optional)………………………………………………………………………………………………….116
Display Monitor……………………………………………………………………………………………………………………….. 0
Password Activated………………………………………………………………………………………………………………….122
1. Fuel Gauge………………………………………………………………………………………………………………………122
2. Engine Coolant Temperature Gauge…………………………………………………………………………………………………..123
3. Hydraulic Oil Temperature Gauge……………………………………………………………………………………………………123
5. ECO Gauge……………………………………………………………………………………………………………………….125
12. Jog Switch……………………………………………………………………………………………………………………..138
13. Camera Mode Selector/ESC Button…………………………………………………………………………………………………..138
14. Multimedia Selector Button……………………………………………………………………………………………………….138
15. Speedometer…………………………………………………………………………………………………………………….139
Warning Pop-up Window……………………………………………………………………………………………………………….139
Heater and Air Conditioner Control Panel………………………………………………………………………………………………….175
Location of Controls and Vents……………………………………………………………………………………………………….175
Control Panel………………………………………………………………………………………………………………………176
Memory Function…………………………………………………………………………………………………………………….180
Additional Operating Instructions…………………………………………………………………………………………………….180
Miscellaneous Electrical Devices…………………………………………………………………………………………………………182
Cabin Light………………………………………………………………………………………………………………………..182
Battery Disconnect Switch……………………………………………………………………………………………………………182
Pilot Cutoff Switch…………………………………………………………………………………………………………………183
Circuit Breaker…………………………………………………………………………………………………………………….183
Fusible Link……………………………………………………………………………………………………………………….183
Fuse Boxes…………………………………………………………………………………………………………………………184
Seat Adjustment……………………………………………………………………………………………………………………….. 0
7. Storage Compartment………………………………………………………………………………………………………………187
8. Left and Right Control Stand Adjustment…………………………………………………………………………………………….187
Cabin Storage Compartments………………………………………………………………………………………………………………193
Sunglass Case………………………………………………………………………………………………………………………….193
Miscellaneous Access Covers and Doors……………………………………………………………………………………………………. 0
Control Valve Upper Cover……………………………………………………………………………………………………………197
Dozer Cylinder Protection Cover………………………………………………………………………………………………………197
Air Gun and Compressor (Optional)………………………………………………………………………………………………………..198
Air Gun……………………………………………………………………………………………………………………………198
How to Use Air Compressor……………………………………………………………………………………………………………198
Wheel Chocks…………………………………………………………………………………………………………………………..201
Operation…………………………………………………………………………………………………………………………………203
To Operate a New Excavator………………………………………………………………………………………………………………203
Lubrication and Filters……………………………………………………………………………………………………………..204
Starting and Stopping Engine…………………………………………………………………………………………………………….204
Inspection Before Starting Engine…………………………………………………………………………………………………….204
Walk Around Checks………………………………………………………………………………………………………………204
Checks Before Starting Engine…………………………………………………………………………………………………….205
Operational Checks Before Starting Engine……………………………………………………………………………………………..206
Engine Start……………………………………………………………………………………………………………………….208
Cold Weather Starting……………………………………………………………………………………………………………….210
Plug Heater (Optional)………………………………………………………………………………………………………………211
Starting Engine With a Booster Cable………………………………………………………………………………………………….213
Connecting Booster Batteries……………………………………………………………………………………………………..213
Disconnecting Booster Batteries…………………………………………………………………………………………………..214
Hydraulic System Warm-up…………………………………………………………………………………………………………….214
Hydraulic System Warm-up – Cold Weather……………………………………………………………………………………………….215
Stopping Engine…………………………………………………………………………………………………………………….217
Checks and Maintenance After Stopping Engine…………………………………………………………………………………………..218
Safety Lever…………………………………………………………………………………………………………………………..219
Travel………………………………………………………………………………………………………………………………..220
Before Traveling……………………………………………………………………………………………………………………221
Over the Road Traveling Procedures……………………………………………………………………………………………………222
Traveling on a Work Site…………………………………………………………………………………………………………….223
Traveling on a Slope………………………………………………………………………………………………………………..224
Parking……………………………………………………………………………………………………………………………225
Travel Problems…………………………………………………………………………………………………………………….227
Cruise Control……………………………………………………………………………………………………………………..227
Engaging Cruise Control………………………………………………………………………………………………………….227
Disengaging Cruise Control……………………………………………………………………………………………………….228
Operating Instructions………………………………………………………………………………………………………………….228
Engine Speed Control………………………………………………………………………………………………………………..228
Engine Exhaust Emission Control System………………………………………………………………………………………………..228
Regeneration of Diesel Particulate Filter (DPF)…………………………………………………………………………………….229
Diesel Particulate Filter (DPF) Regeneration Light and Switch………………………………………………………………………..229
Passive Regeneration…………………………………………………………………………………………………………….232
Active Regeneration……………………………………………………………………………………………………………..232
Manual (Forced) Regeneration……………………………………………………………………………………………………..233
DPF Cleaning (Removing Ash in DPF)………………………………………………………………………………………………..235
Removal and Installation of the DPF Assembly……………………………………………………………………………………….236
Mode Selection……………………………………………………………………………………………………………………..237
Power Mode……………………………………………………………………………………………………………………..237
Work Mode………………………………………………………………………………………………………………………238
Auto Idle Mode………………………………………………………………………………………………………………….238
Boost Mode……………………………………………………………………………………………………………………..239
Work Levers (Joysticks) (ISO Pattern)…………………………………………………………………………………………………240
Left-hand Work Lever (Joystick) (Figure 65 and Figure 66)……………………………………………………………………………240
Intelligent Floating Boom Control (Optional)…………………………………………………………………………………………..243
Intelligent Floating Boom Mode……………………………………………………………………………………………………243
Operating a Breaker……………………………………………………………………………………………………………..244
Truck Loading…………………………………………………………………………………………………………………..244
Operating Precautions…………………………………………………………………………………………………………………..246
Working in Water……………………………………………………………………………………………………………………252
Parking Excavator………………………………………………………………………………………………………………………253
Towing Procedure……………………………………………………………………………………………………………………….254
Releasing Parking Brake Manually……………………………………………………………………………………………………..255
Applying a Manually Released Parking Brake…………………………………………………………………………………………….255
Attachments……………………………………………………………………………………………………………………………257
Bucket Replacement and Reversal………………………………………………………………………………………………………257
Replacement………………………………………………………………………………………………………………………..258
Reversal (If Applicable)…………………………………………………………………………………………………………….259
Hydraulic Attachments (Optional)…………………………………………………………………………………………………………260
Breaker Operation…………………………………………………………………………………………………………………..260
Selection of Hydraulic Breaker……………………………………………………………………………………………………260
Hydraulic Hoses and Tubing for Breaker…………………………………………………………………………………………….260
Breaker Operating Precautions…………………………………………………………………………………………………….261
To Activate Breaker……………………………………………………………………………………………………………..263
Hydraulic Oil and Filter Service Intervals…………………………………………………………………………………………264
Shear Operation (Optional)…………………………………………………………………………………………………………..265
To Activate Shear……………………………………………………………………………………………………………….266
Rotating Operation (Optional)………………………………………………………………………………………………………..268
Quick Coupler Operation (Optional)……………………………………………………………………………………………………269
Securing Work Tool………………………………………………………………………………………………………………269
Attaching Quick Coupler to Excavator………………………………………………………………………………………………269
Releasing the Work Tool………………………………………………………………………………………………………….271
Lifting Objects………………………………………………………………………………………………………………………..272
Lifting Unknown Weight………………………………………………………………………………………………………………273
Lifting Known Weight………………………………………………………………………………………………………………..273
Pick and Carry……………………………………………………………………………………………………………………..273
Operation Under Abnormal Conditions………………………………………………………………………………………………………274
Operation in Extreme Cold……………………………………………………………………………………………………………274
Operation in Extreme Heat……………………………………………………………………………………………………………275
Operation in Dusty and Sandy Areas……………………………………………………………………………………………………277
Operation in Rainy or Humid Conditions………………………………………………………………………………………………..277
Operation in Saltwater Areas…………………………………………………………………………………………………………278
Operation at High Altitudes………………………………………………………………………………………………………….278
Operation During Electrical Storms……………………………………………………………………………………………………278
Equipment Lowering with Engine Stopped………………………………………………………………………………………………..279
Machine Without a Boom Lowering Control Valve………………………………………………………………………………………279
Machine With a Boom Lowering Control Valve…………………………………………………………………………………………281
Long Term Storage………………………………………………………………………………………………………………………282
Before Storage……………………………………………………………………………………………………………………..282
During Storage……………………………………………………………………………………………………………………..283
After Storage………………………………………………………………………………………………………………………283
Inspection, Maintenance and Adjustment……………………………………………………………………………………………………….285
Maintenance Information…………………………………………………………………………………………………………………285
Operational Hour Meter Reading……………………………………………………………………………………………………….285
DOOSAN Genuine Replacement Parts……………………………………………………………………………………………………..285
DOOSAN Genuine Lubricants……………………………………………………………………………………………………………285
Windshield Washer Fluid……………………………………………………………………………………………………………..285
Fresh and Clean Lubricants…………………………………………………………………………………………………………..285
Check Drained Oil and Used Filter…………………………………………………………………………………………………….285
Fuel Strainer………………………………………………………………………………………………………………………285
Welding Instructions………………………………………………………………………………………………………………..286
Do Not Drop Things Inside Machine…………………………………………………………………………………………………….286
Dusty Work Site…………………………………………………………………………………………………………………….286
Avoid Mixing Lubricants……………………………………………………………………………………………………………..286
Locking Inspection Covers……………………………………………………………………………………………………………286
Hydraulic System – Air Bleeding………………………………………………………………………………………………………287
Hydraulic Hose Installation………………………………………………………………………………………………………….287
Checks After Inspection and Maintenance Works………………………………………………………………………………………….287
Safety Precautions………………………………………………………………………………………………………………….288
Machine Setup Position for Maintenance……………………………………………………………………………………………………289
Maintenance Handling Access……………………………………………………………………………………………………………..291
Entering/Leaving/Climbing On Machine………………………………………………………………………………………………….291
Handling Oil, Fuel, Coolant……………………………………………………………………………………………………………..292
Oil……………………………………………………………………………………………………………………………….292
Fuel………………………………………………………………………………………………………………………………292
Engine Oil…………………………………………………………………………………………………………………………294
Grease…………………………………………………………………………………………………………………………….294
Coolant and Water for Dilution……………………………………………………………………………………………………….295
Filters……………………………………………………………………………………………………………………………296
Electrical System Maintenance……………………………………………………………………………………………………………297
Recommend Fuel, Coolant, and Lubricant……………………………………………………………………………………………………298
Lubrication………………………………………………………………………………………………………………………..298
Symbols for “Lubrication and Service Chart”……………………………………………………………………………………………299
Lubrication and Service Chart…………………………………………………………………………………………………….300
Fluid Capacities……………………………………………………………………………………………………………………….303
Table of Recommended Lubricants………………………………………………………………………………………………………….304
Maintenance Intervals…………………………………………………………………………………………………………………..307
10 Hour / Daily Service…………………………………………………………………………………………………………………310
Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear…………………………………………………………..310
Grease Dozer Blade Pins (For First 100 Hours)………………………………………………………………………………………….310
Grease Outrigger Pins (For First 100 Hours)……………………………………………………………………………………………310
Grease Boom, Arm and Front Attachment Pins (for first 100 hours)…………………………………………………………………………310
Check Engine Oil Level………………………………………………………………………………………………………………311
Check Level of Hydraulic Oil Tank…………………………………………………………………………………………………….312
Check for Leaks in Hydraulic System…………………………………………………………………………………………………..313
Check for Leaks in Fuel System……………………………………………………………………………………………………….313
Check Fuel Level……………………………………………………………………………………………………………………314
Check Water Separator & Pre Fuel Filter (Fuel Prefilter) and Drain Water as Required……………………………………………………….315
Check Oil Level of Swing Reduction Device……………………………………………………………………………………………..316
Clean Dust Net in Front of Oil Cooler and Intercooler…………………………………………………………………………………..317
Check Cooling System and Refill as Required……………………………………………………………………………………………317
Check Level of Window Washer Liquid…………………………………………………………………………………………………..318
Inspect Bucket Teeth and Side Cutters for Signs of Wear…………………………………………………………………………………318
Inspect Cooling Fan Blade……………………………………………………………………………………………………………318
Check Air Intake System and Emission Control System Components…………………………………………………………………………..319
Inspect Seat Belt for Proper Operation………………………………………………………………………………………………..319
Inspect Rear View Camera Proper Operation (If Equipped)…………………………………………………………………………………319
Inspect Mirrors for Damage and Adjust and Clean as Required……………………………………………………………………………..320
Inspect Structure for Cracks and Faulty Welds………………………………………………………………………………………….320
Check Operation of All Switches and Travel Alarm (If Equipped)…………………………………………………………………………..320
Check the Operation of Pilot Cutoff Switch…………………………………………………………………………………………….320
Inspection and Maintenance of the Pilot Cutoff Switch……………………………………………………………………………….320
Check Operation of All Exterior Lights, Horn and Control Console Indicator and Display Monitor………………………………………………321
Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds…..321
Check Operation of All Controls and Linkages…………………………………………………………………………………………..322
50 Hour / Weekly Service………………………………………………………………………………………………………………..323
Perform All Daily Service Checks……………………………………………………………………………………………………..323
Grease Arm and Bucket Joint Pins……………………………………………………………………………………………………..323
Grease Swing Bearing………………………………………………………………………………………………………………..324
Grease Dozer Blade Pin………………………………………………………………………………………………………………325
Grease Outrigger Pins……………………………………………………………………………………………………………….325
Grease Front Axle Pin……………………………………………………………………………………………………………….326
Drain Water and Sediment from Fuel Tank……………………………………………………………………………………………….326
Check Air Compressor and Drain Water as Required……………………………………………………………………………………….327
Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)………………………………………………………….327
Change Engine Oil and Filter (After First 50 Hours)…………………………………………………………………………………….327
Inspect for Any Loose or Missing Nuts and Bolts………………………………………………………………………………………..327
250 Hour / Monthly Service………………………………………………………………………………………………………………328
Perform All Daily and 50 Hour Service Checks…………………………………………………………………………………………..328
Grease Boom and Arm Joint Pins……………………………………………………………………………………………………….328
Check Engine Fan and Alternator Belts Wear…………………………………………………………………………………………….331
Change Breaker Filter (Optional)……………………………………………………………………………………………………..332
Replace Hydraulic Oil Return Filter (After First 250 Hours)……………………………………………………………………………..333
Change Pilot Filter (After First 250 Hours)……………………………………………………………………………………………333
Change Brake Filter (After First 250 Hours)……………………………………………………………………………………………333
Inspect Pins and Bushings of the Front End Attachments for Signs of Wear………………………………………………………………….333
Check Fluid Levels in Batteries………………………………………………………………………………………………………333
Inspect for Any Loose or Missing Nuts and Bolts………………………………………………………………………………………..333
Inspect Fuel System Hose Clamps………………………………………………………………………………………………………333
500 Hour / 3 Month Service………………………………………………………………………………………………………………334
Perform All Daily, 50 and 250 Hour Service Checks………………………………………………………………………………………334
Grease Swing Gear and Pinion…………………………………………………………………………………………………………334
Change Engine Oil and Filter…………………………………………………………………………………………………………335
Clean Air-conditioning Outer Filter…………………………………………………………………………………………………..336
Check and Clean Air-conditioning Inner Filter………………………………………………………………………………………….337
Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Cores……………………………………………………338
Grease Driveshaft…………………………………………………………………………………………………………………..339
Grease Front Axle Steering Knuckle……………………………………………………………………………………………………340
Clean Outer Filter of Air Cleaner…………………………………………………………………………………………………….340
Change of Water Separator & Pre Fuel Filter (Fuel Prefilter)…………………………………………………………………………….342
Change Main Fuel Filter……………………………………………………………………………………………………………..344
Fuel System Priming……………………………………………………………………………………………………………..344
Drain and Refill Front Axle Case Oil (After First 500 Hours)…………………………………………………………………………….346
Drain and Refill Rear Axle Case Oil (After First 500 Hours)……………………………………………………………………………..346
Drain and Refill Hub Reduction Gear Oil (After First 500 Hours)………………………………………………………………………….346
Drain and Refill Transmission Fluid (After First 500 Hours)……………………………………………………………………………..346
Change Swing Reduction Device Oil (Drain and Refill After First 500 Hours)………………………………………………………………..346
1,000 Hour / 6 Month Service…………………………………………………………………………………………………………….347
Perform All Daily, 50, 250 and 500 Hour Service Checks………………………………………………………………………………….347
Grease Swing Reduction Device………………………………………………………………………………………………………..347
Change Hydraulic Oil Tank Breather Filter……………………………………………………………………………………………..347
Replace Hydraulic Oil Return Filter…………………………………………………………………………………………………..348
Change Pilot Filter…………………………………………………………………………………………………………………349
Change Swing Reduction Device Oil…………………………………………………………………………………………………….350
Change Brake Filter…………………………………………………………………………………………………………………351
Change Air-conditioning Outer Filter………………………………………………………………………………………………….352
Change Air-conditioning Inner Filter………………………………………………………………………………………………….352
Check Air Conditioner Refrigerant…………………………………………………………………………………………………….353
Change Fuel Cap Filter………………………………………………………………………………………………………………354
Check and Adjust Engine**……………………………………………………………………………………………………………355
2,000 Hour / Yearly Service…………………………………………………………………………………………………………….. 0
Change Radiator Coolant……………………………………………………………………………………………………………..358
Hydraulic Oil Exchange and Suction Strainer Cleaning……………………………………………………………………………………360
Check Alternator and Starter**……………………………………………………………………………………………………….364
Check All Rubber Antivibration Shock Mounts……………………………………………………………………………………………364
Perform and Record Results of Cycle Time Tests…………………………………………………………………………………………364
Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage……………………………………………………………364
Check, Adjust Valve Clearance**………………………………………………………………………………………………………364
Check Head Bolt Torques……………………………………………………………………………………………………………..364
4,000 Hour / Biennial Service……………………………………………………………………………………………………………365
Major Parts – Periodic Replacement……………………………………………………………………………………………………365
4,500 Hour / Biennial Service……………………………………………………………………………………………………………366
Clean Diesel Particulate Filter (DPF)…………………………………………………………………………………………………366
12,000 Hour / 6 Year Service…………………………………………………………………………………………………………….367
Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN)…………………………………………………………………367
Air-conditioning System…………………………………………………………………………………………………………………368
Check Control Panel…………………………………………………………………………………………………………………368
Check Air Conditioner Hoses………………………………………………………………………………………………………….368
Check Condenser…………………………………………………………………………………………………………………….368
Check Magnetic Clutch……………………………………………………………………………………………………………….368
Check Belt Tension………………………………………………………………………………………………………………….368
Bolt and Nut Inspection…………………………………………………………………………………………………………………369
Bucket………………………………………………………………………………………………………………………………..377
Bucket Tooth Replacement…………………………………………………………………………………………………………….377
Bucket O-ring Replacement……………………………………………………………………………………………………………378
Electrical System………………………………………………………………………………………………………………………379
Battery……………………………………………………………………………………………………………………………379
Batteries in Cold Weather………………………………………………………………………………………………………..379
Inspection of Battery Electrolyte Level……………………………………………………………………………………………380
Check Charging State…………………………………………………………………………………………………………….380
Check Battery Terminals………………………………………………………………………………………………………….380
Battery Replacement……………………………………………………………………………………………………………..380
Fuses……………………………………………………………………………………………………………………………..381
Fuse Boxes……………………………………………………………………………………………………………………..381
Fuse Identification……………………………………………………………………………………………………………..382
Engine Cooling System…………………………………………………………………………………………………………………..383
General……………………………………………………………………………………………………………………………383
Types of Antifreeze……………………………………………………………………………………………………………..384
Antifreeze Concentration Tables………………………………………………………………………………………………………385
Table of Standards for Allowed Tap Water………………………………………………………………………………………………385
Electric Viscous Fan Clutch………………………………………………………………………………………………………….386
Removal and Installation of the Cooling Fan Assembly………………………………………………………………………………..386
Fuel Transfer Pump (Optional)……………………………………………………………………………………………………………387
Handling of Accumulator…………………………………………………………………………………………………………………389
Pilot Accumulator…………………………………………………………………………………………………………………..389
Brake Accumulator…………………………………………………………………………………………………………………..390
Release Brake Accumulator Pressure………………………………………………………………………………………………..390
Tires and Wheels……………………………………………………………………………………………………………………….391
Check Tire for Damage……………………………………………………………………………………………………………….391
Tire Changing Procedure……………………………………………………………………………………………………………..392
Venting and Priming Hydraulic System and Other Components…………………………………………………………………………………..396
Main System Pump……………………………………………………………………………………………………………………396
Hydraulic Cylinders…………………………………………………………………………………………………………………396
Swing Motor………………………………………………………………………………………………………………………..397
Transmission……………………………………………………………………………………………………………………….397
Break Line…………………………………………………………………………………………………………………………398
General Venting…………………………………………………………………………………………………………………….398
Maintenance in Special Conditions………………………………………………………………………………………………………..399
Transportation…………………………………………………………………………………………………………………………….401
Loading and Unloading…………………………………………………………………………………………………………………..401
Warning for Counterweight and Front Attachment Removal………………………………………………………………………………….401
Short Distance Self-powered Travel……………………………………………………………………………………………………….404
Trailer Loading/Unloading Procedures……………………………………………………………………………………………………..405
Lifting Machine………………………………………………………………………………………………………………………..409
Troubleshooting……………………………………………………………………………………………………………………………411
Electrical System………………………………………………………………………………………………………………………411
Engine………………………………………………………………………………………………………………………………..412
Turbocharger…………………………………………………………………………………………………………………………..416
Cooling Fan……………………………………………………………………………………………………………………………417
Lubrication System……………………………………………………………………………………………………………………..417
Hydraulic System……………………………………………………………………………………………………………………….418
Air Compressor (Optional)……………………………………………………………………………………………………………….419
Swing System…………………………………………………………………………………………………………………………..420
Travel System………………………………………………………………………………………………………………………….420
Steering………………………………………………………………………………………………………………………………422
Brakes………………………………………………………………………………………………………………………………..422
Specification……………………………………………………………………………………………………………………………..423
Specification………………………………………………………………………………………………………………………….423
Overall Dimensions……………………………………………………………………………………………………………………..426
One – Piece Boom……………………………………………………………………………………………………………………426
Two – Piece Boom……………………………………………………………………………………………………………………427
Disassembled Parts, Dimension and Weight………………………………………………………………………………………………….428
Components…………………………………………………………………………………………………………………………428
Digging Force………………………………………………………………………………………………………………………….430
Working Range………………………………………………………………………………………………………………………….432
One – Piece Boom……………………………………………………………………………………………………………………432
Two – Piece Boom……………………………………………………………………………………………………………………434
Excavator Rated Lift Capacity Tables……………………………………………………………………………………………………..436
Approximate Weight of Workload Materials………………………………………………………………………………………………….456
Index…………………………………………………………………………………………………………………………………….459
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