Doosan DX180LC, DX300LC, DX225NLC, DX225LC, DX255LC Shop Manual
...
DX225LC
Shop Manual
K1015439E
Serial Number 5001 and Up
Product Label
Instructions
Trim Out The Label Along
The Lines And Insert Into
Pocket On The Binder Spine
Pub.No. K1015439E
DX225LC
Serial Number 5001 and Up
Pub. No. K1015439E
1Table of Contents
Publication Request for Proposed Revision
Safety
Track Excavator Safety......................................................................... SP000014
Specifications
Specification for DX225LC.................................................................... SP000908
General Maintenance
General Maintenance Procedures........................................................ SP000016
Standard Torques................................................................................. SP000017
Upper Structure
Cabin .................................................................................................... SP000943
Counterweight....................................................................................... SP000940
Fuel Tank.............................................................................................. SP001005
Fuel Transfer Pump.............................................................................. SP000021
Swing Bearing....................................................................................... SP000022
Swing Reduction Gear.......................................................................... SP000915
Lower Structure and Chassis
Track Assembly .................................................................................... SP000911
Engine and Drivetrain
Air Conditioner...................................................................................... SP000025
Drive Coupling (Main Pump)................................................................. SP000912
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment ............... SP000913
Table of Contents
Page 1
Accumulator.......................................................................................... SP000028
Center Joint (Swivel)............................................................................. SP000029
Cylinders............................................................................................... SP000914
Swing Motor.......................................................................................... SP000194
Travel Motor.......................................................................................... SP000922
Gear Pump ........................................................................................... SP000931
Main Control Valve ............................................................................... SP001024
Axle Piston Pump ................................................................................. SP000932
PTO Server........................................................................................... SP000933
Remote Control Valve (Work Lever / Joystick)..................................... SP000069
Travel Control Valve (with Damper)...................................................... SP000070
Solenoid Valve Assembly ..................................................................... SP000445
Breaker EPPR Valve (Opt) ................................................................... SP000192
Hydraulic Schematic (DX225LC).......................................................... SP000934
Electrical System
Electrical System .................................................................................. SP000935
Electrical Schematic (DX180LC/DX225LC/DX225NLC/DX255LC)...... SP000936
Attachments
Boom and Arm...................................................................................... SP000937
Bucket................................................................................................... SP000939
Table of Contents
Page 2
1Safety
SP000014
TRACK EXCAVATOR SAFETYSP000014
Track
Excavator
Safety
Edition 1
Track Excavator Safety
SP000014
Page 1
MEMO
SP000014
Page 2
Track Excavator Safety
Table of Contents
Track Excavator Safety
Safety Precautions................................................ 5
Applicable Models................................................. 5
To the Operator of a
DOOSAN Excavator ............................................. 6
General Safety Essentials ..................................10
Location of Safety Labels ................................... 11
Summary of Safety Precautions for Lifting
in Digging Mode.................................................. 12
Unauthorized Modifications ................................ 13
General Hazard Information ...............................13
Before Starting Engine .......................................22
Machine Operation .............................................26
Maintenance.......................................................33
Battery ................................................................ 42
Towing................................................................. 44
Shipping and Transportation............................... 45
Lifting With Sling.................................................45
Track Excavator Safety
SP000014
Page 3
SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling the load.
Remember, that ultimately safety is your own responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
MODEL SERIAL NUMBER RANGE
DX180LC 5001 and Up
DX225LC 5001 and Up
DX225NLC 5001 and Up
DX255LC 5001 and Up
DX300LC 5001 and Up
DX340LC 5001 and Up
DX420LC 5001 and Up
DX480LC 5001 and Up
DX520LC 5001 and Up
SP000014
Track Excavator Safety
Page 5
TO THE OPERATOR OF A
DOOSAN
EXCAVATOR
DANGER!
Unsafe use of the excavator could lead to serious injury or
death. Operating procedures, maintenance and equipment
practices or traveling or shipping methods that do not
follow the safety guidelines on the following pages could
cause serious, potentially fatal injuries or extensive damage
to the machine or nearby property.
Please respect the importance of taking responsibility for your
own safety, and that of other people who may be affected by
your actions.
The safety information on the following pages is organized into
the following sections:
1. “General Safety Essentials” on page 1-10
2. “Location of Safety Labels” on page 1-11
3. “Summary of Safety Precautions for Lifting in Digging
Mode” on page 1-12
4. “Unauthorized Modifications” on page 1-13
5. “General Hazard Information” on page 1-13
6. “Before Starting Engine” on page 1-22
7. “Machine Operation” on page 1-26
8. “Maintenance” on page 1-33
9. “Battery” on page 1-42
10. “Towing” on page 1-44
11. “Shipping and Transportation” on page 1-45
12. “Lifting With Sling” on page 1-45
Page 6
SP000014Track Excavator Safety
WARNING!
Improper operation and maintenance of this machine can
be hazardous and could result in serious injury or death.
Operator and maintenance personnel should read this
manual thoroughly before beginning operation or
maintenance.
Keep this manual in the storage compartment to the rear of
the operator's seat, and have all personnel involved in
working on the machine read the manual periodically.
Some actions involved in operation and maintenance of the
machine can cause a serious accident, if they are not done
in a manner described in this manual.
The procedures and precautions given in this manual apply
only to intended uses of the machine.
If you use your machine for any unintended uses that are
not specifically prohibited, you must be sure that it is safe
for others. In no event should you or others engage in
prohibited uses or actions as described in this manual.
DOOSAN
regulations and standards of the country to which it has
been sent. If this machine has been purchased in another
country or purchased from someone in another country, it
may lack certain safety devices and specifications that are
necessary for use in your country. If there is any question
about whether your product complies with the applicable
standards and regulations of your country, consult
DOOSAN
machine.
delivers machines that comply with all applicable
or your
DOOSAN
distributor before operating the
SP000014
Track Excavator Safety
Page 7
SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and Safety
Instructions
This is the Safety Alert Symbol. Wherever it appears in this
manual or on safety signs on the machine you must be alert
to the potential for personal injury or accidents. Always
observe safety precautions and follow recommended
procedures.
Learn Signal Words Used With Safety Alert
Symbol
The words "CAUTION," "WARNING," and "DANGER" used
throughout this manual and on decals on the machine indicate
degree of risk of hazards or unsafe practices. All three degrees
of risk indicate that safety is involved. Observe precautions
indicated whenever you see the Safety Alert "Triangle," no
matter which signal word appears next to the "Exclamation
Point" symbol.
CAUTION!
This word is used on safety messages and safety labels and
indicates potential threat of a hazardous situation that, if
not avoided, could result in minor or moderate injury. It may
also be used to alert against a generally unsafe practice.
WARNING!
This word is used on safety messages and safety labels and
indicates potential threat of a hazardous situation that, if
not avoided, could result in serious injury or death. It may
also be used to alert against highly unsafe practice.
DANGER!
This word is used on safety messages and safety labels and
indicates an imminent hazard of a situation that, if not
avoided, is very likely to cause death or extremely serious
injury. It may also be used to alert against equipment that
may detonate or explode if handled or treated carelessly.
Page 8
SP000014Track Excavator Safety
Safety precautions are described in SAFETY from page -11 on.
DOOSAN
potential hazard in operation and maintenance. Therefore the
safety messages in this manual and on the machine may not
include all possible safety precautions. If any procedures or
actions not specifically recommended or allowed in this manual
are used, you must be sure that you and others can do such
procedures and actions safely and without damaging the
machine. If you are unsure about the safety of any procedures,
contact a
cannot predict every circumstance that might involve a
DOOSAN
distributor.
SP000014
Track Excavator Safety
Page 9
GENERAL SAFETY ESSENTIALS
Accessory Applications
The excavator has been primarily designed for moving earth
with a bucket. For use as a grapple or for other object handling,
contact
Lifting-work applications (unless restricted or prohibited by local
regulations) are permitted in approved lift configuration, to rated
capacity only, with no side-loading. DO NOT use the machine for
activities for which it was not intended. DO NOT use the bucket
for lifting work, unless lift slings are used in the approved
configuration.
Use of an accessory hydraulic hammer (breaker), work in rough
terrain, demolition applications or other hazardous operation
may require installation of additional protective structures to
safeguard the operator.
DOOSAN
Lifting Capacity Rating Configuration
Lifting capacity ratings that are printed at the end of this safety
section are based on the machine being level, on a firm
supporting surface, with hooks and slings attached in approved
configuration. Loads must be balanced and supported evenly.
Use tag lines to keep the load steady if wind conditions and
large surface area are a problem. Work crew hand signals,
individual tasks and safe procedures should all be universally
understood before the lift is made.
for proper installation and application.
IMPORTANT
Before using the excavator to make lifts check municipal
and regional regulations or statutes that could apply.
Governing ordinances may require that all heavy lifting be
done with single purpose equipment specifically designed
for making lifts, or other local restrictions may apply.
Making heavy lifts with a general purpose excavator that
can be used for digging, loading, grading or other work may
be expressly forbidden by a regional injunction or other
legal prohibition. Always follow all the other instructions,
guidelines and restrictions for Safe Lifting in the Operation
and Maintenance Manuals.
Page 10
SP000014Track Excavator Safety
LOCATION OF SAFETY LABELS
Location of safety labels (decals) can vary from unit to unit.
Refer to appropriate Operation and Maintenance Manual, and
parts manual for your unit.
Always replace damaged or faded decals.
SP000014
Track Excavator Safety
Page 11
SUMMARY OF SAFETY
PRECAUTIONS FOR LIFTING
IN DIGGING MODE
DANGER!
Unsafe use of the excavator while making rated lifts could
cause serious, potentially fatal injuries or extensive damage
to the machine or nearby property. Do not let anyone
operate the machine unless they've been properly trained
and understand the information in the Operation and
Maintenance Manual.
To lift safely while in Digging Mode, the following items must be
evaluated by the operator and the work site crew.
• Condition of ground support.
• Excavator configuration and attachments.
• Weight, lifting height and lifting radius.
• Safe rigging of the load.
• Proper handling of the suspended load.
Tag lines on opposite sides of the load can be very helpful in
keeping a suspended load secure, if they are anchored safely to
control points on the ground.
WARNING!
NEVER wrap a tag line around your hands or body.
NEVER rely on tag lines or make rated lifts when wind gusts
are more than 48.3 km/h (30 MPH). Be prepared for any wind
gust when working with loads that have a large surface
area.
Always engage the "Digging Mode" control on the Instrument
Panel before using the excavator for lifting work.
WARNING!
If you need more information or have any questions or
concerns about safe operating procedures or working the
excavator correctly in a particular application or in the
specific conditions of your individual operating
environment, please consult your local
representative.
DOOSAN
Page 12
SP000014Track Excavator Safety
UNAUTHORIZED
MODIFICATIONS
Any modification made without authorization or written approval
DOOSAN
from
machine owner will be held responsible.
For safety's sake, replace all OEM parts with the correct
authorized or genuine
the time to replace fasteners, bolts or nuts with the correct
replacement parts could lead to a condition where the safety of
critical assemblies are dangerously compromised.
can create a safety hazard, for which the
DOOSAN
part. For example, not taking
GENERAL HAZARD
INFORMATION
Safety Rules
Only trained and authorized personnel can operate and maintain
the machine.
Follow all safety rules, precautions and instructions when
operating or performing maintenance on the machine.
Do not operate the machine if you are not feeling well, if you are
taking medication that makes you feel sleepy, if you have been
drinking, or if you are suffering from emotional problems. These
problems will interfere with your sense of judgment in
emergencies and may cause accidents.
When working with another operator or with a person on work
site traffic duty, be sure that all personnel know the nature of the
work and understand all hand signals that are to be used.
Always observe strictly any other rules related to safety.
Safety Features
Be sure that all guards and covers are installed in their proper
position. Have guards and covers repaired immediately if
damaged.
Be sure that you understand the method of use of safety
features such as safety lock lever and the seat belt, and use
them properly.
Never remove any safety features. Always keep them in good
operating condition.
Failure to use safety features according to the instructions in the
Operation and Maintenance Manual could result in serious
bodily injury.
SP000014
Track Excavator Safety
Page 13
Inside Operator's Cabin
When entering the operator's cabin, always remove all mud and
oil from the soles of your shoes. If you operate the travel pedal
with mud or oil stuck to your shoes, your foot may slip and this
may cause a serious accident.
After using the ashtray, make sure that any matches or
cigarettes are properly extinguished, and be sure to close the
ashtray. If the ashtray is left open, there is a danger of fire.
Do not stick suction pads to the window glass. Suction pads act
as a lens and may cause fire.
Do not leave lighters laying around the operator's cabin. If the
temperature inside the operator's cabin becomes high, there is a
danger that the lighter may explode.
Do not use cellular telephones inside the operator's cabin when
driving or operating the machine. There is a danger that this may
lead to an unexpected accident.
Never bring any dangerous objects such as flammable or
explosive items into the operator's cabin.
To ensure safety, do not use the radio or music headphones
when operating the machine. There is a danger that this may
lead to a serious accident.
When operating the machine, do not put your hands or head out
of the window.
When standing up from the operator's seat, always place safety
lock lever securely in the "LOCK" position. If you accidentally
touch the work equipment levers when they are not locked, the
machine may suddenly move and cause serious injury or
damage.
When leaving the machine, lower the work equipment
completely to the ground, set safety lock lever to the "LOCK"
position and shut down engine. Use the key to lock all the
equipment. Always remove key and take it with you.
Clothing and Personal Protective Items
Secure long hair, and avoid loose clothing and jewelry. These
items have the tendency to catch on controls or protrude into
parts and cause serious injury or death.
Do not wear oily clothes. They are flammable.
Full eye protection, a hard hat, safety shoes and gloves may be
required at the work site.
While working on the machine, never use inadequate tools. They
could break or slip, causing injury, or they may not adequately
perform intended functions.
HAOA020L
Figure 1
Page 14
SP000014Track Excavator Safety
Breathing Masks, Ear Protection May Be
Required
Do not forget that some risks to your health may not be
immediately apparent. Exhaust gases and noise pollution may
not be visible, but these hazards can cause disabling or
permanent injuries.
NOTE:
NOTE:
The equivalent continuous A-weighted sound
pressure level at the workstation for this machine is
given in the operation manual.
Measurement is obtained on a dynamic machine
following the procedures and cabin conditions as
described in ISO 6396.
The guaranteed sound power level emitted by the
machinery for this machine is given in the operation
manual.
Measurement is obtained on a dynamic machine with
the procedures as described in 2000/14/EC.
Vibration Level Information
Hands/Arms: The weighted root mean square acceleration to
2
which the hands/arms are subjected, is less than 2.5 m/s
Whole body: The weighted root mean square acceleration to
which the whole body is subjected, is less than 0.5 m/s
Measurements are obtained on a representative machine, using
measuring procedures as described in the following standard:
ISO 2631/1. ISO 5349, and SAE J1166.
.
2
.
Recommendations for Limiting Vibrations
1. Select the right machine, equipment and attachments for a
particular application.
2. Replace any damaged seat by a genuine
Keep the seat maintained and adjusted.
• Adjust the seat and suspension for the weight and
size of the operator.
• Inspect and maintain the suspension and adjustment
mechanisms of the seat regularly.
3. Check that the machine is properly maintained.
• Tire pressure, brakes, steering, linkages, etc.
4. Steer, brake, accelerate, shift gears, move the attachments
and load the attachments smoothly.
SP000014
DOOSAN
part.
Track Excavator Safety
Page 15
5. Adjust the machine speed and travel path to reduce the
vibration level.
• Slow down if it is necessary when traveling through
rough terrain.
• When driving machine, avoid obstacles and
excessive rough terrain.
6. Keep the machine on terrain where working and traveling
conditions are good.
• Remove any large rocks or obstacles.
• Fill any ditches and holes.
• Provide machines for and schedule time to maintain
good terrain conditions.
7. Travel over longer distances (e.g. on public roads) at
adjusted (medium) speed.
• Always adjust the speed to prevent bouncing.
Mounting and Dismounting
Before getting on or off the machine, if there is any oil, grease, or
mud on the handrails, steps, or track shoes, wipe it off
immediately. Always keep these parts clean. Repair any damage
and tighten any loose bolts.
Never jump on or off the machine. In particular, never get on or
off a moving machine. These actions may lead to serious injury.
When getting on or off the machine, always face the machine,
and maintain three-point contact (both feet and one hand or one
foot and both hands) with the handrails, steps, and track shoes
to ensure that you support yourself securely.
Never hold any control levers when getting on or off the
machine.
Apply the door lock securely. If you grip the handrail inside the
door when moving on top of the track shoes, and the door lock is
not applied securely, the door may move and cause you to fall.
Use the points marked by arrows in the diagram when getting on
or off the machine.
FG 00035
Figure 2
Page 16
SP000014Track Excavator Safety
Fuel, Oil and Hydraulic Fluid Fire Hazards
Fuel, oil and antifreeze will catch fire if it is brought close to a
flame. Fuel is particularly flammable and can be hazardous.
Always strictly observe the following.
Add fuel, oil, antifreeze and hydraulic fluid to the machine only in
a well ventilated area. The machine must be parked with
controls, lights and switches turned "OFF." The engine must be
"OFF" and any flames, glowing embers, auxiliary heating units
or spark causing equipment must be extinguished, turned "OFF"
and/or kept well clear of the machine.
Static electricity can produce dangerous sparks at the fuel filling
nozzle. In very cold, dry weather or other conditions that could
produce a static discharge, keep the tip of the fuel nozzle in
constant contact with the neck of the fuel filling nozzle, to
provide a ground.
Keep fuel and other fluid reservoir caps tight and do not start the
engine until caps have been secured.
Precautions When Handling Fluids at High
Temperature
Figure 3
Immediately after operations are stopped, the coolant, engine
oil, and hydraulic oil are at highest temperatures and the radiator
and hydraulic tank are still under pressure. Attempting to remove
cap, drain the oil or coolant, or replace the filters may lead to
serious burns. Always wait for the temperature to go down, and
follow the specified procedures when carrying out these
operations.
To prevent hot coolant from spurting out, shut down engine, wait
for the coolant to cool, then loosen the cap slowly to relieve the
pressure.
To prevent hot oil from spurting out, shut down engine, wait for
the oil to cool, then loosen the cap slowly to relieve the pressure.
HAOA050L
Figure 4
HAOA060L
Figure 5
SP000014
Track Excavator Safety
Page 17
Asbestos Dust Hazard Prevention
Asbestos dust can be HAZARDOUS to your health if it is
inhaled. Materials containing asbestos fiber can be present on
work site. Breathing air that contains asbestos fiber can
ultimately cause serious or fatal lung damage. To prevent lung
damage from asbestos fiber, observe following precautions:
• Use a respirator that is approved for use in an
asbestos-laden atmosphere.
• Never use compressed air for cleaning.
• Use water for cleaning to keep down the dust.
• Work on the machine or component with the wind at
your back whenever possible.
• Always observe any regulations related to the work
site and working environment.
Injury from Work Equipment
Do not enter or put your hand, arm or any other part of your body
between movable parts, such as between the work equipment
and cylinders, or between the machine and work equipment.
If the control levers are operated, the clearance between the
machine and the work equipment will change and this may lead
to serious damage or personal injury.
If going between movable parts is necessary, always position
and secure the work equipment so it cannot move.
ARO1770L
Figure 6
HDO1010L
Figure 7
Fire Extinguisher and First Aid Kit
As a precaution if any injury or fire should occur, always do the
following.
• Be sure that fire extinguishers have been provided
and read the labels to ensure that you know how to
use them. It is recommended that an appropriately
sized (2.27 kg [5 lb] or larger) multipurpose "A/B/C"
fire extinguisher be mounted in the cabin. Check and
service the fire extinguisher at regular intervals and
make sure that all work site crew members are
adequately trained in its use.
• Provide a first aid kit in the storage compartment and
keep another at the work site. Check the kit
periodically and make any additions if necessary.
• Know what to do in case of injury from fire.
• Keep emergency numbers for doctor, ambulance
service, hospital and fire department near your
telephone.
Page 18
HDO1009L
Figure 8
SP000014Track Excavator Safety
If the machine catches fire, it may lead to serious personal injury
or death. If a fire occurs during operation, escape from the
machine as follows:
• Turn the starter switch to the "O" (OFF) position and
shut down engine.
• If there is time, use the fire extinguisher to put out as
much of the fire as possible.
• Use the handrails and steps to escape from the
machine.
The above is the basic method for escaping from the machine,
but changing the method may be necessary according to the
conditions, so carry out practice drills at the work site.
Protection from Falling or Flying Objects
On work sites where there is a danger that falling objects or
flying objects may hit the operator's cabin select a guard to
match the operating conditions to protect the operator.
Working in mines, tunnels, deep pits or on loose or wet surfaces
could produce danger of falling rock or hazardous flying objects.
Additional protection for the operator's cabin could be required in
the form of a Falling Object Protective Structure (FOPS) or
window guards.
HAOA110L
Figure 9
Never attempt to alter or modify any protective structure
reinforcement system, by drilling holes, welding, remounting or
relocating fasteners. Any serious impact or damage to the
system requires a complete integrity reevaluation. Reinstallation,
recertification and/or replacement of the system may be
necessary.
Contact your
DOOSAN
distributor for available safety guards
and/or recommendations to prevent danger of getting hit by
objects that could strike the operator's cabin. Make sure that all
other work site crew members are kept well away from the
excavator and safe from possible hazards.
For breaker operation, install a front guard and apply a
laminated coating sheet to the front glass. Contact your
DOOSAN
distributor for recommendations.
When carrying out demolition or cutting operation, install a front
guard and top guard, and apply a laminated coating sheet to the
front glass.
When working in mines or quarries where there is a danger of
falling rock, install FOPS (Falling Objects Protective Structure)
and apply a laminated coating sheet to the front glass.
If any glass on the machine is broken, replace it with new glass
immediately.
HAOA100L
Figure 10
SP000014
Track Excavator Safety
Page 19
Attachment Precautions
Option kits are available through your dealer. Contact
for information on available one-way (single-acting) and two-way
(double-acting) piping / valving / auxiliary control kits. Because
DOOSAN
that owners may wish to install on their machines, please
contact
and their compatibility with optional kits.
cannot anticipate, identify or test all the attachments
DOOSAN
for authorization and approval of attachments,
DOOSAN
Accumulator
The pilot control system is equipped with an accumulator. For a
brief period of time after the engine has been shut down, the
accumulator will store a pressure charge that may enable
hydraulic controls to be activated. Activation of any controls may
enable the selected function to operate under force of gravity.
When performing maintenance on the pilot control system, the
hydraulic pressure in the system must be released as described
in "Handling of Accumulator" in the Operation and Maintenance
Manual.
The accumulator is charged with high-pressure nitrogen gas, so
it is extremely dangerous if it is handled in the wrong way.
Always observe the following precautions:
• Do not drill or make any holes in the accumulator or
expose it to any flames, fire or heat source.
• Do not weld on the accumulator, or try attaching
anything to it.
• When carrying out disassembly or maintenance of
the accumulator, or when disposing of the
accumulator, the charged gas must be properly
released. Contact your
• Wear safety goggles and protective gloves when
working on an accumulator. Hydraulic oil under
pressure can penetrate the skin and cause serious
injuries.
DOOSAN
distributor.
Indoor Ventilation
Engine exhaust gases can cause fatal accidents, and
unconsciousness, loss of alertness, judgment and motor control
and serious injury.
Make sure there is adequate ventilation before starting the
engine in any enclosed area.
You should also be aware of open windows, doors or ductwork
where exhaust may be carried, or blown by the wind, exposing
others to danger.
ARO1770L
Figure 11
Page 20
SP000014Track Excavator Safety
Emergency Exit
This machine is equipped with a glass breaking tool. It is behind
the operator seat in the upper right corner of the cabin. This tool
can be used in case of an emergency situation that requires the
breaking of glass to exit from the operator's cabin. Grip the
handle firmly and use the sharp point to break the glass.
WARNING!
Protect your eyes when breaking the glass.
FG000178
Figure 12
SP000014
Track Excavator Safety
Page 21
BEFORE STARTING ENGINE
Work Site Precautions
Before starting operations, thoroughly check the area for any
unusual conditions that could be dangerous.
Check the terrain and condition of the ground at the work site,
and determine the best and safest method of operation.
Make sure the ground surface is as hard and horizontal as
possible before carrying out operations. If there is a lot of dust
and sand on the work site, spray water before starting
operations.
If you need to operate on a street, protect pedestrians and cars
by designating a person for work site traffic duty or by erecting
fences and posting "No Entry" signs around the work site.
Erect fences, post "No Entry" signs, and take other steps to
prevent people from coming close to or entering the work site. If
people come close to a moving machine, they may be hit or
caught by the machine, and this may lead to serious personal
injury or death.
Waterlines, gas lines, phone lines and high-voltage electrical
lines may be buried under the work site. Contact each utility and
identify their locations. Be careful not to damage or cut any of
these lines.
Figure 13
DANGER
No Entry
FG000400
Check the condition of the riverbed, and the depth and flow of
the water before operating in water or crossing a river. NEVER
work in water that is more than the permissible water depth.
Any object in vicinity of boom could represent a potential hazard,
or cause the operator to react suddenly and cause an accident.
Use a spotter or signal person when working near bridges,
phone lines, work site scaffolds, or other obstructions.
Minimum levels of insurance coverage, work permits or
certification, physical barriers around the work site or restricted
hours of operation may be mandated by governing authorities.
There may also be regulations, guidelines, standards or
restrictions on equipment that may have to be followed for local
requirements. There may also be regulations related to
performing certain kinds of work. If there is any question about
whether your machine and work site complies with the
applicable standards and regulations contact your local
authorities and agencies.
Avoid entering soft ground. It will be difficult for the machine to
escape.
FG000363
Figure 14
FG000372
Figure 15
Page 22
SP000014Track Excavator Safety
Avoid operating your machine too close to the edge of cliffs,
overhangs, and deep ditches. The ground may be weak in such
areas. If the ground collapses, the machine could fall or tip over
resulting in serious injury or death.
Remember that soil after heavy rain, blasting or after
earthquakes, is weakened.
Newly laid earth and the soil near ditches is typically loose. It
can collapse under the weight of vibration of your machine and
cause your machine to tip over.
Install the head guard (FOPS) if working in areas where there is
a danger of falling rocks.
Checks Before Starting Engine
Every day before starting the engine for the first time, carry out
the following checks. If these checks are not carried out properly,
there is a danger of serious injury.
Remove all wood chips, leaves, grass, paper and other
flammable materials accumulated in the engine compartment
and around the battery. They could cause a fire. Remove any
dirt from the window glass, mirrors, handrails, and steps.
Do not leave tools or spare parts laying around in the operator's
cabin. The vibration of the machine when traveling or during
operations may cause them to fall and damage or break the
control levers or switches. They may also get caught in the gap
of the control levers and cause the work equipment to
malfunction or move dangerously. This may lead to unexpected
accidents.
Check the coolant level, fuel level, and hydraulic tank oil level,
and check for clogged air cleaner and damage to the electrical
wiring.
Adjust the operator's seat to a position where it is easy to
operate the machine, and check the seat belt and mounts for
damage and wear.
Check the operation of the gauges and the angle of the mirrors,
and check that the safety lever is in "LOCKED" position.
If any abnormalities are found in the above checks, carry out
repairs immediately.
SP000014
Track Excavator Safety
Page 23
Engine Starting
Walk around your machine before getting in the operator's cabin.
Look for evidence of leaking fluid, loose fasteners, misaligned
assemblies or any other indications of possible equipment
hazard.
All equipment covers and machinery safety guards must be in
place, to protect against injury while the machine is being
operated.
Look around the work site area for potential hazards, people or
property that could be at risk while operation is in progress.
NEVER start the engine if there is any indication that
maintenance or service work is in progress, or if a warning tag is
attached to controls in the cabin.
A machine that has not been used recently, or is being operated
in extremely cold temperatures, could require a warm-up or
maintenance service before start-up.
Check gauges and monitor displays for normal operation before
starting the engine. Listen for unusual noises and remain alert
for other potentially hazardous conditions at the start of the work
cycle.
Do not short-circuit the starting motor to start the engine. This is
not only dangerous, but may also damage the machine.
When starting the engine, sound the horn as an alert.
Start and operate the machine only while seated.
Before Operating Machine
If checks are not carried out properly after starting the engine, it
may result in a delay in discovering abnormalities in the
machine, and this may lead to personal injury or damage to the
machine.
Carry out the checks in an open area where there are no
obstructions. Do not let anyone near the machine when carrying
out the checks.
• Check the operating condition of the equipment, and
the movement of the bucket, arm, boom, travel, and
swing systems.
• Check the machine for any abnormal noise, vibration,
heat, smell, or abnormality with the gauges. Check
also for leakage of air, oil, and fuel.
• If any abnormality is found, repair the problem
immediately. If the machine is used without repairing
the problems, it may lead to unexpected injury or
failure.
• Clear all personnel from directly around machine and
from the area.
Page 24
SP000014Track Excavator Safety
• Clear all obstacles from the machine's path. Beware
of hazards.
• Be sure that all windows are clean. Secure the doors
and the windows in the open position or in the shut
position.
• Adjust the rearview mirrors for best visibility close to
the machine. Make sure that the horn, the travel
alarm (if equipped), and all other warning devices are
working properly.
• Fasten the seat belt securely.
• Warm up the engine and hydraulic oil before
operating machine.
• Before moving the machine, check undercarriage
position. The normal travel position is with idler
wheels to the front under the cabin and the drive
sprockets to the rear. When the undercarriage is in
the reversed position, the travel controls must be
operated in opposite directions.
SP000014
Track Excavator Safety
Page 25
MACHINE OPERATION
When Swinging or Changing Direction of
Travel
Before operating the machine or the work equipment, always
observe the following precautions to prevent serious injury or
death.
• Start and operate the machine only while seated.
• When changing travel direction from forward to
reverse or from reverse to forward, reduce speed
early and stop the machine before changing travel
direction.
• Sound the horn to warn people in the area.
• Check that there is no one in the area around the
machine. There are blind spots behind the machine,
so if necessary, swing the upper structure to check
that there is no one behind the machine before
traveling in reverse.
• When operating in areas that may be hazardous or
have poor visibility, designate a person to direct work
site traffic.
HAOA190L
Figure 16
• Ensure that no unauthorized person can come within
the turning radius or direction of travel.
Be sure to observe the above precautions even if a travel alarm
or mirrors are installed.
Page 26
SP000014Track Excavator Safety
Loading...