Manual de Operacion PDF

 

Operation and Maintenance Manual

DX220A-2/DX220LCA-2 Excavator

Serial Number 20001

DOOSAN and the DOOSAN logo are registered trademarks of DOOSAN Corporation in the United States world. and various other countries around the Copyright DOOSAN 2017© 

and Up

950106-01987E December 2017 Original Instructions

 

Table of Contents Foreword ............ ........................ ...................... ...................... ....................... ....................... ........................ ...............0-1 ...0-1 Safety ............ ........................ ...................... ...................... ........................ ....................... ....................... .....................1-1 .........1-1 To the Operator of a DOOSAN Excavator Excavator........................ ......................................... ................. 1-1 Safety Decals.... Decals.............................. ............................................... ........................................... .................................. ............ 1-4 General Gene ral ........ ................ ................. ................ ................ ................ ................ ................. ................ ................ ................ ........... ... 1-16 Transportation....................................... Transportation................. .............................................. ........................................... ................... 1-26 Operation Oper ation ......... ................ ................ ................ ................ ................. ................. ................ ................ ................. ............... ....... 1-28 Maintenanc Maint enance e ........ ................ ................ ................ ................ ................ ................. ................ ................ ................. ........... ... 1-44 Environment and Circumstances Circumstances...................... ............................................. ............................... ........ 1-60

Operating Controls ........... ....................... ........................ ........................ ....................... .....................2-1 ..........2-1 Component Locations Locations.................... .......................................... .............................................. .............................. ...... 2-2 Operator's Area............... Area.................................... .............................................. .............................................. ..................... 2-6 Operational Controls and Panels ...................... ........................................... ................................. ............ 2-8 Instrument Panel. Panel...................... ........................................... .............................................. .................................. .......... 2-17 Heater and Air Conditione Conditionerr Control Panel (Optiona (Optional) l)....................... ....................... 2-24 Stereo (Opti (Optional) onal) ........ ................ ............... ................ ................. ................. ................ ................ ................ ............ ..... 2-30 Miscellaneous Electrical Devices.... Devices......................... ............................................. ............................ .... 2-31 Seat Adjustment......................... Adjustment................................................ ............................................ ............................... .......... 2-33 Seat Adjustment (Suspension Seat - Optional) ....................... ............................... ........ 2-34 Seat Belt ........ ................ ................. ................ ................ ................ ................ ................. ................. ................ ................ ......... 2-36 Ceiling Ceili ng Cove Coverr ........ ................ ................. ................ ................ ................. ................ ................ ................ ................ .......... .. 2-37 Door Side Latc Latch h ....... ................ .................. .................. ................. ................ ................ ................. ................ ............ ..... 2-38 Cabin Cabi n Stora Storage ge Compa Compartmen rtments ts ........ ................. ................. ................ ................ ................ ................ ........ 2-38 Cup Holder....... Holder............................ ............................................. .............................................. ................................... ............. 2-39 Door Window Holder.... Holder........................ ............................................. ............................................... ........................ 2-39 Emergenc Emer gency y Glass Brea Breaking king Tool ........ ................ ................ ................ ................. ................ ............ ..... 2-39

DX220A-2/DX220LCA-2

Table of Contents  Contents  I

 

Miscellaneous Access Covers and Doors..................... Doors........................................ ................... 2-40

Operation............ Operation ........................ ...................... ...................... ....................... ....................... ........................ ...............3-1 ...3-1 To Hand Handle le a New Exca Excavator vator ........ ................. ................ ................ ................. ................ ................ ............. ..... 3-1 Starting and Stopping Engine .................. .......................................... .......................................... .................. 3-2 Safety Lever..... Lever.............................. ............................................... ............................................ ................................. ........... 3-15 Travel...................... Travel ............................................. ............................................. .............................................. ............................ .... 3-16 Operating Instructions........ Instructions............................... ............................................. ....................................... ................. 3-21 Operating Precautions ..................... .............................................. ............................................... ........................ 3-25 Parking Excavator........... Excavator................................ ............................................. ............................................ .................... 3-32 Towing Procedure............ Procedure..................................... ............................................... ....................................... ................. 3-33 Attachments ..................... ........................................... .............................................. .......................................... .................. 3-34 Hydraulic Attachments (Optional) ..................... .......................................... ............................... .......... 3-37 Lifting Liftin g Objec Objects ts ........ ................ ................. ................. ................ ................ ................. .................. ................. ............... ....... 3-42 Operation Under Unusual Conditions ...................... .............................................. ........................ 3-44 Long Term Storage .................... .......................................... .............................................. ................................ ........ 3-49

Inspection, Maintenance and Adjustment...............................4-1 Adjustment ...............................4-1 Maintenan Maint enance ce Infor Information mation ....... ................ ................ ................ ................. ................. ................ ................ ........... .. 4-1 Machine Mach ine Setup Position for Maint Maintenanc enance e ......... ................. ................ ................ ................ .......... 4-5 Maintenance Handling Access........................ Access.............................................. ................................... ............. 4-7 Table of Recommended Lubricants Lubricants..................... ............................................. .............................. ...... 4-8 Fluid Capa Capacities cities ........ ................ ................. .................. ................. ................ ................ ................. ................ ............ ..... 4-11 Lubrication and Service Chart................. Chart.......................................... ......................................... ................ 4-12 Maintenance Intervals..... Intervals............................ ............................................. .......................................... .................... 4-15 10 Hour / Daily Serv Service ice ........ ................ ................ ................ ................. ................ ................ ................. ........... ... 4-17 50 Hour / Week Weekly ly Serv Service ice ....... ................ ................ ................ ................. ................ ................ ................ ........ 4-28 250 Hour / Monthly Service........................... Service................................................. ................................... ............. 4-31 500 Hour / 3 Month Service ....................... ............................................ ...................................... ................. 4-37 1,000 Hour / 6 Month Service ....................... ............................................ ................................... .............. 4-47 2,000 Hour / Yearly Service ...................... ............................................ ....................................... ................. 4-56 4,000 4,00 0 Hour / Bienn Biennial ial Serv Service ice ......... ................. ................ ................ ................. ................ ............... .......... 4-61 12,000 Hour / 6 Year Service........................... Service................................................... ................................ ........ 4-62

Table of Contents  II

DX220A-2/DX220LCA-2

 

Air-Cond AirConditioni itioning ng Syste System m ........ ................. ................ ................ ................. ................. ................ ............... .......... 4-63 Bolt and Nut Inspection....... Inspection............................. ............................................ ....................................... ................. 4-64 Bucket..................... Bucket ............................................ ............................................. .............................................. ............................ .... 4-72 Electrica Elect ricall Syste System m ....... ................ ................ ................ ................. ................ ................ ................. ................ ............ ..... 4-74 Engine Cooling System.................... System............................................. ............................................... ........................ 4-78 Handling of Accumulator............ Accumulator.................................. .............................................. ................................ ........ 4-81 Track Trac k Tensi Tension on ................. ......................... ............... ................ ................. ................ ................ ................. ................. ........ 4-82 Venting and Priming Hydraulic System.................... System............................................ ........................ 4-84 Long Term Storage .................... .......................................... .............................................. ................................ ........ 4-86 Maintenance in Special Conditions.. Conditions........................ .............................................. .......................... .. 4-88

Transportation ........................ ................................... ....................... ...................... ...................... ..................5-1 ......5-1 Loading and Unloading Unloading.................. ........................................ .............................................. .............................. ...... 5-2 Lifting Machine..... Machine.......................... ............................................. ............................................. ................................. ............ 5-8

Specification ........................ .................................. ...................... ....................... ...................... .....................6-1 ..........6-1 Standard Specification ...................... .............................................. .............................................. ......................... ... 6-1 Overall Dimensions........ Dimensions............................... ............................................. ............................................. ....................... 6-2 Disassembled Parts, Dimension and Weight. Weight...................... .................................... ............... 6-3 Ground Pressure.............................. Pressure.................................................... .............................................. ............................ .... 6-5 Digging Force........................ Force................................................ .............................................. ..................................... ............... 6-6 Working Wor king Range ........ ................ ................ ................ ................. ................ ................ ................. ................ ................ .......... 6-8 Excavator Rated Lift C Capacity apacity Tables.. Tables.......................... ............................................ .................... 6-10 Approximate Weight of Wo Workload rkload Materials..... Materials............................. ................................ ........ 6-28

Index ...........................................................................................7-1

DX220A-2/DX220LCA-2

Table of Contents  Contents  III

 

Table of Contents  IV

DX220A-2/DX220LCA-2

 

Foreword This Operation & Maintenance Manual was written to give owner or operator instructions on safe operation and maintenance of DOOSAN equipment. READ AND UNDERSTAND THIS OPERATION AND MAINTENANCE MANUAL BEFORE OPERATING YOUR DOOSAN EQUIPMENT. Keep this manual in the cabin so it is always available. If it is lost, order another one from your DOOSAN distributor. If there are any questions, contact your DOOSAN distributor. This manual may illustrate options and accessories not installed on your equipment. Any modification made without written authorization or approval from DOOSAN can create a safety hazard. Always replace parts with genuine DOOSAN parts or DOOSAN authorized replacement parts.

Intended Use The machine is intended to be used under normal conditions for applications described in this manual. If it is used for other purposes, or in potentially hazardous environments, special precautions must be followed and the machine must be equipped for such use. Examples include, but are not limited to, are: falling object guards, work lights, etc. Do not engage in prohibited uses as described in this manual. Contact your DOOSAN distributor for further information.

Engine and Emission Control System Maintenance Proper inspection, maintenance and repair is essential to keeping engine and machine systems properly operating. This includes proper inspection and maintenance of the machine's emission control system. This could include machine and engine components, such as a fuel system, turbocharger, electrical system, air intake system and/or cooling system. As a heavy-duty off-road diesel engine owner, you are responsible for performing required maintenance. The required maintenance procedures are outlined in this Operation & Maintenance Manual, or Shop Manual. Do not remove, alter, or render inoperative, any emission control system.

DX220A-2/DX220LCA-2

Foreword  Foreword  0-1

 

Machine Capacity Do not exceed machine capacity by modifying machine or using unapproved attachments. Exceeding machine capacity can adversely affect machine performance characteristics such as: stability, system certifications such as brakes and steering, and can result in death or serious injury. Contact your DOOSAN distributor for further information.

Attachments These and other attachments are approved for use on this machine. Do not use unapproved attachments. Attachments not manufactured by DOOSAN may not be approved. See your DOOSAN distributor for information about approved attachments and attachment manuals. •

Buckets

•

Hydraulic Breakers

•

Grapples

•

Plate Compactors

•

Quick Couplers

Foreword  0-2

DX220A-2/DX220LCA-2

 

Product Identification Number (PIN) A PIN number is stamped on upper frame under boom foot (Figure 1). 1). It is also stamped on a product identification plate (Figure 2) 2) on outside of cabin on right-hand side. NOTE:

Record these numbers and their locations. These will be required whenever warranty or service work is requested. Keep these numbers on file in case machine is stolen. FG001447

Figure 1

DOOSAN INFRACORE CHINA CO., LTD NO.28 WUZHISHAN ROAD, ECO&TECH DEVELOPMENT AREA YANTAI SHAN DONG

MODEL

PRODUCT IDENTIFICATION NUMBER

MADE IN CHINA

950209-07558

DS1704062

Figure 2

Component Serial Numbers There are many serial numbers on each traceable component of the machine. Record these numbers and their locations. These will be required whenever warranty service work is requested.

DX220A-2/DX220LCA-2

Foreword  Foreword  0-3

 

Engine Identification Engine Data Plate The engine data plate provides important facts about the t he engine. The engine serial number (ESN) and control parts list (CPL) provide information for service and ordering parts. The engine data plate must not be changed unless approved by DOOSAN. 2

The engine data plate and engine serial number are located on the head cover. Have the following engine data available when communicating with a DOOSAN Authorized Repair Location. The following information on data plate is mandatory when sourcing service parts:

1 DS1602358

Reference Number

Description

1

Engine Data Plate

2

Engine Serial Number

Figure 3

Your Machine Serial Numbers Product Identification Number (PIN) Machine Serial No. Engine Serial No. Main Pump Swing Motor Travel Motor Main Control Valve

Safety Messages Safety messages and safety decals included in this manual and on the machine provide instructions how to operate, service and maintain the machine. Safety messages and safety decals indicate potential hazards and describe safety precautions required to avoid hazards. Operator and maintenance personnel should read and understand these safety messages and decals before beginning operation or maintenance.

 SAFETY ALERT SYMBOL Be Prepared - Get to Know All Operating and Safety Instructions. This is a Safety Alert Symbol. Wherever it appears in this manual or on safety decals on the machine, you must be alert to the potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures.

Foreword  0-4

DX220A-2/DX220LCA-2

 

Signal Words The signal words "DANGER", "WARNING", "CAUTION" are used throughout safety messages and safety decals in this manual or on the machine. They indicate an existence of, and the relative seriousness of, a hazard. All three indicate that a safety risk is involved. Observe the precautions indicated whenever a Safety Alert Symbol is present, no matter which signal word appears next to it.

 DANGER DANGER - This signal word is used on safety messages and safety labels and indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

 WARNING WARNING - This signal word is used on safety messages and safety labels and indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

 CAUTION CAUTION - This signal word is used on safety messages and safety labels and indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

Other Signal Words In addition to safety signal words, the following signal words are used to indicate proper and effective use of machine.

IMPORTANT This signal word identifies procedures which must be followed to avoid damage to machine. NOTE:

The word "NOTE" identifies information for effective use.

DX220A-2/DX220LCA-2

Foreword  Foreword  0-5

 

Foreword  0-6

DX220A-2/DX220LCA-2

 

1Safety TO THE OPERATOR OF A DOOSAN EXCAVATOR  DANGER AVOID DEATH 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.

"Safety Decals" on page 1-4

2.

"General" on page 1-16

3.

"Transportation" on page 1-26

4.

"Operation" on page 1-28

5.

"Maintenance" on page 1-44

6.

"Environment and Circumstances" on page 1-60

DX220A-2/DX220LCA-2

Safety  Safety  1-1

 

 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 any others. In no event should you or others engage in prohibited uses or actions as described in this manual. DOOSAN delivers machines that comply with all applicable 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 or your DOOSAN distributor before operating the machine.

 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.

Safety  1-2

DX220A-2/DX220LCA-2

 

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 "Exclamation Point" symbol.

 CAUTION This word is used on safety messages and safety labels and indicates potential 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  threat  of a hazardous situation that, if not avoided, could result in serious injury or death. It may also be used to alert against a 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 explode or detonate if handled or treated carelessly.

Other Signal Words In addition to safety signal words, the following signal words are used to indicate proper and effective use of machine.

IMPORTANT This signal word identifies procedures which must be followed to avoid damage to machine. NOTE:

The word "NOTE" identifies information for effective use.

DX220A-2/DX220LCA-2

Safety  Safety  1-3

 

SAFETY DECALS Safety decals are attached to the machine to alert the operator or maintenance person about potential hazards, the consequences of potential injury, and instructions and/or actions required to avoid the hazard. The location of the safety decals and the description of the decals are reviewed in the following section. Please become familiarized with all safety decals and their messages. Make sure that all the safety decals are in their correct location and legible. Clean or or the replace decals if they are damaged, missing, texts the and safety pictorials are not legible. When you clean the safety decals, use a soft cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety decals because this could loosen the adhesive that secures the decals to the machine. Remember, if a safety decal is attached to a part that is replaced, install a new safety decal on the replacement part. This machine uses safety decals with and without text. The type and number of safety decals can vary depending upon geographical regions and machine models. Safety Decals With Text Safety decals panel. with text consist of a signal word, pictorial andbe a text message In some cases, a pictorial panel may not part of the safety decal.

Safety  1-4

DX220A-2/DX220LCA-2

 

Safety Decals Without Text (No-Text)

Vertical Configuration

Safety decals without text consist of a hazard panel(s) and avoidance panel(s). Hazard panels are located at the top or left side and the avoidance panels are located at the bottom or right side of the decal depending on its configuration. The hazard panels use a black triangular band and a pictorial to identify the hazard and the potential consequences of failure to follow the instructions. Avoidance panels use pictorials and/or prohibition signs to identify the actions necessary to avoid the hazard.

Hazard Panel

A safety decal may contain more than one hazard panel and more than one avoidance panel.

Avoidance Panel

Horizontal Configuration

Hazard Panel

Avoidance Panel FG018723

Figure 4

DX220A-2/DX220LCA-2

Safety  Safety  1-5

 

Information and Location for Safety Decals

20

19

23

15

19

1

DS1703687

Figure 5

Safety  1-6

DX220A-2/DX220LCA-2

 

Information and Location for Safety Decals (Continued)

4

6

5

12

16, 7, 8

17

20

18

9

18 DS1703688

Figure 6

DX220A-2/DX220LCA-2

Safety  Safety  1-7

 

1.

Ge Gene nera rall Ha Haza zard rd (950 (95020 2055-03 0380 804) 4)

1

2

3

EX1301176

 WARNING AVOID DEATH OR SERIOUS INJURY •

Neve Neverr use use ex exca cava vato torr wit witho hout ut in inst stru ruct ctio ions ns..

•

Read Read Oper Operat atio ion n & Main Mainte tena nan nce Manu Manual al befo before re

•

operation. Soun Sound d tthe he horn horn to al aler ertt bys bysta tand nder ers s bef befor ore e operating.

•

Always fasten ten your seat seat belt.

•

Expl Explos osio ion n or electr electroc ocut utio ion n can can oc occu curr if mach machin ine e contacts utility lines or pipes. Check for overhead or underground lines before operating.

•

Se Secu cure re an and d loc lock k fron frontt wind window ow when when it is is in rais raised ed position.

•

At Atta tach chme ment nt in inter terfe fere renc nce e can can caus cause e de deat ath, h, seri seriou ous s injury or machine damage. Check attachment to machine clearance through full working cycle before operation.

•

Keep Keep byst bystan ande ders rs out out of of swi swing ng ar area ea an and d tra trave vell path and always look in the travel direction.

•

Ensu Ensure re mirr mirror ors s and and rear rear vi view ew ca came mera ra ar are e cle clean an and working properly.

•

Neve Neverr oper operat ate e mac machi hine ne operator's position.

•

TO LEAVE THE EXCAVATOR:

Safety  1-8

fr from om

outs outsid ide e

th the e

1)

Lo Lowe werr the the atta attach chme ment nt and and doz dozer er bl blad ade e (if (if equipped) to the ground and make sure all controls are in neutral.

2)

Stop top en engin gine an and rem remo ove ke key y.

3)

Lo Lowe werr sa safet fety y leve leverr to LOCK LOCK po posi siti tion on.. DX220A-2/DX220LCA-2

 

2.

Warn Warnin ing g Tag Tag - "D "Do o Not Not Ope Opera rate te"" (9502 (950205 05-0 -038 3802 02))

 WARNING AVOID DEATH OR SERIOUS INJURY

3.

•

Stop top engine an and d remo emove key key.

•

At Atta tach ch "D "DO O NOT NOT OPER OPERAT ATE" E" warn warnin ing g tag tag to th the e controls before servicing the machine.

•

Do not not o ope pera rate te whe when n per perfo form rmin ing g ins inspe pect ctio ion n or or maintenance.

EX1301177

Ke Keep ep Bys Bysta tan nders ders Awa Away y (950 (95020 2055-03 0380 803) 3)

 WARNING AVOID DEATH OR SERIOUS INJURY •

Keep Keep out of swi swing ng are area an and tra trave vell pat path h.

•

Al Alwa ways ys lo loo ok in in tth he ttrrav avel el di dirrec ecti tio on.

•

Make Make su sure re sw swin ing g are area a is is c cle lear ar of byst bystan ande ders rs an and d objects.

4.

Hot Hot Pres Pressu suri rize zed d Fl Flui uid d (9 (950 50205 205-03 -0378 781) 1)

 WARNING HOT PRESSURIZED FLUID CAN CAUSE SERIOUS BURNS

5.

•

Do not llo oos osen en or op open ca cap p when when hot.

•

Before opening:

EX1301180

1)

Turn engine off.

2)

All llo ow m ma achine tto o co cool.

3)

Ti Tip p ca cap p an and d ope open n slow slowly ly to to reli reliev eve e pres pressu sure re..

Enta Entang ngle leme ment nt iin n Rota Rotati ting ng Par Parts ts (950 (95020 205-0 5-0379 3791) 1)

 WARNING ROTATING PARTS CAN CAUSE DEATH OR SERIOUS INJURY Keep away from belt and rotating parts. Stop engine before servicing.

DX220A-2/DX220LCA-2

EX1301181

Safety  Safety  1-9

 

6.

Rota Rotati tin ng Fan Fan (950 (95020 2055-03 0378 788) 8)

 WARNING CONTACT WITH ROTATING FAN CAN CAUSE DEATH OR SERIOUS INJURY Keep away from fan and rotating parts. Stop engine before servicing.

950205-03788

EX1301182

7.

Ba Batt tter ery y Expl Explos osio ion n (9 (950 5020 2055-03 0378 785) 5)

 WARNING AVOID DEATH OR SERIOUS INJURY

8.

•

Read Read an and d fol follo low w ins instr truc ucti tion ons s in in O Ope pera rati tion on & Maintenance Manual for battery maintenance.

•

Keep Keep ar arcs cs,, spar sparks ks,, flam flames es,, and and ligh lighte ted d tob tobac acco co away.

•

Do not not s sto tore re meta metall tool tools s or or ffla lamm mmab able le mate materi rial als s on or around batteries.

•

Wear Wear sa safe fety ty gogg goggle les s and and rubb rubber er gl glov oves es when when working with batteries.

•

If b ba attery ac acid co contact o oc ccurs: 1)

Fl Flus ush h you yourr skin skin wit with h water water imme immedi diat ately ely and and apply baking soda or lime to neutralize the acid.

2)

Fl Flus ush h you yourr eye eyes s w wit ith h wat water er for for 10 10 - 15 minutes.

3)

Ge Gett me medi dica call atten attenti tion on imm immed edia iate tely ly..

EX1301183

Batt Batter ery y Di Disc scon onne nect ctio ion n (9502 (950205 05-0 -037 3784) 84)

IMPORTANT AVOID ELECTRICAL COMPONENT DAMAGE Disconnecting the battery while the engine is running can cause damage to electrical components. Disconnect battery only when the engine is turned OFF.

Safety  1-10

DX220A-2/DX220LCA-2

 

9.

Fl Flyin ying gD Deb ebri ris s or or O Obj bjec ects ts (9 (9502 50205 05-0 -038 3866 66))

 WARNING HIGH-PRESSURE GREASE CAN CAUSE DEATH OR SERIOUS INJURY •

Trac Track k adju adjust stin ing g sys syste tems ms use use gre greas ase e und under er hi high gh-pressure which can penetrate body if improperly serviced.

•

NEVE NEVER R LOO LOOSE SEN N tra track ck ten tensi sion on grea grease se val valve ve mor more e than one complete turn from the fully tightened position.

•

Bl Blee eed d off off pres pressu sure re sl slow owly ly an and d kee keep p bod body y awa away y from grease valve.

•

Wear eye protection.

•

Read Read an and d fol follo low w ins instr truc ucti tion ons s in in O Ope pera rati tion on & Maintenance Manual for more information on track adjustment.

EX1301185

10. Crus Crush h Haza Hazard rd ((95 95020 0205-0 5-038 3805 05))

 WARNING AVOID DEATH OR SERIOUS INJURY Stay clear of the boom, arm, and attachment.

EX1301186

11. Pressu Pressuriz rized ed Gas Gas and and Fluid Fluid (950205(950205-037 03782) 82)

 WARNING AVOID DEATH OR SERIOUS INJURY •

Heat Heat or im impa pact ct ca can n cau cause se th the e acc accum umul ulat ator or to explode.

•

Keep away from flame.

•

Do not not w wel eld d on or dril drilll iint nto o acc accum umul ulat ator or..

DX220A-2/DX220LCA-2

EX1301187

Safety  Safety  1-11

 

12. 12.

Fa Fall ll Haz Hazar ard d (950 (95020 2055-03 0378 783) 3)

 WARNING AVOID DEATH OR SERIOUS INJURY Do not step in this area.

EX1301188

13. Hot Hot Surf Surfac ace e (950 (95020 2055-03 03777 777))

 WARNING HOT SURFACE CAN CAUSE SERIOUS BURNS •

Do not touch hot surface.

•

Al Allo low w to coo ooll be befo fore re se serv rvic icin ing g. EX1301189

14. Emer Emerge genc ncy y Exit Exit (950 (95020 2055-03 03810 810))

IMPORTANT If primary exit is blocked, use glass breaking tool to break glass for secondary exit. EX1301190

15. ISO Contro Controll P Patte attern rn (950 (950205 205-03 -03860 860))

 WARNING AVOID INJURY OR DEATH Read and understand the Operation & Maintenance Manual for more information. Refer to "Operating Instructions" section of this manual for details regarding the work levers (joysticks) control functions.

Safety  1-12

DX220A-2/DX220LCA-2

 

16. 16.

Fa Fall llin ing g Objec Objectt (95020 (9502055-03 0378 786) 6)

 WARNING UNSUPPORTED DOOR CAN FALL CAUSING DEATH OR SERIOUS INJURY •

•

To open door: 1)

Hold door firmly.

2)

Li Lift ft do door or engages.

sl slow owly ly

un unti till

loc lockin king g

dev devic ice e

To close door: 1)

Hold door firmly.

2)

Pr Pres ess s lock lockin ing g devi device ce to to dise diseng ngag age. e.

3)

Lower door slowly ly..

EX1301198

17. Hydrau Hydraulic lic Breaker Breaker (950 (950205 205-XX -XXXXX XXX)) WARNING

IMPORTANT

Adjust flow rate setting of Breaker Package Valve within flow rate limit of Breaker.

AVOID HYDRAULIC SYSTEM DAMAGE 950205-XXXXX

To adjust breaker impact, see Operation Maintenance Manual for additional instructions.

& DS1703689

18. Li Lift ft/T /Tie ie down down ((950 95020 205-0 5-038 3815) 15) Identifies lift point and tie down point location.

950205-03815

EX1301201

DX220A-2/DX220LCA-2

Safety  Safety  1-13

 

19. Ti Tie e dow down n (9 (950 5020 205-0 5-038 3816 16A) A) Identifies tie down point location.

950205-03816A DS1704063

20. Electr Electric ic We Weldi lding ng Atte Attenti ntion on (95021 (950212-0 2-0244 2440) 0)

IMPORTANT Electrical welding on the frame can damage the electronic parts. 950212-02440

EX1402396

21. Ultra Ultra Low Low Sulf Sulfur ur Dies Diesel el Fuel Fuel (Opti (Option onal) al) (950205-03863, 950205-03864)

ULTRA LOW SULFUR DIESEL FUEL ONLY

IMPORTANT Only use Ultra Low Sulfur Diesel (ULSD) fuel with this machine.

EX1301196

EX1301194

Safety  1-14

DX220A-2/DX220LCA-2

 

22. Hydrau Hydraulic lic Oil Check Check (Optio (Optional nal)) (950205-03965, 950205-06282)

IMPORTANT INCORRECT OIL LEVEL OR INCORRECT FLUID CAN CAUSE HYDRAULIC SYSTEM DAMAGE Place the excavator with the boom and arm fully extended with the attachment on the ground before checking hydraulic fluid level. Use hydraulic oil which is suitable for machine.

EX1505098

68

950205-06282

EX1505099

23. Work Work Le Lever ver (9 (950 5020 205-0 5-072 7269) 69)

IMPORTANT Before you operate the work lever, read the Operation & Maintenance Manual carefully.

950205-07269

DS1704064

DX220A-2/DX220LCA-2

Safety  Safety  1-15

 

GENERAL Safe Operation is Operator's Responsibility Only trained and authorized personnel should operate and maintain the machine. Follow all safety rules, regulations and instructions when operating or performing maintenance on machine. • Do no nott oper operat ate e mac machi hine ne if you you a are re un unde derr the the inf influ luen ence ce of drugs or alcohol. An operator who is taking prescription drugs must get medical advice to determine if he or she can safely operate a machine. •

When When work workin ing g wit with ho oth ther er pe pers rson onne nell o on n a work work site site,, b be e sur sure e that all personnel know nature of work and understand all hand signals that are to be used.

•

Be sure sure th that at all all gua guard rds s a and nd shie shield lds s are are in inst stal alle led d iin n the their ir proper location. Have guards and shields repaired or replaced immediately if damaged.

•

Be sur sure e ttha hatt y you ou under underst stan and d the the use use and and main mainte tenan nance ce of all safety features such as safety lever and seat belt. Use them properly.

•

Neve Neverr rrem emov ove, e, modi modify fy or disa disabl ble e any any safet safety y fea featur tures es.. Always keep them in good operating condition.

•

Alwa Always ys check check fo forr and and know know the the loc locati ation on of un unde derg rgro roun und d and overhead utility lines before excavating.

•

Failu Failure re to use use and and main mainta tain in safet safety y ffea eatur tures es ac acco cord rdin ing g to to instructions in this manual, Safety Manual and Shop Manual can result in death or serious injury.

Know Your Machine Know how to operate your machine. Know the purpose of all controls, gauges, signals, indicators and monitor displays. Know the rated load capacity, speed range, braking and steering characteristics, turning radius and operating clearances. Keep in mind that rain, snow, ice, loose gravel, soft ground, slopes etc., can change operating capabilities of your machine.

Safety  1-16

DX220A-2/DX220LCA-2

 

Proper Work Tools and Attachments Only use work tools and attachments that are recommended by DOOSAN for use on DOOSAN machines. When installing and using optional attachments, read instruction manual for attachment, and general information related to attachments in this manual. Because DOOSAN cannot anticipate, identify or test all attachments that owners may want to install on their machines, contact DOOSAN for written authorization and approval of attachments, and their compatibility with optional kits. Attachments and attachment control systems that are compatible with the machine are required for safe and reliable machine operation. Do not exceed maximum operating weight (machine weight plus attachment). Make sure that all guards and shields are in place on machine and on work tool. Depending on type or combination of work equipment, there is a potential that work equipment could interfere with the cabin or other parts of machine. Before using unfamiliar work equipment, check if there is any potential of interference, and operate with caution. While you are performing any maintenance, testing, or adjustments to attachments, stay clear of the following areas: cutting edges, pinch points, and crushing surfaces. Never use attachment as a work platform or manlift. Contact your DOOSAN distributor about auxiliary hydraulic kits for attachments installation. If you are in doubt about compatibility of a particular attachment with a machine, consult your DOOSAN distributor.

Pressurized Fluids Pressurized air or fluids can cause debris and/or fluids to be blown out. This could result in death or serious injury. Immediately after operations are stopped, coolant, engine oil, and hydraulic oil are at their highest temperatures and the radiator and hydraulic tank are still under pressure. Always wait for temperature to cool down. Follow specified procedures when attempting to remove caps, drain oil or coolant, or replacing filters. Always wait for temperature to cool down, and follow specified procedures when performing these operations. Failure to do so can result in death or serious injury.

FG018457

Figure 7

When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield. Pressure can be trapped in a hydraulic system and must be relieved before maintenance is started. Releasing trapped pressure can cause sudden machine movement or attachment movement. Use caution if you disconnect hydraulic lines or fittings. DX220A-2/DX220LCA-2

Safety  Safety  1-17

 

High-pressure oil that is released can cause a hose to whip or oil to spray. Fluid penetration can result in death or serious injury. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury. Obey all local laws and regulations for disposal of liquids. To prevent hot coolant from spraying out, stop engine and wait for coolant to cool. Using gloves, slowly loosen cap to relieve pressure.

Flying or Falling Objects On work sites where there is a potential hazard that flying or falling objects can hit operator's cabin, select and use a guard to match operating conditions for additional operator protection. Working in mines, tunnels, deep pits, and loose or wet surfaces, could produce hazard of falling rocks or flying objects. Additional protection for operator's cabin could be required such as an Operator Protection Guard (OPG) or window guards. Contact your DOOSAN distributor for information on available protective guards. To prevent personnel from being struck by flying objects, keep personnel out of work area.

HAOA110L

Figure 8

HAOA100L

Figure 9

Safety  1-18

DX220A-2/DX220LCA-2

 

Personal Protective Equipment (PPE) Do not wear loose clothing and accessories. Secure long hair. These items can snag on controls or on other parts of equipment. Do not wear oily clothes. They are highly flammable. 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. Breathing masks and/or ear protection may be required. Wear a hard hat, safety shoes, safety goggles, mask, leather gloves, earplugs and other protective equipment, as required.

HAOA020L

Figure 10

While working on machine, never use inadequate tools. They could break or slip, or they may not n ot adequately perform intended functions.

Correction of Machine Problems If any machine problems are found during operation and maintenance (noise, vibration, smell, incorrect gauges, smoke, oil leakage, etc.), or if any abnormal warning alerts are displayed on display monitor, stop the machine and take the necessary corrective actions. Do not operate machine until problem has been corrected.

Crushing and Cutting Keep objects away from moving fan blades. Fan blades can throw and cut objects. Do not use a wire rope that is kinked or frayed, or a wire rope with any loss of diameter. Wear leather gloves when handling a wire rope. When striking a loose retainer pin, it can fly out and can cause a serious injury. Make sure that area is clear of personnel when striking a retainer pin. To avoid injury to your eyes, wear safety goggles when striking a retainer pin. Do not put your hand, arm or any other part of your body between movable parts. If going between movable parts is necessary, always position and secure work equipment so it cannot move. Properly support equipment before performing any work or maintenance under raised equipment. If control levers are operated, clearance between machine and work equipment will change and this may lead to serious damage or can result in death or serious injury. Stay clear of areas that may have a sudden change in clearance with machine movement or equipment movement. Stay clear of all rotating and moving parts. Unless instructed, never attempt adjustments while machine is moving or while engine is running.

DX220A-2/DX220LCA-2

Safety  Safety  1-19

 

Do not depend on hydraulic cylinders to support raised equipment. Equipment can fall if a control is moved, or if a hydraulic line breaks, is loosened or disconnected. If it is necessary to remove guards to perform maintenance, always install guards after maintenance is completed.

HDO1010L

Figure 11

Hot Coolant and Oils - Burn Prevention Do not touch any part of an operating engine. Immediately after operations are stopped, coolant, engine oil, and hydraulic oil are at their highest temperatures. The radiator and hydraulic tank are still under pressure. Always wait for temperature to cool down. Attempting to remove caps, drain oil or coolant, or replacing filters may lead to serious burns, if done when hot. Relieve all pressure in air system, hydraulic oil system, lubrication system, fuel system, and cooling system, before any FG019095

lines, fittings or related items are disconnected. Figure 12 To prevent hot oil or coolant from spraying out, stop engine, wait for oil and coolant to cool. Using gloves, slowly loosen cap to relieve pressure.

FG019096

Figure 13

Safety  1-20

DX220A-2/DX220LCA-2

 

Fire and Explosion Prevention All fuels, most lubricants and some coolant mixtures are flammable and can cause a fire resulting in death or serious injury, and property damage. Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause fire. Inspect for and remove all flammable materials such as spilled fuel and oil, and debris from machine. Do not allow any flammable materials to accumulate on machine. HDO1015I

Always observe the following: •

Add Add ffue uel, l, oil oil,, anti antifr free eeze ze and and hydr hydrau auli lic c flui fluid d to to ma mach chin ine e only only in a well ventilated area. Machine must be parked with controls, lights and switches turned "OFF". Engine must be "OFF" and any flames, glowing embers, auxiliary heating units or spark causing equipment must be extinguished, or turned "OFF" and kept well clear of machine.

•

Dust Dust that that is ge gene nera rate ted d ffro rom m repa repair irin ing g or or grin grindi ding ng nonmetallic hoods or nonmetallic fenders can be toxic, flammable and explosive. Repair these components in a well ventilated area away from flames or sparks and wear dust mask when grinding painted parts.

Figure 14

FG018458

Figure 15 Maintenance The machine and some attachments have components that are at high temperatures under normal operating conditions. The primary source of high temperatures are the engine and exhaust system. If damaged or incorrectly maintained, the electrical system can be a source of arcs or sparks. Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it can cause a fire hazard. Clean machine often to avoid this accumulation. Flammable debris in an engine compartment is a potential fire hazard. The operator's area, engine compartment and engine cooling system must be inspected every day and cleaned. This is necessary to prevent fire hazards and overheating. Operation Do not use machine where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases. Do not operate machine near any flame. Exhaust shields (if equipped) protect hot exhaust components from oil spray or fuel spray in case of a break in a line, hose, or seal. Exhaust shields must be correctly installed.

DX220A-2/DX220LCA-2

Safety  Safety  1-21

 

Electrical Check all electrical wiring and connections for damage daily. Keep battery terminals clean and tight. Repair or replace any damaged part or wires that are loose or frayed. Clean all electrical connections and tighten all electrical connections. Never check battery charge by placing a metal object across terminal posts. Use a voltmeter or a hydrometer. Battery gas can explode and can result in death or serious injury. Follow procedures in this manual for connecting battery and for jump-starting. Do not jump-start or charge a frozen or damaged battery. Keep any flames or sparks away from batteries. Do not smoke in battery charging area. Improper jumper cable connections can cause an explosion that can result in death or serious injury. Refer to "Starting Engine Engine   With a Booster Cable" on page 3-9, 3-9 , for proper procedure in this manual. Do not charge a frozen battery. This can cause an explosion. After market radios or other electric operated equipment in cabin must have a fuse in the electrical circuit. Hydraulic System Check hydraulic tubes, hoses and fittings for damage, wear or for leaks. Hydraulic lines and hoses must be properly routed and have adequate support and secure clamps. Leaks can cause fires. Never use a flame or bare skin to check for leaks. Tighten or replace any parts that show leakage. Check that all hose and tube clamps, guards, and cushions are securely attached. If they are loose, they can vibrate during operation and rub against other parts. This can cause damage to hoses and cause high-pressure oil to spray on hot surfaces, causing a fire and death or serious injury. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

EX1400129

Figure 16

Safety  1-22

DX220A-2/DX220LCA-2

 

Fueling Use caution when you are refueling a machine. Fuel is flammable and can catch fire if it is brought close to a flame. Stop engine and let it cool before adding fuel. Do not smoke while you are refueling a machine. Do not refuel a machine near flames or sparks. Fill fuel tank outdoors. Keep fuel and other fluid reservoir caps tight and do not start engine until caps have been secured. Store fuels and lubricants in properly marked containers away from unauthorized personnel. Store oily rags and any flammable materials in protective containers. Static electricity can produce dangerous sparks at fuel filling nozzle. In very cold, dry weather or other conditions that could produce a static discharge, keep tip of fuel nozzle in constant contact with neck of fuel filling nozzle, to provide a ground.

EX1400130

Figure 17

Always place plastic fuel containers on the ground before filling. Never Use Ether Starting Aids Do not use ether or starting fluids on any engine that has glow plugs, or an electric grid type manifold heater. These starting aids can cause an explosion and result in death or serious injury. Use procedures in this manual for connecting battery and for  jump-starting.

FG018458

Figure 18 Welding and Grinding Always clean machine and attachment, set battery disconnect switch to "OFF" position, and disconnect wiring from electronic controllers before welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near machine when welding. Toxic dust or gas can be produced when grinding or welding painted parts. Grinding or welding painted parts must be done in a well ventilated area. Wear dust mask when grinding painted parts. Dust generated from repairing nonmetallic parts such as hoods, fenders or covers can be flammable or explosive. Repair such components in a well ventilated area away from flames or sparks. Do not weld on lines or on tanks that contain flammable fluids. Do not flame cut lines or tanks that contain flammable fluid. Clean any such lines or tanks thoroughly with a nonflammable solvent before welding or flame cutting. DX220A-2/DX220LCA-2

Safety  Safety  1-23

 

If a Fire Occurs If a fire occurs: •

Do not not att attem empt pt to move move mach machin ine e or or con conti tinu nue eo ope pera rati tions ons..

•

Tu Turn rn star starte terr swi switc tch h to to ""O" O" (OFF) (OFF) posi positi tion on to stop stop en engi gine ne..

•

Use Use han handr drai ails ls,, gua guard rdra rail ils sa and nd step steps s to to g get et of offf mac machi hine. ne.

•

Imme Immedi diat atel ely y ca call ll for for he help lp or fire fire stat statio ion. n.

•

When When us usin ing g a fir fire e ext extin ingu guis ishe her, r, alw alway ays s aim aim exti exting ngui uish sher er at base of fire.

•

If an op opti tion onal al fire fire ex exti ting ngui uish shin ing g sys syste tem m is is in in p pla lace ce,, b be e familiar with its operating procedures.

NOTE:

FG018459

Figure 19

Depending on job conditions, other procedures could be necessary if a fire occurs.

Fire Extinguisher and First-aid Kit (Emergency Medical Kit) To be prepared in the event of a fire: •

Be sure sure that that fire fire ex exti tingu nguis ishe hers rs ha have ve been been pro provi vide ded d and and read 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 cabin. Check and service fire extinguisher at regular intervals and make sure that all work site crew members are adequately trained in its use.

•

Insp In spec ectt fir fire e ext extin ingu guis ishe herr and and s ser ervi vice ce fire fire exti exting ngui uish sher er regularly.

•

Fo Foll llow ow in inst stru ruct ctio ions ns on exti extingu nguis ishe herr ins instr truc ucti tion on plat plate. e.

•

Keep Keep a ffir irst st aid aid kit kit in stor storag age e com compa part rtme ment nt (Figure 21) 21) and keep another kit at work site. Check kit periodically and keep it properly supplied.

•

Keep Keep emer emerge genc ncy y num numbe bers rs fo forr doc doctor tor,, amb ambul ulan ance ce servi service ce,, hospital and fire department readily available.

HDO1009L

Figure 20

EX1403736

Figure 21

Safety  1-24

DX220A-2/DX220LCA-2

 

Electrical System and Electrical Shock  Never short across starter terminals or across batteries. Shorting could damage electrical system and engine neutral start system. When engine is running or immediately after it has stopped, high voltage is generated at injector terminal and inside engine controller, so there is a potential for an electrical shock. Never touch injector terminal or inside of engine controller. NOTE:

If it is necessary to touch injector terminal or inside engine controller, contact your DOOSAN distributor.

Protecting Cabin from Flying Objects (Optional) In a work site where additional operator protection is necessary from flying objects, install adequate protective guards on the cabin.

1

For breaker operation, install a front guard (1, Figure 22 22). ). Contact your DOOSAN distributor for recommendations.

FG000112

Figure 22

Emergency Exit from Operator's Station This machine is equipped with a glass breaking tool. It is found on left pillar of cabin. This tool can be used to break the glass to exit from cabin in an emergency. Grip handle firmly and use sharp point to break glass. •

Be care carefu full als also o n not ot to slip slip on brok broken en piec pieces es of gl glas ass s on on ground.

WARNING

DS1703691

Figure 23 AVOID DEATH OR SERIOUS INJURY Protect your eyes when breaking the glass.

DX220A-2/DX220LCA-2

Safety  Safety  1-25

 

TRANSPORTATION Obey State and Local Over-the-Road Regulations Check federal, state and local laws and regulations regarding weight, width and length of a load before making preparations for transporting on public roads or highways. The hauling vehicle, trailer and load must be in compliance with applicable regulations for the shipping route. Partial disassembly of excavator may be necessary to meet travel restrictions or particular conditions at work site. See Shop Manual for information on partial disassembly. Refer to "Transportation" on page 5-1, 5-1, for information on loading, unloading and towing. The machine can be disassembled into parts for transporting. Contact your DOOSAN distributor for assistance with disassembly.

Loading and Unloading To prevent machine tipping or roll-over when loading or unloading machine, always do the following: •

Perf Perfor orm m loa loadi ding ng and and unl unloa oadi ding ng on only ly on firm firm an and d lev level el ground. Maintain a safe distance from edge of road or drop-off.

•

Neve Neverr use use work work eq equip uipmen mentt to to loa load d or or unl unloa oad d mac machi hine ne.. T The he machine may fall or tip over.

•

Alwa Always ys u use se loa loadi ding ng ram ramps ps of a ade dequ quat ate e stre streng ngth th and and capacity. Be sure that ramps are wide, and long enough to provide a safe loading slope. Take steps to prevent ramps from moving out of position or coming off.

•

Clea Clean n ram ramp p surfa surface ces s so so they they are are fre free e of gr greas ease, e, oi oil, l, ice ice and and loose materials. Remove dirt from machine tracks and undercarriage. On a rainy day, be careful since ramp surfaces can be slippery.

•

Turn au auto id idle sw switch ""O OFF".

•

Run Run en engi gine ne at low low spee speed d an and d trav travel el slow slowly ly..

•

When When on ramp ramps, s, do no nott ope opera rate te an any y contr control ol le leve verr e exc xcep eptt for travel lever.

•

Neve Neverr cor correc rectt y your our steer steerin ing g on on ram ramps ps.. IIff n nec eces essa sary ry,, d dri rive ve off ramps, correct machine direction, then drive back onto ramps.

•

When When dri drivi ving ng up up or do down wn ramp ramps, s, the the cen cente terr of gr grav avit ity y of machine will change suddenly causing the tracks to drop down to the ramps or trailer. This will occur at the joint between the ramps and trailer. Travel slowly over this point.

Safety  1-26

DX220A-2/DX220LCA-2

 

•

Fo Forr mac machi hine nes s equ equip ippe ped d wit with h a cabi cabin, n, al alwa ways ys lo lock ck door door after loading machine to prevent door from suddenly opening during transportation.

Transporting Machine When transporting machine on a trailer or truck, do the following: •

Th The e wei weigh ght, t, trans transpo port rtat atio ion n heig height, ht, and and o ove vera rall ll le leng ngth th of machine may change depending on work equipment attached to it. Always check the machine dimensions and work equipment's dimensions before transporting.

•

When When passi passing ng ov over er br bridg idges es or stru struct ctur ures es on pri priva vate te la land nd,, check that structure is strong enough to support weight of machine. Before traveling on public roads, check with appropriate authorities and follow their instructions.

DX220A-2/DX220LCA-2

Safety  Safety  1-27

 

OPERATION Always make sure that the machine is properly maintained.

Before Engine Starting Machine Condition Every day before starting engine for first time, perform the following checks and repair machine before operating, as necessary. If these checks are not properly done death or serious injury could result. •

Chec Check k c coo oola lant nt,, ffuel uel,, and and hydrau hydrauli lic c ttan ank k oil oil leve levels ls,, a and nd check for clogged air cleaner and damage to electrical wiring.

•

Chec Check k o ope pera rati tion on of gaug gauges es,, cam camer eras as (if eq equi uipp pped ed)) and and angle of mirrors, and check that safety lever is in LOCKED position.

•

Chec Check k that that wor work k equi equipm pmen entt and and trav travel el con contr trol ols s mov move e freely, and work controls return to "NEUTRAL" when released.

•

Chec Check k tha thatt atta attach chme ment nt is pro prope perl rly ya att ttach ached ed and and loc locke ked. d.

Make sure that the machine is equipped with a lighting system that is adequate for job conditions and lights are working properly. Before moving machine, check position of undercarriage. The normal travel position is with idler wheels to front under cabin and drive sprockets to rear. When undercarriage is rotated in reversed position, directional or travel controls must be operated in opposite directions. Before performing checks, move machine to an area where there are no obstructions, and operate slowly. Do not allow personnel near machine. Know maximum operating dimensions of your machine.

Safety  1-28

DX220A-2/DX220LCA-2

 

Work Site Before starting operations, thoroughly check work area for any hazards, such as underground utility lines, overhead electrical lines, unstable ground, excessive slopes, etc. Before starting engine and moving machine, make sure that no one is underneath machine, around machine, or on machine. Know width and length of your machine and work equipment to maintain proper clearance when you operate machine or work equipment near fences or near boundary obstacles. Know appropriate work site hand signals and personnel that are authorized to give hand signals. Follow hand signals from only one person.

DANGER

No Entry No Entry

EX1300680

Figure 24

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 work site. Erect barricades or fences, post "No Entry" signs, and take other steps to prevent people from coming close to or entering work site. If people come too close to a moving machine, they may be struck or caught by machine, and this can result in death or serious injury.

DX220A-2/DX220LCA-2

Safety  Safety  1-29

 

Mounting/Dismounting Before getting on or off machine, if there is any oil, grease, or mud on handrails, guardrails, 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 machine. In particular, never get on or off a moving machine. These actions can result in death or serious injury. When getting on or off machine, always face machine. Maintain three-point contact (both feet and one hand or one foot and both hands) with handrails, guardrails, steps, and track shoes to ensure that you support yourself securely.

EX1301111

Figure 25

Never hold onto any control levers when getting on or off machine. Securely latch door. If you grip handrail inside door when moving on top of track shoes, and door latch is not securely engaged, door may move and cause you to fall. Use points marked by arrows in diagram when getting on or off machine. Do not carry tools or supplies when you mount or dismount the machine. EX1301112

Figure 26

DS1703773

Figure 27

Safety  1-30

DX220A-2/DX220LCA-2

 

Cleaning Remove all straw, wood chips, leaves, grass, paper and other flammable debris accumulated in engine compartment, mufflers and around battery. Remove any dirt from window glass, mirrors, handrails, and steps. Do not leave tools or spare parts in operator's cabin. Vibration of machine during operation can cause tools or spare parts to fall and damage or break control levers or switches. Tools and spare parts can also get caught in spaces between control levers cause accidental causingand death or serious injury. movement of work equipment When entering operator's cabin, always remove all mud and oil from your shoes. If you operate travel pedal with mud or oil stuck to your shoes, your foot could slip off the control, or dirt and debris may interfere with proper operation of control levers. After using ashtray, make sure that any matches or cigarettes are properly extinguished, and be sure to close ashtray. Clean window glass and working lights for fo r good visibility. Do not stick suction pads to window glass. Suction pads act as a lens and can cause fire. Never bring flammable or explosive items into operator's cabin. Do not leave cigarette lighters laying around operator's cabin. If temperature inside operator's cabin becomes too high, there is a potential hazard that lighter could explode. Secure all loose items such as lunch boxes, and other items that are not a part of equipment.

Operator Station Inspect condition of seat belt and mounting hardware. Replace any parts that are worn or damaged. Do not use a seat belt extension on a retractable seat belt. Adjust seat so full pedal travel can be achieved with operator's back against back of seat. Keep all windows and doors closed on machine. Adjust operator's seat to a position where it is easy to perform operations, and check that there is no damage or excessive wear to seat belt or mounting clamps. Adjust and clean mirrors so area to rear of machine can be seen clearly from operator's seat. When standing up from operator's seat, always place safety lever securely in "LOCK" position. If you accidentally move work equipment levers when they are not locked, the machine could suddenly move and cause damage, death or serious injury.

DX220A-2/DX220LCA-2

Safety  Safety  1-31

 

Seat Belt Check seat belt daily for correct function. Inspect seat belt system more often if machine is exposed to severe environmental conditions or applications. Conduct the following inspections and replace seat belt system as necessary: 1.

Check Check web webbin bing. g. If If syst system em iis s equi equippe pped d with with a retract retractor, or, pul pulll webbing completely out and inspect full length of webbing. Look for cuts, wear, fraying, dirt and stiffness.

2.

Check Check bu buck ckle le and and llat atch ch for corr correc ectt ope operat ratio ion. n.

3.

Make Make s sure ure latch latch p plat late e is is not not excess excessive ively ly wor worn, n, defo deforme rmed d or buckle is not damaged or casing is broken.

4.

Check Check retr retrac acto torr web web sto stora rage ge d dev evic ice e (if (if equip equippe ped) d) by by extending webbing and checking that it spools out and retracts correctly.

5.

Check Check webbing webbing in areas areas e expos xposed ed to to ultra ultravio violet let (UV (UV)) rays rays from sun or extreme dust or dirt. If original color of webbing in these areas is extremely faded and/or webbing is packed with dirt, webbing strength may be reduced. NOTE:

Contact your DOOSAN distributor for seat belt system replacement parts.

 WARNING AVOID DEATH OR SERIOUS INJURY Failure to properly inspect and maintain seat belt and seat belt system can cause lack of operator restraint and can result in death or serious injury. Before fastening seat belt, check that there is no problem in belt mounting bracket. If it is worn or damaged, replace seat belt. Fasten seat belt so it is not twisted. Always wear seat belt when operating machine.

Safety  1-32

DX220A-2/DX220LCA-2

 

Work Site Rules •

If vis visib ibil ilit ity y cann cannot ot be suf suffi fici cien entl tly y ass assur ured ed,, us use e a ffla lagm gman an.. The operator should pay careful attention to signals and follow instructions from flagman.

•

Sign Signal als s sho shoul uld d onl only yb be e giv given en by on one e fla flagm gman an..

•

When When work workin ing g in in dar dark k pla place ces, s, tu turn rn "O "ON" N" work work ligh lights ts and and front lights on the machine. Set up additional lighting in area.

•

Stop Stop or ope operat ratio ions ns ifif there there is poo poorr vi visi sibi bili lity ty,, su such ch a as s fo fog, g, s sno now, w, rain, sandstorms.

•

Chec Check k mirr mirror ors s and and rea rearr view view came camera ra (if (if equ equip ippe ped) d) on on machine before starting operations. Clean off any dirt and adjust view for good visibility.

When operating or traveling during poor visibility conditions, follow the preceding work site rules. It may not be possible to adjust all visual aids to see all the way around the machine. Therefore, additional precautions such as flagman, barricades, etc., must be taken to keep other personnel out of the work area.

Boost Starting or Charging Engine Batteries Follow these instructions to prevent an explosion or fire when connecting booster cables to batteries: •

Tu Turn rn "OF "OFF" F" all all ele elect ctri ric ce equ quip ipme ment nt befo before re conn connec ecti ting ng le lead ads s to battery. This includes electric switches on battery charger or battery booster equipment.

•

When When boos boostt sta starti rting ng fro from m anot anothe herr m mac achi hine ne or vehi vehicl cle e do do not allow two machines to touch. Wear safety goggles and gloves while battery connections are made.

•

24 volt volt b bat atte tery ry u uni nits ts cons consis isti ting ng of ttwo wo s ser erie ies s con conne nect cted ed 12 volt batteries have a cable connecting one positive (+) terminal on one of the 12 volt batteries to a negative (-) terminal on the other battery. Booster or charger cable connections must be made between the nonseries connected positive (+) terminals and between the negative (-) terminal of the booster battery and metal frame of the machine being boosted or charged. The final booster cable connection, at metal frame of the machine being charged or boost started, must be as far away from the batteries as possible. Refer to "Starting Engine With a Booster Cable" Cable"   on page 3-9, 3-9, for proper procedure in this manual.

•

Conn Connec ectt pos posit itiv ive e (+) (+) cab cable le first first wh when en in inst stal alli ling ng cabl cables es and and disconnect negative (-) cable first when removing them.

DX220A-2/DX220LCA-2

Safety  Safety  1-33

 

Starting Engine Only operate the machine from the operator's seat with your seat belt fastened. Only operate controls while engine is running. Check for proper operation of all controls and all protective devices while you operate the machine slowly in an open area. •

Read Read an and d unde unders rsta tand nd contr control ol patte pattern rn befo before re oper operati ating ng.. Check that movement of the machine matches display on control pattern it does not label. match, replace it immediately with label. correctIfcontrol pattern

•

Chec Check k o ope pera rati tion on of work work equi equipm pment ent,, ttra rave vell sys syste tem m a and nd swing system.

•

Chec Check k for for any prob proble lem m wit with h m mac achi hine ne.. C Che heck ck fo forr unu unusu sual al sounds, vibration, heat, odor, or improper readings from gauges. Check for any oil or fuel leaks.

•

If an any y pro probl blem em is fo foun und, d, stop stop oper operat atio ion na and nd perf perfor orm m rrep epai airs rs immediately.

Do not use cellular telephones inside operator's cabin when driving or operating the machine. When operating the machine, do not extend your hands or head out of window. The boom and arm linkage can allow work tool or attachment to contact undercarriage or cabin. Be aware of position of work tool. •

Do no nott att attem empt pt to star startt eng engin ine e by by s sho hortrt-ci circ rcui uitin ting g eng engin ine e starting circuit. This can result in death or serious injury, or fire.

•

When When start startin ing g eng engin ine, e, soun sound d horn horn as a war warni ning ng to al aler ertt personnel in the work area.

If there is a warning tag or "DO NOT OPERATE" tag hanging from work levers (joysticks) or travel control levers, do not start engine or move levers. •

Prev Preven entt per perso sonn nnel el from from walk walking ing or stan standi ding ng unde underr rrai aise sed d boom, unless it is properly supported.

NOTE:

When starting engine in cold temperatures, "white engine exhaust smoke" from the tail pipe can occur until engine reaches normal operating temperatures. Also, a white residue, because of water vapor inside engine, can form at the engine oil fill location. These conditions will not affect engine performance or damage the engine or other exhaust system components.

Safety  1-34

DX220A-2/DX220LCA-2

 

Swinging or Traveling As a machine operator, you should know and follow local, state and federal laws and regulations when operating on public roads road s or highways. It is important to keep in mind that the machine, in comparison with the rest of traffic, is a slow moving and wide vehicle which can cause traffic delays. Pay attention to traffic behind you and allow traffic to pass you. Before operating the machine or work equipment, always observe the following precautions to prevent death or serious injury. •

When When chan changi ging ng trav travel el di direc recti tion on fro from m for forwa ward rd to reve revers rse e or or from reverse to forward, reduce speed and stop machine before changing travel direction.

•

Sou ound nd ho horn rn to al ale ert pe peop ople le in ar area ea..

•

Chec Check k ttha hatt the there re is no on one e iin n are area aa aro round und mach machin ine. e. Th Ther ere e are restricted visibility areas behind machine so, if necessary, swing upper structure slowly to check that there is no one behind machine before traveling in reverse.

•

When When op oper erat atin ing g in in area areas s wit with h po poor or visi visibi bili lity, ty, de desi sign gnat ate e a flagman to direct work site traffic.

•

Keep Keep una unauth uthor oriz ized ed pe pers rson onne nell awa away y ffro rom m tur turni ning ng rad radiu ius s or or travel path of the machine.

EX1400131

Figure 28

Be sure to observe above precautions even if a travel alarm or mirrors are installed. •

Chec Check k th that at tra trave vell a ala larm rm work works s prop proper erly ly an and d tha thatt mirr mirror ors s are are clean, not damaged and properly adjusted.

•

Alwa Always ys latc latch h doo doorr and and wind window ows s o off ope opera rato tor' r's s cab cabin in in position (open or closed).

•

On wo work rk site sites s whe where re th ther ere e iis s a haza hazard rd of flyi flying ng or fal falli ling ng objects, or of objects entering operator's cabin, check that door and windows are securely closed. Install additional guards, if work site application requires them.

DX220A-2/DX220LCA-2

Safety  Safety  1-35

 

Never turn starter switch to "O" (OFF) position when traveling. This can lead to a loss of steering control.

Travel Position

Do not operate attachments while traveling. Do not change selected travel mode (FAST/SLOW) while traveling. Never travel over obstacles or excessive slopes that will cause machine to tilt severely. Avoid any slope or obstacle that can cause machine to tilt 10° or more to right or left, or 30° or more from front to rear.

40 - 50 cm (16 - 20 in.)

Do not operate steering controls suddenly. Work equipment can hit ground and this can damage machine or structures in area. When traveling on rough ground, travel at low speed, and avoid sudden changes in direction. Always operate within permissible water depth. Permissible water depth is up to centerline of upper track roller(s). When passing over bridges or structures on private land, check that structure is strong enough to support weight of machine. Before traveling on public roads, check with appropriate authorities and follow their instructions.

EX1300681

Figure 29

Never exceed maximum permitted load for bridges. Always operate machine with idler wheels to front under cabin and drive sprockets to rear. Know permitted ground pressure. Ground pressure of the machine may change depending on attachment and load. Keep height and length of attachment in mind.

Safety  1-36

DX220A-2/DX220LCA-2

 

Lifting and Digging The operator is responsible for any load carried when traveling on public roads and while working with the machine. •

Keep Keep lo load ads s sec secur ure e so so the they yd do o not not fa fall ll off off whi while le ope operat ratin ing. g.

•

Do no nott e exc xcee eed d maxi maximu mum m load load ffor or the the m mac achi hine ne.. Mach Machin ine e operation will be affected when center of gravity changes, caused by extended loads and different attachments.

To lift loads safely when in digging mode, the following must be evaluated by the operator and work site crew. • Condition of groun round d support. rt. •

Exca Excava vato torr conf config igur urat atio ion n and and atta attach chme ment nts. s.

•

Weig Weight ht,, lift liftin ing g he heig ight ht an and d sw swin ing g ra radi dius us..

•

Safe rigging of load.

•

Prope roperr h han andl dliing of su susp spen ende ded d lo load ad..

Always watch load. Bring load close to the machine before traveling any distances or swinging load. Lifting capacity decreases as load is moved further from the machine. Set tracks at right angles to road shoulder or drop-off with sprocket at rear when performing operations to make it easier to move away from the work area. Do not suddenly lower, swing, or stop work equipment. •

Do not not mov move e buck bucket et over over he head ad of other other pers person onne nell or or ove overr the operator's seat of dump trucks or other hauling equipment. The load may spill or bucket can hit dump truck causing property damage or cause death or serious injury.

DX220A-2/DX220LCA-2

Safety  Safety  1-37

 

Operation on Slopes If the machine has to be used on a slope, pile soil to make a platform that will keep the machine as horizontal as possible. Improper traveling on steep slopes could result in machine tipping, roll-over or sliding down the slope. Always fasten your seat belt. When possible, operate machine up slopes and down slopes. Avoid operating machine across slope.

2 0  0 -  3  0 c m  0  m  ( 8  8 -  1  2 i n  2  n )   

On slopes, In carry bucket 20 ~ 30 cm (8 - hills, 12 in)banks aboveorground. case of an approximately emergency, quickly lower bucket or work tool to ground to help stop machine. Do not travel on grass, fallen leaves, or wet steel plates. Even slight slopes can cause machine to slide down a slope. Travel at low speed and make sure that the machine is always traveling directly up or down slope.

 cc m  3 3 0        2 0

Do not change travel direction on a slope. This could result in tipping or sliding sideways of machine.

  )  in  i  n  1 1 2       8  (   ( 

Improper operation when working on slopes can cause a tip over. Use caution when swinging or operating work equipment on slopes. Do not swing work equipment from uphill side to downhill side when bucket is loaded. This could cause machine to tip or roll-over. In addition, lower bucket as far as possible, keep it pulled into front, and keep swing speed as slow as possible. EX1300691

Figure 30 If the machine begins to slide down on a grade, immediately dump load and turn the machine downhill. Be careful to avoid any ground condition which could cause the machine to tip. Tipping can occur when you work on hills, on banks, or on slopes. Tipping can also occur when you cross ditches, ridges, or travel over unexpected obstructions. Keep the machine under control. Do not overload the machine beyond capacity. •

•

When When trave traveli ling ng up a ste steep ep slop slope, e, exten extend d work work eq equi uipm pment ent to front to improve balance, keep work equipment approximately 20 ~ 30 cm (8 ~ 12 in) above ground, and travel at low speed.

EX1300682

Figure 31

Do not not tur turn n o on n slo slope pes s or or trav travel el acro across ss slop slopes es.. Alw Alway ays s go go down to a flat place to change position of the machine, then travel backup the slope again.

Safety  1-38

DX220A-2/DX220LCA-2

 

Towing

Cloth

To prevent death or serious injury when towing, always do the following: •

Fo Foll llow ow the the ins instr truc ucti tion on give given n in in thi this s man manua ual. l.

•

When When perfo perform rmin ing g pre prepa parat ratio ion n wor work k for for towi towing ng with with two two or or more personnel, determine signals to use and correctly follow these signals.

• •

Alwa Always ys atta attach ch wire wire rope rope on onto to le left ft an and d rig right ht ho hook oks s and and secure in position. If engi engine ne on probl problem em mach machin ine e w wil illl not not start start or there there is a failure in brake system, always contact your DOOSAN distributor.

•

Neve Neverr go b bet etwe ween en ttow owin ing g mach machin ine e an and d to towe wed d ma mach chin ine e during towing operation.

•

Do not pe perfo rform rm to towi wing ng on stee steep p slo slope pes, s, so sele select ct a p pla lace ce where slope is gradual. If there is no place where slope is gradual, perform operations to reduce angle of slope before starting towing operation.

•

When When towi towing ng a mac machi hine ne,, alw alway ays s use use a wir wire e rop rope e wit with h a sufficient towing capacity.

•

Do not t u use se a w wir ire e of rrope ope that that is kink ki nked edleather or fray frayed ed, , o orr awhen wire wire ropeno with any loss diameter. Wear gloves handling a wire rope.

•

Do no nott use use light lightwe weig ight ht to towi wing ng ho hook ok for to towi wing ng an anot othe herr machine.

•

Towing Wire

Make Make su sure re tha thatt towi towing ng ey eyes es an and d tow towin ing g devi device ces s are are adequate for towing loads.

•

Only Only co conn nnec ectt wir wire e rrop ope e tto o a draw drawba barr o orr to to a hitc hitch. h.

•

Oper Operat ate e the the mach machin ine e s slo lowl wly y a and nd be caref careful ul no nott tto o appl apply y any sudden load to wire rope.

DX220A-2/DX220LCA-2

Towing Wire

Towing Wire EX1400132

Figure 32

Safety  Safety  1-39

 

Attachment Never let anyone ride on any work attachment, such as bucket, crusher, grapple, or clamshell (grab bucket). This creates a falling and crushing hazard, and can result in death or serious injury. The clamshell, grapple, or magnet can swing in all directions. Move work levers (joysticks) in a continuous motion. Failure to move work levers (joysticks) in a continuous motion can cause clamshell, grapple, or magnet to swing into cabin or into a EX1400133

person in work area. This can result in death or serious injury. • When When using using a for fork k or or grap grapple ple,, do do n not ot atte attemp mptt to to pic pick k up up an an object with its tips. This could damage the machine or cause personal injury, if picked-up object slips off attachment. •

Do no nott use use impa impact ct fo force rce of work work eq equi uipm pmen entt for for de demo moli liti tion on work. This could damage work equipment, cause broken materials to fly off or tipping. This could result in death or serious injury.

•

Do no nott use use wor work k equ equip ipme ment nt or s swi wing ng m mec echa hani nism sm to to p pul ulll load in any direction. This could cause the work equipment to move suddenly if the load releases and can result in death or serious injury.

Figure 33

Equipment Lowering with Engine Stopped Before lowering any equipment with the engine stopped, clear the area around the equipment of all personnel and bystanders. The procedure to use will vary with the type of equipment to be lowered. Keep in mind most systems use a high-pressure fluid or air to raise or lower equipment. The procedure can cause high-pressure air, or hydraulic pressure, or some other media to be released to lower the equipment.

Safety  1-40

DX220A-2/DX220LCA-2

 

Engine Stop Turn engine starter switch to "O" (OFF) position and remove engine starter switch key. Before lowering any equipment with engine stopped, clear area around equipment of all personnel and bystanders. This procedure will cause high-pressure air or hydraulic pressure to be released to lower equipment. Do not stop engine immediately after the machine has been operated under load. This can cause overheating and accelerated wear of engine components. After the machine is parked, allow engine to run for five minutes before stopping the engine. This allows hot areas of engine to cool gradually. •

Do not not leav leave e ope opera rato tor' r's s sea seatt whe when n the there re is a rai raised sed lo load ad..

Parking Machine Avoid making sudden stops, or parking machine wherever it happens to be at end of workday. Park machine on firm and level ground away from traffic and away from high walls, drop-offs and any area of potential water accumulation or runoff.

12 0

If parking on inclines is unavoidable, block crawler tracks to prevent movement. Lower bucket or other working attachment completely to ground, or to an overnight support saddle. To prevent unintended or accidental movement.

Block

When parking on public roads, provide fences, signs, flags, or lights, and put up any other necessary signs to ensure that passing traffic can see machine clearly. Park machine so machine, flags, signs and fences do not obstruct traffic. After front attachment has been lowered to an overnight storage position and all switches and operating controls are in "OFF" position, safety lever must be moved to "LOCK" position. This will disable all pilot control functions.

Unlock

Always close door of operator's cabin and lock all equipment to prevent any unauthorized person from operating the machine.

Figure 34

Lock

EX1401035

The hydraulic system remains pressurized, provided accumulator, is charged even when engine is not running. Accumulator pressure should decrease in a short time (approximately one minute). While hydraulic system maintains a charge, hydraulic work tools and machine controls remain functional. Machine movement will occur if any controls are moved. This can result in death or serious injury. Always move safety lever to "LOCK" position before stopping off engine or immediately after engine stops running.

EX1300684

Figure 35

DX220A-2/DX220LCA-2

Safety  Safety  1-41

 

Preservation/Storing Machine Perform the following if storing excavator for more than one month. Conditions

Maintenance Required

Cleaning

Pressure wash undercarriage and track assemblies. Inspect for damage or loose or missing parts.

Lubrication

Perform all daily lubrication procedures. Apply a coating of light oil to exposed plated metal surfaces, such as hydraulic cylinder rods, etc. Apply a coating of light oil to all control linkages and control cylinders (control valve spools, etc.)

Battery

Turn "OFF" the battery disconnect switch.

Cooling System

Inspect coolant recovery ery tank to make sure that anti tiffre ree eze level in sy system is at correct level. Every 90 days, use a hydrometer to measure protection level of coolant. Refer to "Antifreeze Concentration Tables" on page 4-80, 4-80, to determine amount of protection cooling system requires. Add coolant as required.

Hydraulic System

Once a month, start engine and follow procedures in "Hydraulic System Warm-up" on page 3-11, 3-11, listed in this manual.

1.

Co Comp mple lete te the the prec preced edin ing g step steps. s.

2. 3.

Wash Wash mach machin ine e and and touc touch h up pain paintt fi fini nish sh to to avoi avoid d rusti rusting ng.. Treat Treat expo exposed sed parts parts w with ith antirus antirustt a agen gent, t, lubr lubrica icate te machin machine e thoroughly and apply grease to unpainted surfaces like lifting and tilting cylinders etc.

4.

Fill Fi ll ffue uell tank tank and and h hyd ydrau rauli lic c oi oill tank tank to to "F "FUL ULL" L" m mark arks. s.

5.

Cove Coverr exha exhaus ustt pipe pipe (par (parki king ng ou outs tsid ide) e)..

6.

Make Make sur sure e th that at co cool olan antt is a att prop proper er con concen centra trati tion on fo forr expected lowest temperatures.

7.

Park Park machi machine ne o on n leve level, l, ffirm irm gro ground und whe where re ther there e is is no ris risk k of freezing, landslide or flooding. Avoid parking machine on a slope. Keep in mind that theft and burglary risk can be minimized by: •

Remo Removi ving ng star starte terr key key when when th the e mac machi hine ne is left left unattended.

•

Lo Lock ckin ing g doo doors rs an and d cov cover ers s aft after er work workin ing gh hou ours rs..

•

Tu Turni rning ng of offf e ele lect ctri rica call curr curren entt w with ith batt batter ery y d dis isco conne nnect ct switch.

•

Pa Park rk mach machin ine e w whe here re risk risk of th thef eft, t, bu burg rgla lary ry an and d damage is minimized.

•

Remo Removi ving ng va valu luab able les s fro from m c cab abin in su such ch as ce cell llul ular ar phone, computer, radio and bags.

See "Long Term Storage" on page 3-49 3-49,, for more information.

Safety  1-42

DX220A-2/DX220LCA-2

 

Check After Long-term Parking •

All oil and fluid levels.

•

Tension of all belts.

•

Air pressure.

•

Air cleaner.

•

Bat atte teri ries es and and e ellec ectr tric ical al c con onne nect ctio ions ns..

•

Lubric ricate ate al all g gre rea asing points.

• •

Wipe of off g grrease ase ffrrom pi piston rrod ods s. Insp In spec ectt for for sign signs so off nes nests ts (i.e (i.e.. bir birds ds,, rode rodents nts,, etc etc.) .)

•

Insp In spec ectt saf safet ety y llab abel els s ((dec decal als) s).. R Rep epla lace ce if da dama mage ged, d, worn worn,, or missing.

DX220A-2/DX220LCA-2

Safety  Safety  1-43

 

MAINTENANCE Improper operation and maintenance can result in death or serious injury. Read manual and safety decals before operating or maintaining the machine. Follow all instructions and safety messages.

 WARNING AVOID DEATH OR SERIOUS INJURY Follow instructions before operating or servicing machine. Read and understand the Operation & Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can result in death or serious injury. •

Neve Neverr ser servi vice ce DOOS DOOSAN AN eq equi uipm pmen entt w wit itho hout ut in inst stru ruct ctio ions ns..

•

Alwa Always ys lowe lowerr buc bucke kett a and nd blad blade e to to g gro roun und d bef before ore do doin ing g any any maintenance.

•

Us Use e corr correc ectt proc proced edur ure e to lif liftt and and supp suppor ortt exca excava vato tor. r.

•

Clea Cleani ning ng an and d mai maint nten enan ance ce are are req requi uire red d dai daily ly..

•

Weld Weldin ing g or or gri grind ndin ing g pai paint nted ed parts parts mus mustt b be e d don one e in in wel welll ventilated areas.

•

Wear Wear a dus dustt mas mask kw whe hen n gri grind ndin ing g pain painte ted dp par arts ts.. Tox Toxic ic dust dust and gas can be produced.

•

Vent Vent exha exhaus ustt to to o out utsi side de when when en engi gine ne must must be runn runnin ing g ffor or service.

•

Exha Exhaus ustt s sys ystem tem must must be tigh tightly tly sea seale led. d. Exha Exhaus ustt fum fumes es ar are e hazardous and can cause death or serious injury.

•

Stop Stop an and d all allow ow en engi gine ne to co cool ol an and d cle clean an en engi gine ne of flammable materials before checking fluids.

•

Neve Neverr s ser ervi vice ce or ad adju just st mach machin ine e with with en engi gine ne runni running ng unless instructed to do so in this manual.

•

Avoi Avoid d con conta tact ct wit with h lea leaki king ng hy hydr drau auli lic c flu fluid id or dies diesel el fuel fuel under pressure. It can penetrate skin or eyes.

•

Neve Neverr fill fill fu fuel el ttan ank kw whi hile le eng engin ine e run runni ning ng,, whil while es smo moki king ng,, or or when near open flame.

•

Keep Keep body body,, jew jewel elry ry and and clo clothi thing ng away away from from mo movi ving ng parts parts,, electrical contact, hot parts and exhaust.

•

Wear Wear ey eye e pro prote tect ctio ion n to to gua guard rd from from ba batt tter ery y aci acid, d, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for welding.

Safety  1-44

DX220A-2/DX220LCA-2

 

•

Lead Lead-ac -acid id ba batte tteri ries es produ produce ce flam flamma mabl ble e and expl explos osiv ive e gases.

•

Keep Keep arc arcs, s, spark sparks, s, flam flames es and and llig ight hted ed to toba bacc cco o awa away y ffro rom m batteries.

•

Batt Batter erie ies s con conta tain in ac acid id whic which h burn burns s eye eyes so orr ski skin no on n cont contac act. t.

•

Wear Wear pro prote tect ctiv ive e cloth clothin ing. g. If If acid acid c con onta tact cts s body body,, flus flush h wel welll with water. For eye contact flush well and get immediate medical attention from a physician familiar with this injury.

•

Th The e main mainte tena nanc nce e proc proced edur ures es whi which ch are are gi give ven n in in th this is manual can be performed by the owner or operator without any specific technical training. Maintenance procedures which are not in this manual must be performed ONLY BY QUALIFIED SERVICE PERSONNEL. Always use genuine DOOSAN replacement parts.

•

Only Only auth author oriz ized ed pers person onne nell sho shoul uld d s ser ervi vice ce an and d rep repai airr tthe he machine. Do not allow unauthorized personnel into work area.

•

Lowe Lowerr w wor ork k equ equip ipme ment nt an and d sto stop p eng engin ine e bef befor ore e perf perfor ormi ming ng maintenance.

•

Par ark k mac machi hine ne on firm firm and and lev level el gr grou ound nd..

•

Tu Turn rn sta start rter er swit switch ch to "O "ON' N' posi positio tion n and and keep keep safet safety y llev ever er in "UNLOCK" position. Cycle work levers and forth, left and right at full stroke 2 to 3(joysticks) times to back eliminate remaining internal pressure in hydraulic circuit. Then move safety lever to "LOCK" position.

•

Chec Check k tha thatt b bat atte tery ry rela relay y is is "OF "OFF" F" an and d mai main n pow power er is shut shut off. (Wait for approximately one minute after turning "OFF" engine starter switch key and press horn switch. If horn does not sound, the main power is shut off.)

•

Put Put bloc blocks ks und under er tra track ck to to prev preven entt the the mac machi hine ne fro from m moving.

•

To pre preve vent nt inju injury ry,, do do not not pe perfo rform rm ma maint inten enan ance ce with with en engi gine ne running. If maintenance must be done with engine running, perform maintenance with at least two workers and do the following: – One One wor worke kerr mus mustt alw alway ays s sit sit in the op oper erat ator or's 's seat seat and and be ready to stop engine at any time. All workers must maintain contact with other workers. –

When When ma main inten tenanc ance e ope operat ratio ions ns are are nea nearr fan fan,, fan fan belt belt,, or other rotating parts, there is a potential hazard of being caught in rotating parts. Keep hands and tools away.

•

Neve Neverr d dro rop p or or in inse sert rt tools tools or ot other her obje object cts s int into o rota rotati ting ng fan fan or fan belt. Parts can break off and hit someone.

•

Do not to touc uch h a any ny cont control rol le leve vers rs or contr control ol peda pedals ls.. If If a any ny control levers or control pedals must be operated, always give a signal to other workers and instruct them to move away.

DX220A-2/DX220LCA-2

Safety  Safety  1-45

 

•

When When pe perf rfor ormi ming ng ma main inte tena nanc nce e of en engi gine ne an and d you you are are exposed to engine noise for long periods of time, wear hearing protection while working.

•

If no nois ise e fro from m the the mach machin ine e iis s ttoo oo loud loud,, itit c can an caus cause e temporary or permanent hearing problems.

•

Do no nott smo smoke ke when when you you s ser ervi vice ce an ai airr c con ondi diti tion oner er or if refrigerant gas is present.

•

Inhali Inha ling ng fume fumes s eit eithe herr fro from m a flame flame or ga gas s ffrom rom a ciga cigare rett tte e that has contacted air conditioner refrigerant can cause

• •

death or serious injury. Neve Neverr put put mai mainte ntena nanc nce e flui fluids ds in into to glas glass s cont contai aine ners rs..  Drain all liquids into a suitable containers. Unle Unless ss inst instru ructe cted d oth other erwi wise se,, p per erfor form m mai maint nten enan ance ce with with equipment in servicing position. Refer to this manual for procedure for placing equipment in servicing position.

Warning Tag Alert others that service or maintenance is being performed by attaching a "DO NOT OPERATE" warning tag to the operator's cabin controls – and other machine areas, if required. Use of a chain or cable to keep the safety lever in the fully lowered "LOCK" position, complies with OSHA's lockout requirements. "DO NOT OPERATE" warning tags, are available from your DOOSAN distributor. •

Alwa Always ys a att ttac ach h "DO "DO N NOT OT OPER OPERAT ATE" E" warn warnin ing g tag tag to wo work rk equipment control lever in the operator's cabin to alert others that you are performing service or maintenance on the machine. Attach additional warning tags on the machine, if necessary.

•

Keep Keep warn warnin ing g tags tags in ttoo ooll b box ox whil while e itit is not not us used. ed. If the there re is is not tool box or in the owner manual storage pocket.

•

If an any y oth other er pe pers rson on star starts ts engi engine ne,, and and op oper erat ates es cont control rol levers or control pedals while you are performing service or

Figure 36

EX1301177

maintenance, it can result in death or serious injury. Attach a "DO NOT OPERATE" warning tag to starter switch or to controls before servicing or repairing equipment. Warning tags are available from your DOOSAN distributor.

Safety  1-46

DX220A-2/DX220LCA-2

 

Cleaning Clean machine before performing inspection and maintenance. If inspection and maintenance are done when machine is dirty, it will become more difficult to locate problems, and you could slip on steps and work platform areas and injure yourself. When washing machine, do the following: •

Wear Wear shoe shoes s wit with h non nonsl slip ip sole soles s to to p pre reven ventt sli slipp ppin ing g and and falling.

•

Wear Wear safe safety ty go gogg ggle les sa and nd pr prot otect ectiv ive ec clo loth thin ing g whe when n was washi hing ng machine with high-pressure steam or water.

•

Do not not spra spray y w wat ater er di dire rect ctly ly on elec electri trica call com compo ponen nents ts (sensors, connectors). If water gets into electrical system, it can cause operation problems.

•

Pick Pick up an any y tool tools s or or hamm hammer ers s ttha hatt a are re la layi ying ng in wo work rkpl plac ace. e. Wipe up any grease or oil to prevent slippery substances, that can cause tripping or slipping.

•

When When clea cleani ning ng cabi cabin n ttop op wind window ow wh whic ich h iis s mad made e of of polycarbonate material, use tap water. Avoid use of organic solvents for cleaning, such as benzene, toluene or methanol. These solvents can cause a chemical reaction that will dissolve and damage the window.

EX1400134

Figure 37

Proper Tools and Clothing Only use tools that are intended for the type of service to be done. Metal pieces from low quality or damaged tools, such as chisels or hammers, can break off and hit a service person in the eyes or face causing serious injury.

Disassembling Precautions When using a hammer to remove pins, pins can fly out or metal particles may break off. Always do the following: •

Hitt Hittin ing g hard hard me meta tall pin pins, s, buck bucket et te teet eth, h, cutt cuttin ing g edg edges es or bearings with a hammer, can cause metal pieces to break or fly off resulting in serious injury. Always wear safety goggles and leather gloves. Keep other personnel away.

Use of Lighting When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use proper lighting equipment to prevent arcs or sparks that could cause a fire or explosion resulting in death or serious injury.

DX220A-2/DX220LCA-2

Safety  Safety  1-47

 

Fire and Explosion Prevention Fuels, most lubricants and some coolant mixtures are flammable. Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire resulting in property damage or death or serious injury. Store all fuels and all lubricants in properly marked and approved containers and keep away from all unauthorized personnel. Store oily rags and other flammable material in a protective container.

HDO1015I

Figure 38

Tighten all fuel and oil caps. Do not smoke while you refuel machine or while you are in a refueling area. Do not smoke in battery charging areas or in areas that contain flammable material. Clean all electrical connections and tighten all electrical connections. Check electrical wires daily for wires that are loose or frayed. Tighten all loose, and repair or replace all frayed, electrical wires before operating machine. Remove all flammable materials and debris from the engine compartment, exhaust system components and hydraulic lines.

FG018458

Figure 39

Safety  1-48

DX220A-2/DX220LCA-2

 

Burn Prevention When checking radiator coolant level, stop engine, let engine and radiator cool down, then check coolant recovery tank. If coolant level in coolant recovery tank is near upper limit, there is enough coolant in radiator. Using gloves, loosen radiator cap slowly to release internal pressure before removing radiator cap. If coolant level in coolant recovery tank is below lower limit, add coolant. Cooling system conditioner contains alkali which can cause personal injury. Do not allow alkali to contact skin, eyes, or mouth. Allow cooling system components to cool before draining cooling system. Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. Vent hydraulic tank only after engine has been stopped and hydraulic tank is cool. Using gloves, slowly tilt hydraulic tank air breather to relieve pressure. Relieve all pressure in hydraulic oil system, in fuel system, or in cooling system before disconnecting any lines, hoses, fittings, or related components. Batteries give off flammable fumes that can explode and start a fire.

haae2090

Figure 40

Do not smoke while you are checking battery electrolyte level. Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact skin or eyes. Always wear safety goggles and face protection when working with batteries.

DX220A-2/DX220LCA-2

Safety  Safety  1-49

 

Rubber That Contains Fluorides Observe extra great care when it is suspected that you may have to handle rubber that contains fluorides. Certain seals which have to withstand high operating temperatures (e.g. in engines, transmissions, axles, hydraulic motors and pumps) may be made from rubber that contains fluorides, which, when exposed to high heat (fire), forms hydrogen fluoride and hydrofluoric acid. This acid is very corrosive and cannot be rinsed or washed off from the skin. It causes very severe burns which take a long time to heal. It usually means that damaged tissue must be surgically removed. Several hours may pass after contact with the acid, before any symptoms appear and therefore one is not given any immediate warning. The acid may remain on the machine parts for several years after a fire. If swelling, redness or a stinging feeling appears and one suspects that cause may be contact with heated rubber that contains fluorides, contact a medical doctor immediately. If a machine, or part of a machine, has been exposed to fire or severe heat, it must be handled by specially trained personnel. In all handling of machines after a fire, thick rubber gloves and protective goggles must be used. The a part which been very hot and which be area madearound of rubber that has contains fluorides must may be decontaminated by thorough and ample washing with limewater (a solution or suspension of calcium hydroxide, i.e. slaked lime in water). After the work has been completed, the gloves must be washed in limewater and then discarded.

Safety  1-50

DX220A-2/DX220LCA-2

 

Rubber and Plastics Polymer materials when heated, can form compounds that create a health hazard and can harm the environment. Scrapped rubber and plastics must never be burned. Extra precautions must be taken when servicing machines that have been in a fire or exposed to extreme heat. If gas cutting or welding is to be done near such materials, the following safety instructions must be followed: •

Prot rotect th the ma materia rial fr from he heat.

•

Use Use prot protec ecti tive ve gl glove oves, s, pro prote tect ctiv ive e gog goggl gles es and and an an app appro rove ved d respirator.

Waste Hazardous to the Environment Painted parts or parts made of plastic or rubber which are to be scrapped must never be burned, but must be taken care of by an approved refuse handling plant. Batteries, plastic objects and anything else which is suspected of being dangerous to the environment must be taken care of in an environmentally safe way. Check List After Fire When handling a machine which has been damaged by fire or been exposed to intense heat, the following protective measures must under all circumstances be followed: Use thick, gloves made of rubber and wear goggles which are certain to protect your eyes. Never touch burned components with your bare hands, as there is a risk that you may come into contact with melted polymer materials. First wash thoroughly with plenty of limewater (a solution or suspension of calcium hydroxide, i.e. slaked lime in water). As a precaution, seals (O-rings and other oil seals) should always be handled as if they were made of rubber that contains fluorides. Treat skin, which is suspected of having touched burned rubber that contains fluorides, with Hydrofluoric Acid Burn Jelly or something similar. Seek medical advice. Symptom may not appear until several hours afterwards. Discard gloves, rags etc. which are suspected of having touched burned rubber that contains fluorides.

DX220A-2/DX220LCA-2

Safety  Safety  1-51

 

Welding Repairs

IMPORTANT When disconnecting or connecting connectors between ECU/DCU and engine, or connector between ECU/DCU and the machine, always disconnect the battery to prevent damage to ECU/DCU. If you do not follow this procedure, the ECU/DCU will be damaged and/or the engine will not operate properly. When performing welding repairs, perform welding in a properly equipped place. Repairs must be performed by a qualified welder. Welding operations, can create potential hazards, including generation of gas, fire, or electric shock. Never let an unqualified welder do welding. A qualified welder must do the following: •

To pr prev even entt batt batter ery y exp explo losi sion on,, tur turn n bat batte tery ry di disc scon onne nect ct switch to "OFF" position.

•

Disc Discon onne nect ct the the neg negat ativ ive e ((-) -) ca cabl ble e of of b bat atte tery ry..

•

To preve prevent nt ge gene nera rati tion on of gas, gas, rem remov ove e pai paint nt from from lo loca cati tion on of the weld.

•

If hyd hydra raul ulic ic equi equipm pmen ent, t, p pip ipin ing g or or co comp mpon onen entt por ports ts clo close se to them are heated, a flammable gas or mist could result in an explosion or fire. To prevent this, protect and insulate components from excessive heat.

•

Do not weld weld on pipe pipes s o orr o on n tube tubes s tha thatt con contai tain n fla flamm mmab able le fluids. Do not flame cut pipes or tubes that contain flammable fluids. Before welding on pipes or tubes, or before flaming cut pipes or tubes, clean them thoroughly with a nonflammable solvent. Make sure pressure inside pipes or tubes does not cause a rupture of the component parts.

•

If hea heatt is is app appli lied ed direc directl tly y to to rubb rubber er ho hose ses s or or p pip ipin ing g unde underr pressure, they may suddenly break, so cover and insulate them with a fireproof covering.

•

Wear pr protective cl clothing.

•

Make Make su sure re th ther ere e is is g goo ood d ven venti tila lati tion on..

•

Remo Remove ve all all fla flamm mmab able le ob obje ject cts s and and make make sure sure a ffir ire e extinguisher is available.

Safety  1-52

DX220A-2/DX220LCA-2

 

Preparation for Electrical Welding On Body Structure 1.

Tu Turn rn bat batte tery ry dis disco conn nnec ectt swit switch ch to to "O "OFF FF"" posi positi tion on..

2.

Disc Discon onnec nectt the the neg negati ative ve (-) cabl cable eo off b batt atter ery. y.

OFF

ON

OFF

3.

Proceed wi with w we elding.

4.

Conn Connect ect th the e neg negat ativ ive e ((-) -) cabl cable e of of b bat atte tery ry..

5.

Cl Clea ean n batt batter ery y comp compar artm tmen ent. t.

6.

Tu Turn rn bat batte tery ry dis disco conn nnec ectt swit switch ch to to "O "ON" N" posi positi tion on..

7.

Clos Close eb bat atte tery ry co comp mpar artm tmen entt doo door. r.

OFF O    N    

O    N    

EX1500481

Figure 41

Warning for Counterweight and Front Attachment Removal

WARNING AVOID DEATH OR SERIOUS INJURY Removal of the machine counterweight, front attachment or any other part can affect the stability of the machine. This could cause unexpected movement, and result in death or serious injury. Never remove counterweight or front attachment unless the upper structure is in-line with the lower structure. Never rotate the upper structure once the counterweight or front attachment has been removed.

DX220A-2/DX220LCA-2

EX1401352

Figure 42

Safety   Safety

1 53

 

Lock Inspection Covers When performing maintenance with inspection cover open, use lock bar to secure cover and prevent accidental lowering of the cover caused by wind or movement of the machine.

Working on Machine When performing maintenance operations on machine, prevent tripping and falling by keeping area around your feet clean and free of objects and debris. Always do the following: •

Do not spill oil or grease.

•

Do no not le leave ave tto ools lay layiing ar around.

•

Watch your step when walking.

•

Neve Neverr jum jump p down down from from mach machin ine. e. Whe When n get getti ting ng on on or or off off machine, use steps and handrails, and maintain a three-point contact (both feet and one hand or both hands and one foot) to support yourself.

•

If job job rreq equi uire res s iit, t, we wear ar prot protec ecti tive ve clot clothi hing ng..

•

To prev preven entt inj injur ury y ffrom rom slip slippi ping ng or fall fallin ing, g, when when wo worki rking ng on hood or covers, never stand or walk on areas except areas

•

•

ARO1380L

Figure 43

equipped with nonslip pads. If it is nece necess ssar ary y tto o work work under under rais raised ed eq equi uipm pment ent or th the e machine, support work equipment and machine securely with blocks and stands strong enough to support weight of work equipment and machine. Do no nott wor work ku und nder er th the e mac machi hine ne if trac track k sho shoes es ar are e llif ifted ted of offf ground and the machine is supported only with work equipment. If any control levers are moved, or there is damage to hydraulic system, work equipment or the machine will suddenly drop causing death or serious injury. injury .

Safety 

DX220A-2/DX220LCA-2

1 54

 

Accumulator The pilot control system is equipped with an accumulator. For a short period of time after engine has been stopped, accumulator will store a pressure charge that allow hydraulic controls to be activated. Activation of any controls will allow selected functions to operate under force of gravity. When performing maintenance on pilot control system, release hydraulic pressure in system as described in "Handling of of   Accumulator" on page 4-81. 4-81. The accumulator is charged with high-pressure nitrogen gas. If it is improperly handled it can explode causing death or serious injury. Always observe the following precautions: •

Do no nott d dri rill ll or pu punc nch h hol holes es in ac accu cumu mula lato torr or or e exp xpos ose e itit tto o any flames, fire or external heat source.

•

Do no not we weld on on ac accumulator.

•

When When pe perf rfor ormi ming ng disa disass ssem embl bly y or or m mai aint nten enan ance ce of accumulator, or when disposing of accumulator, charged nitrogen gas must be properly released. Contact your DOOSAN distributor for assistance.

•

Wear Wear safe safety ty gogg goggle les s and and leath leather er glov gloves es when when work working ing on an accumulator. Hydraulic oil under pressure can

EX1400135

Figure 44

penetrate skin and result in death or serious injury. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

Compressed Air •

When When clea cleani ning ng filt filter ers, s, radi radiat ator or or ot other her comp compon onen ents ts with with compressed air, there is a hazard of flying particles that can result in serious injury.

•

Alwa Always ys wear wear safe safety ty goggl goggles es,, dus dustt m mas ask, k, le leat athe herr g glo love ves, s, and other protective devices.

DX220A-2/DX220LCA-2

Safety   Safety

1 55

 

Track Tension Adjustments Track adjusting systems use grease under high-pressure to keep track under tension. Grease under high-pressure can penetrate body and result in death or serious injury. Watch track or track spring to see if track is being loosened. NEVER LOOSEN track tension grease valve. To release pressure from crawler frame track tension assembly, you should NEVER attempt to disassemble track adjuster or attempt to remove track tension grease valve assembly. Keep your face and body away from grease valve. Refer to "Track Tension" on page 4-82, 4-82, for proper procedure in this manual or Shop Manual.

HAOA110L

Figure 45

Supports and Blocking for Work Equipment Do not allow weight or equipment loads to remain suspended and unsupported. Lower work group to ground before leaving operator's seat. Do not use hollow, cracked or unsteady wobbling supports. Do not work under any equipment supported only by a lifting  jack.

HDO1042L

Figure 46

Safety 

DX220A-2/DX220LCA-2

1-56

 

High-pressure Lines, Tubes and Hoses When inspecting or replacing high-pressure piping or hoses, check to verify that pressure has been released from circuit. Failure to release pressure can result in death or serious injury. Release pressure as described in "Handling of Accumulator" on  on  page 4-81. 4-81. Always do the following: •

Wear Wear ey eye e pro prote tect ctio ion n and and le leat athe herr glo glov ves es..

•

Flui Fluid d lea leaks ks from from hy hydr drau auli lic c hos hoses es or pres pressu suri rize zed d components can be difficult to see but has enough force to pierce skin and can result in death or serious injury. Always use a piece of wood or cardboard to check for suspected hydraulic leaks. Never use your hands or expose your fingers. Wear safety goggles.

•

Do no nott ben bend d hig highh-pr pres essu sure re line lines. s. Do no nott str strik ike e high-pressure lines. Do not install lines, tubes or hoses that are bent or damaged.

•

Make Make sure sure th that at al alll cla clamp mps, s, guar guards ds an and d hea heatt shi shiel elds ds ar are e correctly installed to prevent vibration, rubbing against other parts, and excessive heat during operation.

•

Repl Replac ace e hos hose e or co comp mpon onen ents ts ifif any any of of th the e foll follow owin ing g problems are found: –

Dama Damage ge or leak leakag age e fro from m hos hose e end end fitt fittin ing. g.

–

Wear, Wear, dama damage ge,, c cut utti ting ng of hose hose cov cover erin ing, g, or wire wire braiding is exposed on any hose.

–

Cove Coverr por porti tion on is sw swol olle len n in in any any se sect ctio ion. n.

–

The The hos ose e is tw twis iste ted d or crus crushe hed. d.

–

Fo Fore reig ign n mate materi rial al is is em embe bedd dded ed in in hose hose cov cover erin ing. g.

–

Hose end is deformed.

–

Conn Connec ecti tion on fit fitti ting ngs s are are dama damage ged d or leak leakin ing. g.

NOTE:

Refer to "Hose In-service Lifetime (European Standard ISO 8331

EX1400129

Figure 47

Limit   and  

EN982 CEN)" on page 4-62 , for additional European regulations. High-pressure is generated inside engine fuel lines when engine is running. Before performing inspection or maintenance of fuel line system, wait for at least thirty seconds after stopping engine to let internal pressure drop and tip breather cap up to release residual pressure. Oil or fuel leaks from high-pressure hoses can cause fire or improper operation, which can result in death or serious injury. If any loose bolts are found, stop work and tighten to specified torque. If any damaged hoses are found, stop operations immediately and contact your DOOSAN distributor for replacement parts.

DX220A-2/DX220LCA-2

Safety   Safety

1-57

 

Battery Battery Hazard Prevention Battery electrolyte contains diluted sulfuric acid and generates hydrogen gas. Hydrogen gas is highly explosive, and improper handling can cause death or serious injury, or fire. Do not allow electrolyte to contact skin or eyes. Always wear safety goggles and protective clothing when servicing batteries. Wash hands after touching batteries and connectors. Use of acid-resistant gloves is recommended. precautions.

Always

observe

the

following

•

Do no nott smo smoke ke or brin bring ga any ny flam flame e nea nearr bat batte tery ry..

•

When When wo work rkin ing g wit with h bat batte terie ries, s, Alwa Always ys we wear ar s saf afety ety goggl goggles es,, protective clothing, and acid-resistant gloves.

•

If you you s spi pill ll bat batte tery ry e ele lect ctro roly lyte te on on yours yoursel elff or your your clo cloth thes es,, immediately flush area with water.

•

If batte battery ry el elec ectr trol olyt yte e get gets s into into your your ey eyes es,, flu flush sh th them em immediately with large quantities of water and get immediate medical attention from a physician familiar with this injury.

•

If you you acc accid iden ental tally ly drin drink k ba batt tter ery y elec electro troly lyte te,, call call a pois poison on prevention center immediately andwith getthis immediate attention from a physician familiar injury. medical

•

When When clea cleani ning ng to top p sur surfa face ce of batte battery ry,, w wip ipe e iitt wit with h a clea clean, n, damp cloth. Never use gasoline, thinner, or any other organic solvent or detergent.

•

Tighten battery caps.

•

If bat batter tery y elec electro troly lyte te is is fr froz ozen en,, do no nott char charge ge b bat atte tery ry or or star startt engine with power from another source. This could cause the battery to explode and start a fire.

•

When When char chargin ging g bat batte tery ry or star starti ting ng with with powe powerr fro from ma ano noth ther er source, let battery electrolyte thaw and check that there is no leakage of battery electrolyte before starting operation.

• •

Alwa Always ys remo remove ve ba batt tter ery y from from mach machin ine eb bef efor ore e char chargin ging. g. Do not use use o orr cha charg rge e b bat atte tery ry if ba batt ttery ery el elec ectr trol olyt yte e lev level el is below LOW LEVEL line. This can cause an explosion. Periodically check battery electrolyte level and add distilled water to bring electrolyte level to FULL LEVEL line.

•

Befo Before re main mainta tain inin ing g or or wor worki king ng with with batt batter erie ies, s, ttur urn n sta start rter er switch to "O" (OFF) position.

Safety 

EX1400136

Figure 48

DX220A-2/DX220LCA-2

1-58

 

Since there is a potential hazard that sparks could be generated, always do the following: •

Do no nott llet et to tool ols, s, ring rings s or or oth other er meta metall obj objec ects ts mak make e a any ny contact between battery terminals. Do not leave tools or other metal objects lying near battery.

•

When When disc discon onne nect ctin ing g ba batt tter ery y term termin inal als, s, wait wait ffor or approximately one minute after turning engine starter switch key to "O" (OFF) position, and be sure to disconnect grounding terminal; negative (-) terminal first. Conversely, when connecting them, begin with positive (+) terminal and then grounding (-) terminal, Make sure that all terminals are connected securely.

•

Flam Flamma mabl ble e hy hydr drog ogen en gas gas is is gene genera rate ted d when when bat batte tery ry is is charged. Remove battery from machine, take it to a well ventilated place, and remove battery caps, before charging it.

•

Afte Afterr cha charg rgin ing, g, tigh tighte ten n bat batte tery ry ca caps ps se secu cure rely ly..

•

Afte Afterr cha charg rgin ing, g, se secu cure re ba batt tter ery y bac back k in in mach machin ine. e.

When repairing or welding electrical system, wait for approximately one minute after turning engine starter switch key "OFF". Then disconnect negative (-) terminal of battery to stop flow of electricity.

DX220A-2/DX220LCA-2

Safety   Safety

1-59

 

ENVIRONMENT AND CIRCUMSTANCES Work Site Areas Requiring Extra Caution •

Do no nott ope opera rate te too too clo close se to edg edge e of of a qua quay, y, ra ramp mp,, etc etc..

•

Do no nott ope opera rate te too too clo close se to ed edge ge of a ste steep ep slop slope e or or drop-off. Take care when working in a place where machine may tip over.

•

Do no nott o ope pera rate te on sof softt g grou round nd or nea nearr riv riverb erban anks ks that that cou could ld collapse or where ground may not support weight of excavator.

•

Obse Observ rve ec chan hange ges s iin n gro groun und d and and trac tracti tion on cond condit ition ions s afte afterr a rain or other changes in weather.

Digging Under an Overhang Do not dig work face under an overhang. This can cause overhang to collapse and fall on top of the machine. •

Do not perfo perform rm ov overh erhead ead de demo moli liti tion on wo work rk.. T Thi his s can can caus cause e broken debris to fall on damage. top of machine causing death orobjects seriousand injury, or property

EX1300686

Figure 49

Deep Digging Do not perform deep digging under front of machine. The ground under machine may collapse and cause machine to fall resulting in death or serious injury. Working loads resulting on loose,insoft or uneven ground, cause side loadheavy conditions a tip over and injury.can Traveling without a load or a balanced load may also be hazardous. Never rely on lift jacks or other inadequate supports when work is being done. Block tracks fore and aft to prevent any movement. Use machine only for its intended purpose. Using it for other purposes will cause failures. •

Do no nott perf perfor orm m dem demol olit itio ion n work work unde underr mac machi hine ne.. The There re is a hazard that the machine may become unstable and tip over.

•

When When work workin ing g on on or or fro from m top top of bu buil ildi ding ngs s or or oth other er structures, check if structure can support weight of

EX1300687

Figure 50

machine and attachment. If a building structure collapses, this can cause death or serious injury. Safety 

DX220A-2/DX220LCA-2

1-60

 

Drop-off or Edge When working at edge of an excavation or near a drop-off, the machine could tip over, which can result in death or serious injury. Always fasten your seat belt. Check ground conditions of work site before operating to prevent the machine from falling or roll-over, and to prevent ground, stockpiles, or banks from collapsing. Do not travel too close to edge of a drop-off.

Poor Visibility For good visibility, always do the following: •

When When work workin ing g in in d dar ark k are areas as,, a att ttac ach h w wor orki king ng ligh lights ts and and front lights to the machine. If necessary, set up additional lighting at work site.

•

Stop Stop ope opera rati tion ons s when when v vis isib ibil ilit ity y is poo poor, r, suc such h as in fog fog,, mist mist,, snow, and rain. Wait for visibility to improve before starting operation.

To avoid hitting work equipment and damaging other property, always do the following: •

When When wo work rkin ing g in in tun tunnel nels, s, on brid bridge ges, s, un unde derr ele elect ctri rica call wires, or when parking the machine or performing other operations in places with limited height, be careful not to hit and damage other equipment or property.

•

To prev preven entt hit hitti ting ng ob obje ject cts, s, op oper erat ate e mac machi hine ne at a slo slow w speed when working in confined spaces, indoors, or in crowded areas.

•

Do no nott swi swing ng bu buck cket et ov over er the the top top of pe pers rson onne nell or or ov over er operator's cabin of dump truck.

Loose or Soft Ground Do not operate on soft ground or near edge of drop-offs, overhangs, and deep ditches. The ground can collapse because of the weight of the machine causing the machine to fall or rollover. Check ground conditions before beginning work with the machine. If ground is soft, reposition the machine before operating. The excavated material must not be dumped too close to edge. How far away from edge of trench excavated material must be dumped depends on soil type and moisture content. If loose clay is being excavated, place it at least 5 m (16 ft) away from edge. If excavated material is dumped too close to edge, its weight can cause a landslide. Thawing of frozen ground, rain, traffic, piling and blasting are other factors which increase risk of landslide. The risk also increases on sloping ground. If it is not possible to dig a trench and adequately equipment.

slope

DX220A-2/DX220LCA-2

its

sides,

always

install

shoring

Safety   Safety

1-61

 

Loose ground may easily give way under weight of the machine. When working on loose or unstable ground, it is important not to dig too deep and to carefully reposition the machine. Do not panic and do not raise bucket, if ground should begin to collapse. Lower work equipment to improve stability of machine. Never dig under machine, if there is a potential of causing a landslide.

High-voltage Cables Do not travel or operate machine near electrical cables or overhead power lines. There is a hazard of electric shock, which can cause property damage and result in death or serious injury. The bucket or other attachment does not have to make physical contact with power lines for current to cause an electrocution. Use a spotter and hand signals to stay away from power lines not clearly visible to operator. On work sites where machine ma chine may operate close to electrical cables, always do the following: •

Reme Rememb mber er that that ele elect ctri rica call v vol olta tage ge det deter ermi mine nes s wha whatt tthe he minimum distance is to stay away from the power line. See the following table for minimum distances when working near electrical power lines. Electrical flashover can occur

EX1300688

Figure 51

and damage machine and cause death or serious injury.

•

Voltage

Minimum Distance

6.6 kV

3 m (9' 10")

33.0 kV

4 m (13' 1")

66.0 kV

5 m (16' 5")

154.0 kV

8 m (26' 3")

275.0 kV

10 m (32' 10")

Alwa Always ys conta contact ct th the e p pow ower er comp compan any y res respon ponsi sibl ble e bef before ore beginning work near high voltage power lines.

Safety 

DX220A-2/DX220LCA-2

1-62

 

Underground Operation If excavation is in an underground location or in a building, make sure there is adequate overhead clearance, and adequate ventilation. Special equipment and engines may be required in some countries. Contact your DOOSAN distributor for more information. Check that there is sufficient room for machine and load. Move slowly. Make sure that authorities or companies responsible for underground cables, utilities, and electrical lines have been contacted and that their instructions are followed. Also check which rules apply to ground personnel regarding exposing cables, utilities and electrical lines. Consider all electrical cables as live.

EX1300689

Figure 52

Working in Water

IMPORTANT Do not exceed maximum permissible water depth. The water level must not reach higher than centerline of upper track roller(s) (1, Figure 53 53). ). After working in water, lubricate all lubrication points on undercarriage, which have been underwater so water is removed. Check that no water has entered travel gearboxes and undercarriage components.

1

EX1300690

Figure 53

Working in Contaminated Environment When working within area which is contaminated or where there is a health risk, check local regulations and contact your DOOSAN distributor for assistance with identifying what additional safety precautions need to be taken.

DX220A-2/DX220LCA-2

Safety   Safety

1-63

 

Operation in Extreme Conditions Operation In Extreme Cold In extremely cold weather, avoid sudden travel movements and stay away from even slight slopes. The machine could slide down the slope. Snow accumulation could hide potential hazards and slippery surfaces. Warming up engine for a short period may be necessary to avoid operating with sluggish or reduced working capacity. The  jolting shocks and impact loads caused by bumping or bottoming boom or attachment could cause severe stress in very cold temperatures. Reducing work cycle rate and workload may be necessary. If machine is to be operated in extremely cold weather temperatures, certain precautions must be taken. The following paragraphs detail checks to be made to be certain machine is capable of operating at these temperatures. 1.

Preh Prehea eatt the the eng engin ine e bef befor ore e sta start rt-u -up. p. •

2.

Pr Preh ehea eatt the the en engi gine ne be befo fore re star startt-up up.. W Wai aitt 3 to 4 seconds after preheating until voltage of the battery

return, and then actuate the starter switch. Keep Keep batter batteries ies fully fully c charg harged ed tto o preve prevent nt free freezin zing. g. IIff di disti stille lled d water is added to batteries, run engine at least one hour to mix electrolyte solution. When temperature drops below -10°C, efficacy of the battery is reduced accordingly. Insulation of the battery prevents reduction of efficacy, and supports improvement of starting power of the starter.

WARNING AVOID DEATH OR SERIOUS INJURY Explosion of attempt the battery can cause or serious injury. Never to directly heatdeath the battery with open fire. 3.

Keep Keep engi engine ne in good good mech mechani anical cal condit condition ion for eas easy y star startin ting g and good performance during adverse weather.

4.

Use engine engine oil wit with h prop proper er specifi specificat cation ions s for for expect expected ed temperatures. Refer to "Table of Recommended  Recommended  Lubricants" on page 4-8, 4-8 , in this manual or Shop Manual for details.

5.

Always Always keep keep the the fuel fuel tank tank full fully y fille filled d af after ter com comple pletio tion n of the operation. Always drain water from the fuel tank before and after the operation. In addition, check the water separator, and drain it if required. The fuel filter, if frozen, may interrupt the flow of fuel. Periodically remove water from the fuel tank, drain water from the filter, and replace the

Safety 

DX220A-2/DX220LCA-2

1-64

 

filter upon regular basis. To prevent fuel from being clogged because of formation of wax in fuel, make sure that wax formation point of fuel is lower than atmospheric temperature.

 WARNING AVOID DEATH OR SERIOUS INJURY Explosion of the fuel tank can cause serious injury or death. Never attempt to directly heat the fuel tank with open fire  6.

Lubr Lubric icat ate e enti entire re mach machin ine e ac acco cord rdin ing g to "Lubrication and and   Service Chart" on page 4-12, 4-12 , in this manual or lubrication chart on machine.

7.

Star Startt engin engine e and and allo allow w it to to reac reach h norm normal al o ope pera rati ting ng temperature before operating. •

If mud mud and and ice ice co coll llec ects ts an and d free freeze zes s on on any any of of mov movin ing g parts while machine is idle, apply heat to thaw frozen material before attempting to operate machine.

•

Oper Operat ate e h hyd ydra raul ulic ic un unit its s wit with h c car are e unt until il th they ey hav have e reached normally.a temperature which enable them to operate

•

Chec Check k all all mach machin ine e cont contro rols ls and and fun funct ctio ions ns to to be sur sure e they are operating correctly.

8.

An extr extra a ou outer ter air filter filter must must be kept kept in ope operat rator' or's s cabin cabin to replace element that could become iced and cause restricted airflow to engine.

9.

Clean Clean off off all mud, snow snow and and ice to prevent prevent freezin freezing. g. Cover Cover machine with a tarp if possible, keep ends of tarp from freezing to ground.

Operation in Extreme Heat Continuous operation of machine in high temperatures can cause machine to overheat. Monitor engine and hydraulic system temperatures and stop machine to let it cool, when necessary. 1.

Make Make fre frequ quen entt inspe inspecti ction ons s an and d serv servic ices es o off fan fan and and radiator. Check coolant level in radiator. Check grilles and radiator fins for accumulation of dirt, debris and insects which could block cooling passages. •

Fo Form rmat atio ion n of sca scale le and and rus rustt in coo cooli ling ng sys syste tem m occu occurs rs more rapidly in extremely high temperatures. Change antifreeze each year to keep corrosion inhibitor at full strength.

•

If nece necess ssar ary, y, flus flush h cool coolin ing g syst system em peri periodi odica call lly y to keep passages clear. Avoid use of water with a high alkali content which increases scale and rust formation.

DX220A-2/DX220LCA-2

Safety   Safety

1-65

 

2.

Check Check leve levell of bat batter tery y elect electrol rolyte yte daily. daily. Keep Keep elect electrol rolyte yte above plates to prevent damage to batteries. Use a slightly weaker electrolyte solution in hot climates. Batteries self-discharge at a higher rate if left standing for long periods at high temperatures. If machine is to stand for several days, remove batteries and store in a cool place.

IMPORTANT Do not store acid type storage batteries near stacks of tires. Acid fumes can damage rubber. 3.

Serv Servic ice e fue fuell sys syste tem m as as dir direc ecte ted d in in "Check Fuel Level" on  on  page 4-19  4-19  and "Check for Leaks in Fuel System" on  on   page 4-20, 4-20, of this manual. Check for water content before filling fuel tank. High temperatures and cooling off cause condensation in storage drums.

4.

Lubr Lubric icat ate e as as spe speci cifi fied ed in "Lubrication and Service Chart"  Chart"  on page 4-12, 4-12, in this manual or Lubrication Decal on machine.

5.

Do not not par park k ma mach chin ine e in sun sun for for llong ong perio periods ds of of time time.. If possible, park machine under cover to protect it from sun, dirt and dust. A.

Cover Cover mac machin hine e ifif no no s suit uitabl able e shel shelter ter is availa available ble.. Protect engine compartment and hydraulics from dirt and debris.

B.

In hot, hot, damp damp clima climates tes,, corro corrosio sion nw will ill occ occur ur on on all all pa parts rts of machine and will be accelerated during rainy season. Rust and paint blisters will appear on metal surfaces and fungus growth on other surfaces.

C.

Protect Protect all unf unfini inishe shed, d, expo exposed sed sur surfac faces es with with a film film of of preservative lubricating oil. Protect cables and terminals with ignition insulation compound.  Apply paint or suitable rust preventive to damaged surfaces to protect them from rust and corrosion.

Operation In Dusty and Sandy Areas Operation of machine can cause dust in almost any area. However, when in predominantly dusty or sandy areas, additional precautions must be taken. 1.

Keep Keep cool cooling ing system system fin fins s and and coolin cooling g a area reas s c clea lean. n. Blo Blow w out with compressed air, if possible, as often as necessary.

 WARNING AVOID DEATH OR SERIOUS INJURY Wear goggles when using compressed air to prevent face or eye injury.

Safety 

DX220A-2/DX220LCA-2

1-66

 

2.

Use Use care care whe when n serv servic icin ing g fuel fuel sys syste tem m to prev preven entt dust dust and and sand from entering tank.

3.

Serv Servic ice e air air cle clean aner er at at frequ frequen entt inter interva vals ls,, che check ck air air restriction indicator daily and keep dust cup and dust valve clean. Prevent dust and sand from entering engine parts and compartments as much as possible.

4.

Lubr Lubric icate ate and and perf perfor orm m servi service ces s out outli line ned d on curre current nt lubrication chart on machine and "Lubrication and Service  Service  Chart" on page 4-12. 4-12 . Clean all lubrication fittings before applying lubricant. Sand mixed with lubricant becomes very abrasive and accelerates wear on parts.

5.

Prot Protec ectt machi machine ne from from dus dustt and san sand d as much much as as possi possibl ble. e. Park machine under cover to keep dust and sand from damaging unit.

Operation in Rainy or Humid Conditions Operation under rainy or humid conditions is similar to that as in extreme heat procedures previously listed. 1.

Keep Keep all all e exp xpos osed ed sur surfa face ces s coat coated ed wit with h prese preserv rvat ativ ive e lubricating oil. Pay particular attention to damaged or unpainted surfaces. Cover all paint cracks and chip marks as soon as possible to prevent corrosive effects.

Operation in Saltwater Areas Saltwater and saltwater spray is very corrosive. When operating in saltwater areas, or in or around snow, observe the following precautions: 1.

When When expo exposed sed to to sal saltw twat ater er,, dry mac machi hine ne th thor orou oughl ghly y and and rinse with freshwater, as soon as possible.

2.

Keep Keep all all e exp xpos osed ed sur surfa face ces s coat coated ed wit with h prese preserv rvat ativ ive e lubricating oil. Pay attention to damaged paint surfaces.

3.

Keep Keep al alll p pai aint nted ed surfa surface ces s in in g goo ood d rep repai air. r.

4.

Lubric Lubricate ate mac machin hine e as as p pres rescri cribed bed on lub lubric ricati ation on cha chart rt on machine or "Lubrication and Service Chart" on page 4-12, 4-12 , in this manual. Shorten lubricating intervals for parts exposed to salt water.

5.

Check Check ope operati rating ng control controls s to to ensu ensure re pro proper per functio functional nality ity and that they return to "NEUTRAL" when released.

DX220A-2/DX220LCA-2

Safety   Safety

1-67

 

Operation at High Altitudes Operation instructions at high altitudes are the same as those provided for extreme cold. Before operating at high altitudes, engine fuel and air mixture may have to be adjusted according to appropriate engine manual. 1.

Check Check engin engine e opera operati ting ng tem tempe pera ratur ture e for for evid eviden ence ce of of overheating. The radiator cap must make a perfect seal to maintain coolant pressure in cooling system. •

Perfo Perform rm wa warm rmin ing-u g-up po ope pera rati tion on thoro thoroug ughl hly. y. If mach machin ine e is not thoroughly warmed up before control levers or control pedals are operated, reaction of machine will be slow.

•

If ba batt tter ery y ele elect ctro roly lyte te is fro froze zen, n, do not not char charge ge ba batte ttery ry or start engine with a different power source. There is a potential hazard that could cause a battery explosion or fire.

•

Be Befo fore re cha charg rgin ing g or sta start rtin ing g engi engine ne wit with h a diff differ eren entt power source, thaw battery electrolyte and check for any leakage of electrolyte before starting.

Operation During Electrical Storms During electrical storms, do not enter or exit machine. •

If you you are are off off mac machi hine ne,, kee keep p awa away y fro from m mac machi hine ne unti untill s stor torm m passes.

•

If you are in cabi cabin, n, rema remain in seat seated ed with with mach machin ine es sta tati tion onar ary y until storm passes. Do not touch controls or anything metal.

Exhaust Ventilation Engine exhaust gases can cause unconsciousness, loss of alertness, judgment and motor control. This can result in death or serious injury. Make sure there is adequate ventilation before starting engine in any enclosed area. Check for and be aware of any open windows, doors or ductwork where exhaust may be carried, or blown by wind, exposing others to hazardous exhaust gases.

ARO1770L

Figure 54 Ventilation for Enclosed Area If it is necessary to start engine within an enclosed area, or when handling fuel, flushing oil, or paint; open doors and windows to ensure that adequate ventilation is provided to prevent gas poisoning. Diesel engine exhaust contains products of combustion which can be harmful to your health. Always run engine in a well ventilated area. If you are in an enclosed area, vent exhaust to outside. Safety 

DX220A-2/DX220LCA-2

1-68

 

Asbestos Information

 WARNING AVOID DEATH OR SERIOUS INJURY Avoid exposure to dust containing asbestos as it can cause death or serious injury to the lungs and other organs (mesothelioma, lung and other cancers, and asbestosis). Asbestos dust can be HAZARDOUS to your health if it is inhaled. Materials containing asbestos fiber can be present on work sites. Breathing air that contains asbestos fiber can ultimately cause serious or fatal lung damage or diseases such as mesothelioma, lung and other cancers, and asbestosis. To prevent lung damage from asbestos fiber, observe the following precautions: •

Use Use an an a app pprov roved ed resp respir irato atorr ttha hatt is is app appro rove ved d for for us use e in in a an n asbestos-laden atmosphere.

•

Use Use wat water er for for c cle lean anin ing g tto o kee keep p dow down nd dus ust. t.

•

Alwa Always ys obse observ rve e a any ny regu regula lati tion ons s rel relat ated ed to work work site site and and working environment.

•

Avoi Avoid d brus brushin hing g or or g gri rind ndin ing g mat materi erials als th that at conta contain in as asbe besto stos. s.

•

A vac vacuu uum m cle clean aner er that that is eq equip uipped ped with with a hig high h effi effici cien ency cy particulate air filter can also be used.

•

Comp Comply ly with with appl applic icab able le laws laws an and d rregu egula lati tion ons s for for w wor orkp kpla lace ce..

•

Stay Stay aw away ay fro from m area areas s tha thatt mig might ht have have as asbe best stos os pa parti rticl cles es in air.

Silica Dust Information

 WARNING AVOID DEATH OR SERIOUS INJURY Avoid exposure to dust containing crystalline silica particles as it can cause serious injury to the lungs (silicosis). Cutting or drilling concrete containing sand or rock containing quartz can result in exposure to silica dust. Do not exceed Permissible Exposure Limits (PEL) to silica dust as determined by OSHA or other work site rules, laws and regulations. Use a respirator, water spray or other means to control dust. Silica dust can cause lung disease and is known to the state of California to cause cancer.

DX220A-2/DX220LCA-2

Safety   Safety

1-69

 

Disposal of Hazardous Materials Physical contact with used motor oil or gear oil could create a health risk. Wipe oil from your hands promptly and wash off any remaining residue. Used motor oil or gear oil is an environmental contaminant and should only be disposed of at approved collection facilities. To prevent pollution of environment, always do the following: •

Neve Neverr dum dump p was waste te oil oil in in a sew sewer er s sys yste tem, m, rive rivers rs,, etc etc..

•

Alwa Always ys put put dra drain ined ed oi oill fro from m you yourr mac machi hine ne in app appro rove ved, d, le leak ak proof containers. Never drain oil directly onto ground.

•

FG009156

Figure 55

Obey Obey appr appropr opria iate te laws laws an and d reg regula ulati tion ons s w whe hen n dis dispo posi sing ng of harmful materials such as oil, fuel, solvent, filters, and batteries.

Improperly disposing of waste can threaten environment. Potentially harmful fluids must be disposed of according to local regulations. Use all cleaning solutions with care. Report all necessary repairs.

Sound Sound Level Information: Hearing protection may be required when machine is operated with an open operator station for extended periods or in a noisy environment. Sound pressure level (LpA) at operator position (Measurement according to ISO 6396)

76 dB(A)

Sound power level (LwA) around the machine (Measurement according to 2000/14/EC with applicable appendices and measuring method according to ISO 6395)

109 dB(A)

Safety 

DX220A-2/DX220LCA-2

1-70

 

Vibration Information NOTE:

The level of vibration is influenced by many different parameters such as operator training, job site organization, weather, material, environment, machine type, machine and seat suspension system, attachments, and condition of the machine.

Measurements are obtained on a representative machine, using measuring procedures as described in the following standards: ISO 2631/1, ISO 5349, and SAE J1166. Vibration levels were given consideration in accordance with uncertainty (K) determined to manufacturer. Hand/Arm Vibration Level The vibration total value to which the hand-arm system is subjected, is less than 2.5 m/s2. Whole Body Vibration Level The highest root mean square value of weighted acceleration to which the whole body is subjected, is less than 0.5 m/s2.

Guidelines forReduce Use and WorkingLevels Conditions of Earth-moving Machinery to Vibration (ISO/TR 25398 Annex E) Properly adjusting and maintaining machines, operating machines smoothly, and maintaining the terrain conditions can reduce whole-body vibrations. The following can help the users of earth-moving machinery reduce whole-body vibration levels. 1.

Use Use the the righ rightt type type and and siz size e of m mac achi hine ne,, equi equipm pmen ent, t, and and attachments.

2.

Main Mainta tain in mach machin ines es acco accord rdin ing g to the the manufa manufact cture urer' r's s recommendations: (for wheeled machine)

3.

4.

•

Tire pressure;

•

Brake and steering systems;

• Cont Contro rols ls,, hy hydr drau auli lic c sy syst stem em an and d link linkag ages es.. Keep Keep the the ter terra rain in whe where re the the m mac achi hine ne is is wo work rkin ing g an and d travelling in good condition: •

Remo Remove ve an any y llar arge ge rock rocks s or or obs obsta tacl cles es;;

•

Fill a an ny di ditches an and h ho oles;

•

Pr Prov ovid ide e mac machi hine nes s and and sc sche hedu dule le time time to main mainta tain in terrain conditions.

Use Use a seat seat in in conf conform orman ance ce wit with h ISO ISO 7096 7096 a and nd kee keep p the the seat maintained and adjusted: •

Ad Adju just st the the sea seatt and and susp suspen ensi sion on fo forr the the we weig ight ht an and d size of the operator;

•

Inspec Insp ectt and and main mainta tain in th the e sea seatt sus suspe pens nsio ion n and and adjustment mechanisms.

DX220A-2/DX220LCA-2

Safety   Safety

1-71

 

5.

Stee Steer, r, bra brake ke,, acce accele lera rate te,, shif shiftt ge gear ars, s, a and nd mov move e the the attachments smoothly. (for wheeled machine)

6.

Adjust Adjust the mac machin hine e spee speed d and and travel travel path path to to m mini inimiz mize e the the vibration level:

7.

•

Driv Drive e ar arou ound nd ob obst stac acle les s and and rough rough terr terrain ain cond condit itio ions ns;;

•

Slow Slow do down wn wh when en it is ne nece cess ssar ary y to to g go o o ove verr rou rough gh terrain.

Minimi Minimize ze vibrat vibration ions s for for lon long g work work cyc cycle le or long long dist distanc ance e travelling: (for wheeled machine) • Us Use e mac machi hine nes s equi equipp pped ed wi with th sus suspe pens nsio ion n sys syste tems ms;;

8.

•

Us Use e lif liftt arm arm su susp spen ensi sion ons s on on whe wheel el load loader ers; s;

•

If no suspe suspensi nsion on syst system em is av avai aila labl ble, e, reduc reduce e spee speed d to to prevent bouncing;

•

Haul Haul m mac achi hine nes s lon long g dist distan ance ces s betw betwee een n work worksi site tes. s.

Back Back pain pain associ associate ated d with with wholewhole-bod body y vibr vibrati ations ons can be caused by other risk factors. To minimize the risk of back pain: •

Adjus Adjustt the the seat seat an and d con contr trol ols s to to achie achieve ve good good pos postu ture re;;

•

Ad Adju just st the the mir mirro rors rs to mi mini nimi mize ze twis twiste ted d po post stur ure; e;

• •

Pr Prov ovid ide e brea breaks ks to rred educ uce e lon long g per perio iods ds of sitt sittin ing; g; Av Avoi oid d jjum umpi ping ng d dow own n fr from om th the ec cab ab or acc acces ess s sys syste tem; m;

•

Mini Minimi mize ze re repe peat ated ed ha hand ndli ling ng an and d lift liftin ing go off loa loads ds;;

•

Mini Minimi mize ze an any y sho shock cks s and and jolt jolts s dur durin ing g spo sport rts s and and leisure activities.

Safety 

DX220A-2/DX220LCA-2

1-72

 

2Operating The "Operating Controls" section presented here consists of the following groups: 1.

"Component Locations" on page 2-2

2. 3.

"Operator's Area" on page 2-6 "Operational Controls and Panels" on page 2-8

4.

"Instrument Panel" on page 2-17

5.

"Heater and Air Conditioner Control Panel (Optional)" on on   page 2-24

6.

"Stereo (Optional)" on page 2-30

7.

"Miscellaneous Electrical Devices" on page 2-31

8.

"Seat Adjustment" on page 2-33

9.

"Seat Adjustment (Suspension Seat - Optional)" on page page   2-34

10.

"Seat Belt" on page 2-36

11.

"Ceiling Cover" on page 2-37

12. 13.

"Door Side Latch" on page 2-38 "Cabin Storage Compartments" on page 2-38

14.

"Cup Holder" on page 2-39

15.

"Door Window Holder" on page 2-39

16.

"Emergency Glass Breaking Tool" on page 2-39

17.

"Miscellaneous Access Covers and Doors" on page 2-40

Each group is explained with a point location drawing or photo and a brief description of each control, switch, gauge or valve. Indicator lights work besides the gauges on the instrument panel. The operator should monitor machine pressure on the instrument panel with indicator lights. These lights will only show there is a problem.

 WARNING AVOID DEATH OR SERIOUS INJURY Warning lights. When any one or more of the warning lights on the control console, comes "ON", immediately stop operation and stop unit. Investigate and correct the problem before proceeding with operation.

Controls

Operating Controls  Controls  2-1

DX220A 2/DX220LCA 2

 

COMPONENT LOCATIONS 21

1

2

 

3

4

20

19

5

18

17 16

6 15 14 13

7

11

12

8 10

9 DS1703692

Figure 1

Reference Number

Description

Reference Number

Description

1

Cabin

12

Track Link and Shoe

2

Boom Cylinder

13

Idler

3

Boom

14

Track Adjuster

4 5

Arm Cylinder Arm

15 16

Track Guard Upper Roller

6

Bucket Cylinder

17

Lower Roller

7

Guide Link

18

Sprocket

8

Push Link

19

Travel Motor

9

Bucket

20

Counterweight

10

Side Cutter

21

Hood

11

Tooth Point

Operating Controls  2-2

DX220A 2/DX220LCA 2

 

1

2

3

8 4

5

6

7

DS1703693

Figure 2

Reference Number

Description

Reference Number

Description

1

Engine

5

Main Pump

2

Radiator

6

Main Fuel Filter

3

Precleaner

7

Engine Oil Filter

4

Air Cleaner

8

Muffler

Operating Controls  Controls  2-3

DX220A 2/DX220LCA 2

 

8 13 10 9

6

5

3 12

11

4

7

2

1

DS1703790

Figure 3

Reference Number

Description

Reference Number

Description

1

Battery

8

Surge Tank

2

Fuel Tank

9

Fuel Prefilter

3

Fuel Cap

10

Additional Water Separator

4

Hydraulic Oil Tank

11

Pilot Filter

5

Air breather

12

Breaker Filter (Optional)

6

Return Filter

13

Window Washer Fluid (Optional)

7

Suction Filter

Operating Controls  2-4

DX220A-2/DX220LCA-2

 

1

2

4 3

5

DS1703789

Figure 4

Reference Number

Description

Reference Number

Description

1

Main Control Valve

4

Center Joint

2

Swing Device

5

Solenoid Valve

3

Swing Bearing

Operating Controls  Controls  2-5

DX220A-2/DX220LCA-2

 

OPERATOR'S AREA 11 16

1

13 21

10

12

3 25 4 9

15

 

23 18

24

8 19

14

22

2 7 17 20 5 6 DS1703791

Figure 5

Operating Controls  2-6

DX220A-2/DX220LCA-2

 

Reference Number

Description

Reference Number

Description

1

Seat

14

Defroster Vent (Optional)

2

Left-hand Work Lever (Joystick)

15

Face Vent (Optional)

3

Right-hand Work Lever (Joystick)

16

Rear Vent (Optional)

4

Travel Lever

17

Foot Vent (Optional)

5

Travel Pedal

18

Stereo (Optional)

6

Footrest

19

Hour Meter

7 8

Safety Lever Air Conditioner Unit (Optional)

20 21

Mat Seat Belt

9

Display Monitor

22

Breaker Electric Pedal (Optional)

10

Storage Space (Large)

23

Cup Holder

11

Storage Space (Heating and Cooling - Optional)

24

DMS Laptop Computer Connector

12

Storage Compartment (1)

25

Fuse Box

13

Storage Compartment (2)

Operating Controls  Controls  2-7

DX220A-2/DX220LCA-2

 

OPERATIONAL CONTROLS AND PANELS

18

6

5

4

3

2

1

11

13

12

14

10

9

8

7

15

16

17

DS1703793

Figure 6

Operating Controls  2-8

DX220A-2/DX220LCA-2

 

Reference Number

Description

Reference Number

Description

1

Starter Switch

10

Wiper Control Switch

2

Engine Speed Control Dial

11

Horn Button

3

Heater and Air Conditioner Control Panel

12

Breaker Button

13

Work Mode Select Button

4

Auxiliary Mode Switch

14

Power Mode Button

5

Photo Sensor

15

Auto Idle Button

6 7

Power Socket for 12V Travel Speed Selector Switch

16 17

Display Monitor Breaker Electric Pedal (Optional)

8

Light Switch

18

Safety Lever

9

Cabin Work Light Switch

Operating Controls  Controls  2-9

DX220A-2/DX220LCA-2

 

1. Starter S Sw witch

O   ACC I

A three-position starter switch is used to start or stop engine for equipment operation. O.

Turnin Turning g swit switch ch to tthis his positi position on tturn urns s e engi ngine ne "OFF" "OFF" with its electrical system. In this position, engine is "OFF" but interior cabin light and fuel tank transfer pump (if equipped) are functional.

ACC.Without starting engine, you can operate some electronic devices. – Stereo I.

EX1402126

Figure 7

Tu Turn rnin ing g swit switch ch tto o this this p pos osit itio ion n turn turns s en engi gine ne ele elect ctri rica call system "ON". When the switch is first turned "ON", six indicator/warning symbols across top of the display monitor, will turn "ON" for approximately two seconds. The battery warning symbol and engine oil pressure warning symbol should remain "ON" after the other four have turned "OFF". NOTE:

Preheat Indicator Symbol - The operation of the preheat cycle depends on coolant temperature. When the engine coolant is cold enough, the preheat indicator symbol will remain "ON"The until preheat engine preheat cycle is completed. cycle takes about twenty seconds to complete, and the indicator symbol will turn "OFF". When the symbol turns "OFF", engage the starter.

.

Moving Moving s swit witch ch to thi this s positi position on will will crank crank engine. engine. When engine starts, release key and allow it to return to "I" (ON) position. Do not operate the starter switch for more than fifteen seconds at a time. This will help prevent damage to starter.

WARNING AVOID DEATH OR SERIOUS INJURY DO NOT USE STARTING FLUIDS. The preheat system could cause the starting fluid to explode.

Operating Controls  2-10

DX220A-2/DX220LCA-2

 

2. Engi Engine ne Sp Spee eed d Con Contr trol ol Di Dial al The engine speed is controlled by the dial. Rotating it clockwise increases engine speed (rpm) and counterclockwise decreases engine speed. A

Low Low idl idle e (Lo (Lowe west st en engi gine ne spe peed ed))

B

Hi High gh id idle le (H (Hig ighe hest st en engi gine ne sp spee eed) d)

NOTE:

The auto idle system will automatically reduce engine speed to idle speed approximately four seconds after all of the control levers are in the neutral position. This system is designed to reduce fuel consumption and noise. See "15. "15.   Auto Idle Button" on page 2-15.

HAOA690L

Figure 8

3. Heate Heaterr an and d Air Air Co Cond ndit itio ione nerr Co Cont ntro roll Panel This panel is used to control air conditioner and heater in operator's cabin. Refer to "Heater and Air Conditioner  Conditioner  Control Panel (Optional)" on page 2-24 for 2-24 for more details.

A/C AUTO

AUTO

OUTSIDE  

MAX

A/C

TEMP

OFF SEL

MODE

FG000029

Figure 9

4. Auxi Auxili liar ary y Mo Mode de Sw Swit itch ch I

When the control system is out of order, the pump system can be controlled manually. O.

In this this positi position, on, the manual manual pum pump p contr control ol iis s "O "OFF" FF"..

I.

In th this is posi positi tion on,, the the manu manual al pu pump mp cont contro roll is is ""ON ON". ".

O

CAUTION DS1704065

AVOID INJURY Be sure to turn pump control to "O" (OFF) position, after the control system is operating properly.

Figure 10

Operating Controls  Controls  2-11

DX220A-2/DX220LCA-2

 

5. Photo S Se ensor The photo sensor detects the radiant energy of the sun. In auto mode the air conditioner will automatically adjust the air temperature based on to the detected radiant energy.

FG000399

Figure 11

6. Powe Powerr So Sock cket et fo forr 12 Vo Volt lt This is a power socket for only 12V DC devices. This socket can be used for charging a cellular phone or powering a small 12V DC electrical device. Open the cap when using it. NOTE:

12 V

This socket is designed for small electrical capacity devices. Do not use this socket for large electrical capacity devices. Thus, damage can be avoided.

HAAE1990

Figure 12

7. Trav Travel el Spee Speed d Se Sele lect ctor or Sw Swit itch ch O

WARNING

I

AVOID DEATH OR SERIOUS INJURY Do not operate the travel speed selector switch when unit is in motion. Temporary loss of control could result. DS1703979

This switch activates the automatic speed range for travel. O.

In this this p posi ositio tion, n, "LO "LOW" W" travel travel speed speed is sel select ected. ed.

I.

In th this is posi positi tion on,, ""HI HIGH GH"" trav travel el spee speed d iis s sel selec ecte ted. d.

Figure 13

Operating Controls  2-12

DX220A-2/DX220LCA-2

 

8. Light S Sw witch This switch is used to turn "ON" the lights. O.

In th this is posi positi tion on,, all all ligh lights ts a are re ""OF OFF" F"..

I.

In thi this s po posi siti tion on,, all all illu illumi mina nati tion on lig light hts s of the the inst instru rume ment nt panel and the control switches are turned "ON".

II.

In tthis his positi position, on, all illumi illuminati nation on lligh ights ts and and work work ligh lights ts are turned "ON".

I

O

II

FG000024

 CAUTION

Figure 14

AVOID INJURY Do not leave instrument panel or work lights "ON" when the engine is not running. Leaving lights "ON" with the engine stopped will discharge batteries.

9. Cabi Cabin n Work Work Li Ligh ghtt Swi Switc tch h This switch is used to control the cabin work lights, if unit is equipped with them. O.

In this this positi position, on, all cab cabin in work work lights lights are turned turned ""OFF OFF". ".

I.

In thi this s po posi siti tion, on, th the e fron frontt cabi cabin n work work lig light hts s on the the fro front nt top of cabin will turn "ON".

II.

In tthis his positi position, on, the front front cabi cabin n work work lights lights on tthe he front front top of cabin and rear cabin work lights on rear top of cabin will turn "ON".

I

O

II

FG000026

Figure 15

10. Wiper Wiper Contro Controll Switch Switch This switch is used to control the front window wiper. O.

In this this pos positi ition, on, spr spray ay wind windshi shield eld washer washer flu fluid id onto onto the windshield.

I.

In th this is posi positi tion on,, low lower er winds windshi hiel eld d wip wiper er is "OFF "OFF". ".

II.. II

In thi this s po posi siti tion on,, lowe lowerr wi wind ndsh shie ield ld wip wiper er run runs s at a constant speed.

NOTE:

Operating wiper without washer fluid or when there is sand or dirt present will damage the window and wiper.

I

O

II

DS1703694

Figure 16

Operating Controls  Controls  2-13

DX220A-2/DX220LCA-2

 

11. Horn Button Button (L (Left-ha eft-hand nd Work Lever) Press the lower button on the top of the left-hand work lever (joystick) to sound horn. NOTE:

The starter switch must be "ON".

DS1703695

Figure 17

12. Breake Breakerr B Butt utton on Press the lower button on the top of the right-hand work lever (joystick) to boost the hydraulic pressure. Refer to the "Work Mode and Breaker Operation" on page 3-23. 3-23 .

DS1703697

Figure 18

13. Work Mode Selec Selectt But Button ton When optional equipment is installed on the equipment, breaker mode can be selected.  Breaker mode are only activated when the options are installed.

 CAUTION

AVOID INJURY

Before using any attachment in a work application, be sure to check its functional control. Make sure that the desired movement or action is being activated by the control. e.g. opening/closing, CW/CCW, crowd/dump, etc.

DS1703960

Figure 19

Operating Controls  2-14

DX220A-2/DX220LCA-2

 

14. Power Power Mode Mode B Butto utton n Press the right button the top of the right-hand work lever (joystick) to use power mode. Refer to the "Power Mode"  Mode"  on page 3-21. 3-21.

DS1703698

Figure 20

15. Auto Auto Id Idle le B Butto utton n When the auto idle system is activated, the engine will automatically reduce speed to "IDLE" approximately four seconds after all of the control levers are in the neutral position. This system is designed to reduce fuel consumption and noise.

DS1703699

Figure 21

16. Displa Display y Mon Monito itorr See "Instrument Panel" on page 2-17.

DS1703700

Figure 22

Operating Controls  Controls  2-15

DX220A-2/DX220LCA-2

 

17. Breaker Breaker Elect Electric ric Ped Pedal al (Optional (Optional)) This pedal is used to activate hydraulic breaker. O.

In tthi his s po posi siti tion on,, brea breake kerr does does n not ot o ope pera rate. te.

I.

In this this po posi siti tion on,, bre break aker er is op oper erat ated ed.. O I DS1602362

Figure 23

18.. Safe 18 Safety ty Le Leve verr See "Safety Lever" on page 3-15.

Unlock

Lock

Figure 24

EX1300566

Operating Controls  2-16

DX220A-2/DX220LCA-2

 

INSTRUMENT PANEL

2

5

1

3

4

DS1703701

Figure 25 Reference Number

Description

Reference Number

Description

1

Fuel Gauge

4

LCD Control Button

2

Engine Coolant Temperature Gauge

5

Display Warning Symbols

3

LCD Information Area

Operating Controls  Controls  2-17

DX220A-2/DX220LCA-2

 

Functional check  When the engine starter switch is turned to "I" (ON) position, all gauge bands, switch/button indicator lights and warning lights will turn "ON" and the alarm buzzer will sound about two seconds.

1. Fuel Gauge Shows remaining fuel quantity in tank. WHIT WH ITE E ZON ZONE E( RED RE D ZON ZONE E(

) - IInd ndic icat ates es a nor norma mall fue fuell qua quant ntit ity. y. ) - IInd ndic icat ates es th that at th the e fue fuell lev level el is lo low. w.

If the gauge pointer moves into the red zone, the fuel level symbol will turn "ON". Stop operation and immediately and add fuel. NOTE:

See "5. Display Warning Symbols" on page 2-  19 , for location of this warning symbol and others.

DS1703702

Figure 26

Check the fuel level on firm and level ground.

2. Engi Engine ne Co Cool olan antt Te Temp mper eratu ature re Gaug Gauge e The colored bands indicate the temperature of the engine coolant. WHITE WHIT E ZON ZONE E ( ) - Indi Indica cate tes s tem tempe pera ratu ture re is with within in the normal operating range. RED RE D ZON ZONE E(

) - Indi Indica cate tes s tem tempe pera ratu ture re is to too o hig high. h.

During operation, the pointer must be in the white zone. If the gauge pointer moves into the red zone, the engine coolant temperature warning light will turn "ON", a warning buzzer will sound, and the engine speed will be automatically reduced. Allow gauge the engine to runinatthe lowwhite idle speed until the temperature registers zone again. When the white zone is reached, allow the engine to idle for an additional three - five minutes before shutting down the engine. If not allowed to idle, heat surge may develop which will damage the engine. Allowing the engine to idle will dissipate heat. Check the coolant level, look for a loose fan belt, inspect for debris around radiator, and so on. When the temperature reaches the normal range, the engine speed will automatically recover.

DS1703703

Figure 27

Operating Controls  2-18

DX220A-2/DX220LCA-2

 

3. LCD LCD IInf nfor orm mat atiion Area Area This screen displays an RPM gauge, error codes, an hour meter, and TPS calibration.

DS1703704

Figure 28

4. LCD LCD Cont Contro roll Butto utton n This button is used to shift between display types in the LCD information area.

DS1703705

Figure 29

5. Disp Displa lay yW War arni ning ng Sy Symb mbol ols s Reference Number

Description

1

Charge Warning Symbol

2

Engine Oil Pressure Warning Symbol

3

Engine Coolant Temperature Warning Symbol

4

Water in Fuel Warning Symbol

5

Hydraulic Oil Overheat Warning Symbol

6

Air Cleaner Clogged Warning Symbol

7

Fuel Shortage Warning Symbol

8

Engine Preheat Symbol

9

Power Mode Symbol

10

Auto Idle Symbol

11

Eco Mode Symbol

12

Breaker Symbol

13

Travel High Speed Symbol

14

Machine Check Warning Symbol

DS1703706

Figure 30

Operating Controls  Controls  2-19

DX220A-2/DX220LCA-2

 

1.

Charge Wa Warning ing Sy Symbol This symbol indicates when the engine starter switch is turned "ON", and should go "OFF" after the engine starts. If it does not turn "OFF", shut the engine down immediately and determine the cause of the problem.

HAOA610L

Figure 31

2.

En Engi gine ne Oil Oil Pre Press ssur ure e Warn Warnin ing g Symb Symbol ol This symbol indicates when the engine starter switch is turned "ON", and should go "OFF" after the engine starts. For example, if the engine oil pressure becomes too low, the light will turn "ON" and a warning buzzer will sound. If this happens, shut the engine down immediately and determine the cause of the problem. If you continue to work when this light is "ON", it will result in serious engine damage.

CAUTION

HAOA620L

Figure 32 AVOID INJURY If you continue to work when this light is "ON", it will result in serious engine damage.

3.

Engi Engine ne Coo Coola lant nt Tem Tempe pera ratu ture re War Warni ning ng Symb Symbol ol If engine coolant overheats, this symbol appears on the screen an alarm will sound, and the engine speed will be automatically reduced, until coolant temperature drops. Do not turn engine "OFF" because this will cause coolant temperature to rise and can cause engine to siege because of heat surge. NOTE:

Check the engine coolant temperature gauge. If the gauge pointer moves into the red zone, the engine coolant temperature warning light will turn "ON", a warning buzzer will sound, and the engine speed will be automatically reduced. Allow the engine to run at low idle speed until the temperature gauge registers in the white zone again. When the white zone is reached, allow the engine to idle for an additional three - five minutes before shutting down the engine. If not allowed to idle, heat surge may develop which will damage the engine. Allowing the engine to idle will dissipate heat. Check the coolant level, look for a loose fan belt, inspect for debris around radiator, and so on.  When the temperature reaches the normal range, the engine speed will automatically recover.

HAOD350L

Figure 33

Operating Controls  2-20

DX220A-2/DX220LCA-2

 

4.

Wa Wate terr In Fuel Fuel Warn Warnin ing g Symb Symbol ol This symbol indicates when the water is full in the fuel prefilter. When this symbol appears drain the water from the fuel prefilter as soon as possible.

DS1603475

Figure 34

5.

Hydr Hydrau auli lic cO Oil il Over Overhe heat at Warn Warnin ing g Symb Symbol ol If the hydraulic oil temperature is too high, this symbol appears on the screen.

FG000056

Figure 35

6.

Air Air Clea Cleane nerr Cl Clog ogge ged d Wa Warn rnin ing g Symb Symbol ol This symbol indicates when the air cleaner is clogged. If this symbol is displayed, immediately stop operation and replace or clean the air filter. After the air filter has been serviced, restart machine operation to remove warning symbol.

FG000053

Figure 36

7.

Fuel Fuel Sh Shor orta tage ge Wa Warn rnin ing g Symb Symbo ol If the fuel quantity is too low, this symbol appears on the screen. If this light turns "ON", add fuel as soon as possible.

FG000057

Figure 37

Operating Controls  Controls  2-21

DX220A-2/DX220LCA-2

 

8.

Engine Pr Preheat Sy Symbol In cold weather this symbol indicates that the engine preheat function is operating. When this indicator symbol turns "OFF", it means that engine preheat cycle has been completed.

HAAE2000

Figure 38

9.

Power Mode Symbol Pressing the left button on the right work lever enters the machine into the power mode. This symbol lights up upon shifting into the power mode.

FG019132

Figure 39

10. 10.

Auto Auto Idle Idle Symb ymbol Pressing the right button on the right work lever enters the machine into the auto Idle mode. This symbol lights up upon shifting into the auto Idle mode.

DS1703707

Figure 40

11. 11.

ECO Mode Symb ymbol This symbol lights up based on the TPS value when the machine is in the ECO mode.

ECO  O EX1301004

Figure 41

Operating Controls  2-22

DX220A-2/DX220LCA-2

 

12. 12.

Br Brea eake kerr Sym Symb bol Pressing the right button on the left work lever enters the machine into the breaker mode. This symbol lights up upon shifting into the breaker mode.

FG028171

Figure 42

13. 13.

Tr Trav avel el High High Spee Speed dS Sym ymbo boll This symbol is on when the machine travels at high speed.

DS1704066

Figure 43 14 14..

Mach Machin ine e Chec Check k Symb Symbol ol Respective symbols light up when functions of the machine are not operating. NOTE:

If a symbol is lit up, after moving the machine to a safe location, find the cause of the malfunction and perform necessary repairs.

EX1301379

Figure 44

DX220A-2/DX220LCA-2

Operating Controls  Controls  2-23

 

HEATER AND AIR CONDITIONER CONTROL PANEL (OPTIONAL) Location of Controls and Vents

DS1703774

Figure 45 The heater and air conditioner are combined into one unit in the rear cover behind the operator's seat. The operator can control cabin temperature using the control panel installed in the switch panel.

Operating Controls  2-24

DX220A-2/DX220LCA-2

 

Control Panel

1

3

10

7

8

OUTSIDE

A/C AUTO

A/C AUTO

MAX

TEMP

OFF

SEL

MODE

4

5

2

6

9

FG000086

Figure 46 Reference

Reference Description Automatic Temperature Control Button

Number 6

Description Air Inlet Selector Button

7

Fan Speed Selector Button

2

Off Button

8

Air Conditioner Button

3

Temperature Control Button

9

Defroster Button

4

Temperature Unit Selector Button

10

LCD Display

5

Air Outlet Selector Button

Number 1

NOTE:

1.

When the light switch is turned to "I" or "II" position, the LED for illuminating in the control panel will turn "ON".

Auto Automa matic tic Te Temp mper eratu ature re Cont Contro roll But Butto ton n This button is used to control the temperature level in the cabin, according to the temperature setting of the operating panel. When the automatic temperature control function is activated, the word "AUTO" will be displayed in the upper left of LCD display.

AUTO

When the system is in "AUTO" mode, specifications can be manually changed by pushing another button. If a function is manually changed, the word "AUTO" does not appear in the LCD display, but the unchanged functions will remain in "AUTO" mode.

FG000088

Figure 47

Operating Controls  Controls  2-25

DX220A-2/DX220LCA-2

 

2.

Off Button This button is used to stop the fan and air conditioner.

OFF

FG000089

Figure 48

3.

Temp Temper erat atur ure e Cont Contro roll Butt Button on These buttons are used to control the cabin temperature. Temperature is adjustable from 17°C (62°F) to 32°C (90°F) by 0.5°C (1°F) increments. Temperature setting is displayed on the LCD.

TEMP

When the system is turned "ON", the previously set temperature is used as a starting point.

FG000090

Figure 49

4.

Temp Temper erat atur ure e Uni Unitt Sele Select ctor or Bu Butt tton on This button gives the choice to select either °C or °F.

SEL

FG000094

Figure 50

5.

Mode Selector Button This button is used to select which combination air outlets will be used.

MODE

FG000096

Figure 51

Operating Controls  2-26

DX220A-2/DX220LCA-2

 

A.

Used Used to to dire direct ct air air flo flow w to upper upper port portion ion of ope operato rator's r's cabin from both the front and rear.

DS1703775

Figure 52 B.

Used Used to to dire direct ct air air flo flow w to upper upper port portion ion of ope operato rator's r's cabin from both the front and rear. It will also deliver air to the lower portion of operator's cabin from under the operator's seat.

DS1703776

Figure 53 C.

Used Used to dir direct ect air flo flow w to to lower lower por portion tion of o oper perato ator's r's cabin and feet. This mode is mainly used for heating.

DS1703777

Figure 54 D.

Used Used tto o di dire rect ct air air flo flow w to the the fron frontt wi windo ndow w and and to operator's feet.

DS1703778

Figure 55

Operating Controls  Controls  2-27

DX220A-2/DX220LCA-2

 

6.

Ai Airr In Inle lett Sel Selec ecto torr Bu Butt tto on This button is used to select fresh air from outside the cabin, or recirculate air within the cabin. Pressing this switch enables the choice between fresh air and recirculating air within the operator's cabin. The select mode is displayed on the LCD.

FG000101

Figure 56 A.

B.

"A" Symbol Symbol - Draw Draws s ffres resh h air air into operato operator's r's cab cabin. in. Used to exchange air within the operator's cabin with fresh air. Used to remove condensation or ice on window (Winter/Rainy Season).

A

"B" Sym Symbol bol - Reci Recircu rculate lates s air air withi within n th the e opera operator tor's 's cabin. Used to quickly warm or cool the operator's cabin.

B

FG000102

Figure 57

7.

Fan Spe peed ed Se Sele lect ctor or Bu Butt tto ons These buttons are used to control the speed of the blower fan. Momentarily, pressing a button, changes the speed one stage. Continuously pressing and holding a button, repeatedly changes the speed.

FG000103

Figure 58

8.

Ai Airr Cond Condit itio ion ner Butt Butto on This button is used to turn the air conditioner "ON" or "OFF". When this function is activated, an "A/C" is displayed in the upper left corner of the LCD.

A/C

FG000105

Figure 59

Operating Controls  2-28

DX220A-2/DX220LCA-2

 

9.

Defroster Button Used to direct air flow to front window.

FG000106

Figure 60

10. LCD Disp isplay This display shows the current setting. OUTSIDE

A/C AUTO

MAX

FG000107

Figure 61

Memory Function The air conditioner panel has a memory function. When the starter switch is turned "OFF", the settings for the panel will be stored. When the excavator is started, the last stored setting will be used.

Additional Operating Instructions A proper indoor temperature in summer is 5 - 6°C (10 - 12°F) less than the outdoor temperature. Operate the air conditioner for twenty - thirty minutes a week to circulate the refrigerant in the system. NOTE:

The blower button must be on "Three Bars".

If operating the air conditioner or heater for a long time, operate the air inlet selector button, and when smoking, vent the air to the outside to prevent irritation to eyes.

Operating Controls  Controls  2-29

DX220A-2/DX220LCA-2

 

STEREO  (OPTIONAL) Before operating the stereo read operation manual enclosed with stereo.

Stereo 6

AM

7

FM

8

LOUD

PUSH AST

VOLUME

TUNE

MENU

5

MP3 ST RDS REG TA TP PTY PTY AF DIR INT RPT RDM EQ USB

USB

9 10

AUX 

1 II

 

2 RPT  

4 INFO  

3 RDM  

5 D-

 

6 D+

4

3

1 2

WL1500796

Figure 62 Reference Number

Description

Reference Number

Description

1

Power/Volume Control

6

LCD

2

Preset Station

7

AM Selection

3

Tuning Up/Down

8

FM Selection

4

USB Loading Port

9

USB Selection

5

Menu

10

Auxiliary Mode

Operating Controls  2-30

DX220A-2/DX220LCA-2

 

MISCELLANEOUS ELECTRICAL DEVICES Cabin Light A light is installed on the top of the operator's cabin. The light will work despite starter switch position. NOTE:

If light is left "ON" for a long time while the engine is not running, the battery will be discharged.

FG000417

Figure 63

Pilot Cutoff Switch When the safety lever is put into "LOCK" position, the switch deactivates the work and travel levers. With the work and travel levers deactivated, no digging/operational work can be done. Unlock

Lock

EX1300566

Figure 64

Circuit Breaker (60A) A main circuit breaker is in the battery box. It will automatically cut off in case of an electrical short circuit or overload. This will prevent the electrical wiring and components from being burned or damaged. If the circuit breaker is cut off, check all related circuits, this means something is wrong in the electrical circuit. After maintenance, press the red button for normal operation of circuit breaker.

HAAE2110

Figure 65

Operating Controls  Controls  2-31

DX220A-2/DX220LCA-2

 

Fusible Link  A fusible link is in the battery box. A

If the engine does not crank, first check that the starter switch is turned "ON" and that no power is available (No indicator lights will light.). Check that the "A" portion (Figure ( Figure 66 66)) of the fusible link is not broken or burned through. Replace the fusible link if damage and investigate cause.

WARNING

HAAE2120

Figure 66

AVOID DEATH OR SERIOUS INJURY When changing the fusible link, replace the fusible link with the same capacity part. Otherwise, a fire could break out in the wiring harness and/or other components of the circuit. Always use original DOOSAN parts.

Fuse Boxes There are two fuse boxes (Figure (Figure 67 67)) on the left side of the heater box. The fuses prevent electrical devices from overloading or shorting. A decal attached inside the fuse box access cover indicates the function and amperage of each fuse. NOTE:

For a further explanation see "Fuse Boxes" on page   4-76 .

Spare fuses are mounted on the inside of fuse box access cover. Change a fuse if the element separates. If the element of a new fuse separates, check the circuit and repair the circuit.

CAUTION AVOID INJURY Always replace fuses with the same type and capacity fuse that was removed. Otherwise, electrical damage could result.

FG000110

Figure 67

Operating Controls  2-32

DX220A-2/DX220LCA-2

 

SEAT ADJUSTMENT  WARNING AVOID DEATH OR SERIOUS INJURY Adjust the seat position before starting operations or after changing the operator. Always fasten your seat belt while operating machine. Adjust the seat so that the control levers and pedals can be operated freely and easily with the operator back against the backrest.

1. Forw Forward ard/B /Bac ackw kwar ard d Adju Adjustm stmen entt Holding lever (1, Figure 68), 68), raise it up, move the seat to the desired position. Release lever to lock the seat in the selected position. Adjustment range is 240 mm (9.4 in).

2. Recl Reclin inin ing g Pos Posit itio ion n Adj Adjus ustm tmen entt Pulling up left lever (2, Figure 68) 68) allows seat backrest to be moved forward or backward. Sit with your back against the seat back when adjusting it. If your back is not touching the seat back, the seat back may suddenly move forward.

2 1 DS1703708

Figure 68

Operating Controls  Controls  2-33

DX220A-2/DX220LCA-2

 

SEAT ADJUSTMENT (SUSPENSION SEAT OPTIONAL)  WARNING AVOID DEATH OR SERIOUS INJURY Adjust the seat position before starting operations or after changing the operator. Always fasten your seat belt while operating machine. Adjust the seat so that the control levers and pedals can be operated freely and easily with the operator back against the backrest.

1. Forw Forward ard/B /Bac ackw kwar ard d Adju Adjustm stmen entt Holding lever (1, Figure 69), 69), raise it up, move the seat to the desired position. Release lever to lock the seat in the selected position. Adjustment range is 200 mm (7.9 in).

2

3 5

2. Seat Seat Tilt Tilt and and H Hei eigh ghtt Adj Adjus ustm tmen entt Forward Tilt Pull lever (2, Figure 69) 69) down to adjust the angle of the front of the seat. There are four positions that it can be set at. Rear Tilt Pull lever (3, Figure 69) 69) up to adjust the angle of the rear of the seat. There are four positions that it can be set at. Seat Height It is possible to move the seat up or down by combining adjustments forward and rear tilt. Adjust the seat according to operator's size and work conditions. Height adjustment is 60 mm (2.4 in).

3. Susp Suspen ensi sion on Adju Adjust stme ment nt Turning knob (4, Figure 69) 69) to right makes the suspension harder. Turning knob to left makes the suspension softer. Adjust according to operator's weight by checking the weight indicator dial. Adjustment range is from 40 ~ 130 kg (88 ~ 287 lb).

1

 

4 DS1703709

Figure 69

Operating Controls  2-34

 

4. Recl Reclin inin ing g Pos Posit itio ion n Adj Adjus ustm tmen entt Pulling up the right lever (5,Figure (5, Figure 69) 69) allows the seat backrest to be moved forward or backward. Sit with your back against the seat back when adjusting it. If your back is not touching the seat back, the seat back may suddenly move forward.

DX220A-2/DX220LCA-2

Operating Controls  Controls  2-35

DX220A-2/DX220LCA-2

 

SEAT BELT  WARNING AVOID DEATH OR SERIOUS INJURY The seat belt is for the operator's safety and should always be worn. Before driving the machine, adjust the seat to the desired position for maximum comfort and machine control, then fasten the seat belt. Seat belts must be worn across the pelvic region and adjusted snugly to lessen the chance and severity of injury in case of an accident. Never fasten a seat s eat belt across the abdomen. Under no circumstances should the operator be standing in the cabin when operating the excavator. Do not adjust the seat position while the vehicle is moving because a loss of control can result. Stop the machine, apply the parking brake, and then adjust the seat. Always, check the condition of seat belt and belt bracket before not useoritworn. with twists in it. Replace belt fastening or bracketit.if Do damaged

Seat Belt Locking and Unlocking 1

Insert belt end (1, Figure 70) 70) into the buckle (2). Pull belt to check that belt end is locked into buckle.

2

Adjust belt length so that it comfortably tight against operator's pelvic region (hipbone).

HDO2058I

Figure 70 Press button (3, Figure 71) 71) in center of buckle (2) and pull out belt (1) to unlock.

1 2

3

HDO2059I

Figure 71

Operating Controls  2-36

DX220A-2/DX220LCA-2

 

CEILING COVER NOTE:

If machine is equipped with the optional transparent ceiling cover never use any chemical cleaners on its surface. Only use warm water to wash dust and dirt from its surfaces, and after that, dry it with a soft fabric towel.

Unlock

Lock

EX1300566

Figure 72

Opening the Ceiling Cover 1.

Lo Lowe werr b buc ucke kett o orr wor work k too tooll to to g gro roun und. d.

2.

Move safety lever (Figure 72) 72) to "LOCK" position.

3.

Pull lock (1, Figure 73 73)) in front center of ceiling cover and push it up with handle.

Closing the Ceiling Cover 1.

Lo Lowe werr b buc ucke kett o orr wor work k too tooll to to g gro roun und. d.

2.

Move safety lever (Figure 72) 72) to "LOCK" position.

3.

Pul ulll d dow own nc cov over er wi with th ha hand ndle le (Figure 73) 73) so lock (1) can be locked into bracket in ceiling frame.

FG000190

Figure 73

Operating Controls  Controls  2-37

DX220A-2/DX220LCA-2

 

DOOR SIDE LATCH 1.

The do door si side la latch (1 (1, Figure 74) 74) is used to secured door to side of cabin when it is opened. NOTE:

Keep door closed and locked when machine is not in use.

1 FG000196

Figure 74 2.

To rel relea ease se doo doorr from from sid side e of cab cabin in,, push push lat latch ch leve leverr (2, (2, Figure 75) 75) down. The latch lever is to the left of operator's seat.

2 FG000673

Figure 75

CABIN STORAGE COMPARTMENTS

2

There are two storage compartments behind the operator's seat. The large compartment nonperishable items.

(1,

Figure

76) 76)

is

for

storing

The covered other one (2, Figure 76) 76) is interconnected with the air conditioner. It can be supplied with either warm or cool air when air conditioner is turned "ON".

1 FG000209

Figure 76 There is a separate small tray (3, Figure 77) 77) on right side of operator's seat.

3

FG000675

Figure 77

Operating Controls  2-38

DX220A-2/DX220LCA-2

 

CUP HOLDER There is a cup holder on the right side of the cabin (1, Figure  Figure  78). 78). Open the access cover and lower it to a horizontal position.

1

DS1703710

Figure 78

DOOR WINDOW HOLDER 1

When the machine is being operated with the cabin door window opened, window vibration can be reduced by tightening knob (1, Figure 79) 79) against the window.

FG000206

Figure 79

EMERGENCY GLASS BREAKING TOOL The excavator is equipped with a glass breaking tool. It is to the upper right corner of the cabin. This tool can be used in case of an emergency that requires breaking glass to exit from operator's cabin. Grip handle firmly and use sharp point to break glass.

WARNING AVOID DEATH OR SERIOUS INJURY Protect your eyes when breaking the glass.

DS1703691

Figure 80

Operating Controls  Controls  2-39

DX220A-2/DX220LCA-2

 

MISCELLANEOUS ACCESS COVERS AND DOORS Side Door Open the side access door and slide prop rod (1, Figure 81 81)) in slot (2) until it locks at end of slot.

1 2

FG000165

Figure 81

Battery Box Door 1

Opening Open door until locking device (1, Figure 82) 82) latches. Closing While holding door, press locking device to release lock and close door. FG000166

Figure 82

Engine Cover 2

Open cover and slide prop rod (1, Figure 83) 83) in slot (2) until it locks in notch at the end of slot to support the cover.

1

To close cover, move end of prop rod out of notch so it can slide in slot.

FG013197

Figure 83

Operating Controls  2-40

DX220A-2/DX220LCA-2

 

3Operation TO HANDLE A NEW EXCAVATOR All DOOSAN excavators are inspected before leaving the factory. However, it is required that operator follow these steps during the initial break-in period. Failure to follow these steps can result in damage to the equipment or reduced performance. Hour

Load

For first 50 hours of operation

Maintain about 80% load of full capacity (Engine rpm: 80% of rated rpm)

After After firs firstt 5 50 0 hou hours rs of of oper operat atio ion n

Fu Full ll lo load ad

If machine is used at full load before befo re it is broken in, it could affect the overall performance and service life of the machine. NOTE:

1.

Chec Check k dail daily y fo forr leak leakag age e of coo coola lant nt,, fu fuel el,, en engi gine ne oil and hydraulic oil.

2.

Insp Inspec ectt all all lu lubri brica cant nts s dail daily y and and add add ap appr prop opri riat ate e lubricants as required.

3.

Duri During ng ope opera rati tion on,, moni monitor tor all all in instr strum umen ents ts a and nd gauges from time to time.

4.

Avo void id an extr extrem eme e eng engin ine e lloa oad. d.

5.

Oper Operat ate e u uni nitt at 80% 80% lloa oad d u unti ntill eng engin ine e and and al alll other components are at operating temperatures.

6.

Chec Check k tha thatt normally.

7.

Chec Check k mac machi hine ne for for loos loose e par parts ts or for for d dam amag age e that may have occurred during shipping.

8.

Chec Check k for for loos loose e w wir irin ing g or or term termin inal als, s, chec check k gauge operation and battery electrolyte level.

9.

Afte Afterr the the ma mach chin ine e is n new ewly ly iins nstal talle led d or rrep epla lace ced, d, some of its components are to be initially and only once lubricated/greased or replaced. For details, refer to "Inspection, Maintenance   and Adjustment" on page 4-1 of 4-1 of this manual.

wor work k

eq equip uipme ment nt is oper operati ating ng

Operation  Operation  3-1

DX220A-2/DX220LCA-2

 

STARTING AND STOPPING ENGINE Inspection Before Starting Engine Walk Around Checks

 WARNING AVOID DEATH OR SERIOUS INJURY If flammable materials such as leaves, paper, etc. are allowed to accumulate on high temperature components, such as the engine muffler and turbo, a fire can occur. Fuel, lubricant, and hydraulic oil leaks can cause a fire. Clean machine, remove all flammable materials from machine, and repair machine before operating. Before starting engine, inspect the following items. If any problem is found, repair it before machine operation. 1.

2.

3.

Overall •

Chec Check k for for da dama mage ge,, wear wear,, crac crack, k, oil oil leak leakag age, e, pla play y iin n work equipment, cylinders, linkages and hoses.

•

Chec Check k the the unde underca rcarr rria iage ge for damag damage, e, wear wear,, cra crack ck,, oi oill leakage and loose bolts.

•

Chec Check k ffor or prob problem lems s in do doors ors,, han handr drai ails ls,, gua guard rdra rail ils, s, steps and loose bolts.

•

Clea Clean n and and c che heck ck cabin cabin gl glass ass,, rearv rearvie iew w mi mirro rrors rs,, rrea earr view camera and lights.

•

Cl Clea ean n and and chec check k moni monito tor, r, sw swit itch ches es and and g gau auge ges s in th the e cabin.

Cleaning • Remo Remove ve dirt dirt and and d deb ebris ris from from arou around nd engi engine ne,, radi radiat ator or,, oil cooler and battery. •

Chec Check k and and re remo move ve flam flamma mabl ble e m mat ater eria iall aro aroun und d muffler, turbocharger, battery or other high temperature components.

•

Clea Clean n and and insp inspec ectt fin fins s of of rrad adia iato tor, r, oil oil coo coole ler, r, CA CAC C (Charged Air Cooler), fuel cooler and condenser.

Engine system •

Chec Check k for for cool coolan antt and and oil oil leak leakag age e arou around nd the the e eng ngin ine e and cooling system.

•

Chec Check k eng engin ine e emi emis ssion sion co cont ntro roll s sys yste tem. m.

Operation  3-2

 

4.

5.

Fuel system •

Dr Drai ain n wat water er an and d sed sedim imen entt from from fu fuel el ta tank nk an and d wat water er separator.

•

Chec Check k ffor or fuel fuel le leak akag age e in in fue fuell s sys yste tem. m.

Hydraulic system •

Chec Check k for for hydr hydrau auli lic c oil oil lea leaks ks,, dama damage ged d tubi tubing ng an and d hoses and interference points of components.

6.

Electric sy system • Chec Check k for for da dama mage ged d ele elect ctri rica call cab cable les s and and loos loose e or or missing connectors.

7.

Lubrication •

8.

Safety •

9.

Perfo Perform rm all dail daily y and pe peri riod odic ic main mainte tena nanc nce e ser servi vice ces. s. Perform services according to reading shown on hour meter.

Pe Perf rfor orm m a mac machi hine ne walk walk-a -aro roun und. d. Mak Make e sur sure e th that at no one is under the machine or performing any maintenance on it before starting engine.

Afte fter s sttart arting ma machine •

Chec Check k th that at all all op opera erati tiona onall cont control rols s and compo componen nents ts are in proper operating condition and are functioning correctly. Stop operation and correct any problems before continuing work.

DX220A-2/DX220LCA-2

DX220A-2/DX220LCA-2

 

Checks Before Starting Engine Before starting engine, inspect the following items. If any problem is found, repair it before machine operation. If the oil, fuel or coolant level are below the "LOW" mark, add it. For detail method, see "10 Hour / Daily Service" on page 4-17. 4-17. 1.

Grea Grease se boom boom,, a arm rm and and fro front nt att attac achme hment nt pi pins ns..

2.

Check eng engiine o oiil lev leve el.

3.

Ch Chec eck k lev level el of hy hydr drau auli lic co oil il tank tank..

4.

Check fuel level.

5.

Chec Check ko oil il le leve vell o off swi swing ng redu reduct ctio ion n gea gear. r.

6.

Clea Clean n dust dust net net iin n fron frontt of oil oil c coo oole lerr and and inte interco rcool oler er..

7.

Chec Check kc cool oolin ing g syste system m and and ref refil illl as as requ requir ired ed..

8.

Inspec Inspectt the the buck bucket et teeth teeth and side side c cutt utters ers for sig signs ns of wear wear..

9.

In Insp spec ectt en engi gin ne ffan an bl blad ade. e.

10. 10.

Chec Check k air air in intak take e sys syste tem. m.

11. Inspec Inspectt seat seat belt ffor or any dama damage ge and and proper proper opera operatio tion. n. 12. Inspec Inspectt the struc structure ture for for crack cracks s and faul faulty ty welds welds.. 13. Check Check the the operati operation on of all all switch switches. es. 14.

Check the operatio operation n of all exterior exterior lights, lights, horn, horn, travel travel alarm/  swing alarm (if equipped).

Operation  Operation  3-3

Operation  3-4

DX220A-2/DX220LCA-2

 

Operational Checks Before Starting Engine 1.

Tu Turn rn bat batte tery ry dis disco conn nnec ectt swit switch ch to to "O "ON" N" posi positi tion on ((Figure Figure 1 1). ).

OFF

ON

OFF

OFF

O    N    

O    N    

EX1500481

Figure 1

WARNING AVOID DEATH OR SERIOUS INJURY When leaving operator's seat, move the safety lever to "LOCK" (Figure (Figure 2) 2) position and stop engine to prevent accidental activation of the work levers and controls. 2.

Mo Move ve saf safet ety y le leve verr to "LOC "LOCK" K" po posi siti tion on (Figure (Figure 2 2). ).

3.

Fasten Fasten seat seat b belt. elt. Che Check ck for pro proper per operati operation on and conditi condition. on.

4.

Set Set all all op oper erat atio ion n leve levers rs in "N "NEU EUTR TRAL AL". ".

Unlock

Lock

NOTE: 5.

Figure 2

Be careful not to move any switches when starting engine.

Rota Rotate te the the s sta tart rter er s swi witc tch h to "I "I"" (ON) (ON) pos posit itio ion n (Figure (Figure 3). 3). Check all indicator lights. Warning buzzers will sound for about two seconds. After two seconds, all lights except the following will turn "OFF". •

Charging wa warning lilight

•

Engin ngine e oi oill pr pres essu sure re wa warn rnin ing g ligh lightt

• •

Engin ngine e co cool ola ant te tem mpera peratu ture re ga gaug uge e Fuel gauge

•

Hydraulic oi oil te temper perature ga gauge uge

•

Engin ngine e rpm rpm (0 rpm) rpm) digi digita tall read readou outt

NOTE:

EX1300566

If all the indicator lights do not come "ON" when the key is first turned, there is a problem.

O   ACC I

EX1402154

Figure 3

Operation  Operation  3-5

DX220A-2/DX220LCA-2

 

Engine Start

 WARNING AVOID DEATH OR SERIOUS INJURY Start the engine after sounding horn and making sure that there are no people or obstacles in the area. 1.

Perfo rform all steps in "Checks Before Starting Engine" on  on  page 3-4. 3-4.

2.

Set eng engine ine spe speed ed contro controll dial dial slight slightly ly above above "LOW "LOW IDLE" IDLE" (Figure 4). 4).

3.

Sound horn.

HAOB34L

Figure 4 "

4.

"

Turn Turn start starter er swit switch ch to (STA (START RT)) po posi siti tion on (Figure 5). 5). Engine should start in approximately five seconds.

O   ACC

I

WARNING AVOID DEATH OR SERIOUS INJURY If the engine does not start after approximately fifteen seconds of cranking, release the starter switch. Wait about five minutes and repeat above step.

EX1402153

Figure 5 5.

Aft After er engi engine ne has has star started, ted, releas release e key. key. Key Key will will return return to "I" "I" (ON) position.

6.

Follow pro proc cedures in in "Hydraulic System Warm-up" on  on  page 3-11. 3-11.

Operation  3-6

DX220A-2/DX220LCA-2

 

7.

Aft After er warm warming ing unit, unit, check check all operati operating ng indi indicat cators ors to m make ake sure that all engine systems (oil pressure, coolant, etc.) are in the normal operating range. If any problems are noticed, stop engine. Normal indicators are:

3 4 5

2

6 8 1

7 9

10

DS1703711

Figure 6 No.

8.

9.

Instrument Panel Light or Gauge

Indicator Reading

1

Fuel Gauge

White Range

2

Engine Coolant Temperature Gauge

White Range

3

Engine Oil Pressure Warning

OFF

4

Charge Warning

OFF

5

Water in Fuel Warning

OFF

6

Engine Coolant Temperature Warning

OFF

7

Air Cleaner Clogged Warning

OFF

8 9

Hydraulic Oil Overheat Warning Fuel Shortage Warning

OFF OFF

10

Machine Check Warning

OFF

Chec Check kc col olor or of ex exha haus ustt smo smoke ke.. •

No co colo lorr or or llig ight ht blue blue - Eng Engin ine e is is rrun unni ning ng in go good od condition.

•

Blac Black k - Inco Incomp mple lete te co comb mbus usti tion on.. Che Check ck ca caus use. e.

•

Whit White e or or dar dark k blu blue e - E Eng ngin ine e is is b bur urni ning ng en engi gine ne oi oil. l. Check cause.

Check Check for for u usu sual al en engi gine ne vib vibra ratio tion n and and noise noises. s. If any any are are heard or felt, investigate cause. NOTE:

If engine coolant temperature gauge pointer moves into the red zone, the engine coolant temperature warning light will turn "ON", a warning buzzer will sound, and the engine speed will be automatically reduced. Allow the engine to run at low idle speed until temperature gauge registers in the white zone again. When the white zone is reached, allow the engine to idle for an additional three - five minutes before shutting down the engine. If not allowed to idle, heat surge may develop which will damage the engine. Allowing the engine to idle will dissipate heat. Check the coolant level, look for a loose fan belt, inspect for debris around radiator, and so on.

Operation  Operation  3-7

DX220A-2/DX220LCA-2

 

Cold Weather Starting

WARNING AVOID DEATH OR SERIOUS INJURY DO NOT USE STARTING FLUIDS. The preheat system could cause the starting fluid to explode. Starting fluids should never be used. 1.

Perfor Perform m all all s step teps s in "Opera "Operatio tional nal Checks Checks Before Before Sta Starti rting ng Engine".

2.

Set eng engine ine spe speed ed contro controll dial dial slight slightly ly above above "LOW "LOW IDLE" IDLE" (Figure 7). 7).

3.

Sound horn.

4.

Tu Turn rn star starter ter swit switch ch to "I" (ON) (ON) posit positio ion n (Figure (Figure 8). 8). When preheat cycle is completed, the preheat indicator light (1, Figure 9) 9) will turn "OFF".

HAOB34L

Figure 7

O   ACC I

EX1402154

Figure 8

1

DS1703712

Figure 9

Operation  3-8

DX220A-2/DX220LCA-2

 

5.

Aft After er the prehea preheatt comp complet letion ion,, immedi immediate ately ly turn turn star starter ter switch to

"

"

O   ACC I

(START) position (Figure 10). 10). Engine

should start in approximately five (5) seconds.

WARNING AVOID DEATH OR SERIOUS INJURY If the engine does not start after approximately fifteen seconds of cranking, release the starter switch. Wait about five minutes and repeat above step. 6.

Aft After er engi engine ne has has star started, ted, releas release e key. key. Key Key will will return return to "I" "I" (ON) position (Figure (Figure 10). 10).

7.

Aft After er the eng engine ine starts starts,, check check all operati operating ng ind indica icator tors s to to make sure that all engine systems (oil pressure, coolant, etc.) are in the normal operating range. If any problems are noticed, stop engine.

8.

Follow "Hydraulic System Warm-up" Warm-up" procedures in this section. (See page 3-11)

EX1402153

Figure 10

Starting Engine With a Booster Cable

WARNING AVOID DEATH OR SERIOUS INJURY 1.

An explos explosive ive gas is produ produced ced while while batter batteries ies are in use or being charged. Keep flames or sparks away from the battery area.

2.

Char Charge ge ba batt tter erie ies s iin n a well well ven venti tila lated ted ar area. ea.

3.

Always Always wear wear eye protect protection ion when when starti starting ng a machin machine e

4.

with jumper cables. Impr Improp oper er jum jump p star startin ting g proc proced edur ures es can can caus cause e an explosion resulting in personal injury.

5.

Jump Jump star startt ve vehic hicles les on dr dry y groun ground d or or concr concrete ete.. Do no nott jump start the machine on a steel floor, because the floor is always grounded.

6.

When When startin starting g from from ano anothe therr machin machine, e, make make s sure ure the machines do not touch.

7.

Alwa Always ys conn connec ectt the aux auxili iliar ary y batte battery ry pos posit itive ive (+) (+) terminal too depleted battery positive (+) terminal first. Then connect auxiliary battery negative (-) terminal to the frame of the depleted battery machine second.

8.

Connec Connectt positi positive c cabl able e first ficable rst when whe n iinst nstalli alling ng cables cables and disconnect theve negative first when removing.

HAOA440L

Figure 11

Operation  Operation  3-9

DX220A-2/DX220LCA-2

 

IMPORTANT The machine has a 24V (-) negative ground electrical system. Use the same capacity 24V booster batteries when jump starting engine. If the batteries are drained during starting procedures, jump start engine using auxiliary or booster batteries according to the following procedure; Connecting the Booster Batteries 1.

Stop Stop engin engine e of of th the em mach achine ine on whic which hb boos ooster ter batter batteries ies (3, Figure 12) 12) are mounted.

2.

Co Conn nnec ectt one one en end d of of red red ca cabl ble e ((1, 1, Figure 12) 12) to the positive (+) terminal of the machine batteries (4), and the other end to the positive (+) terminal of the booster batteries.

3.

Co Conn nnec ectt one one en end d of of bla black ck ca cabl ble e (2, (2, Figure 12) 12) to the negative (-) terminal of the booster batteries (3), and then make ground connection to the upper frame (5) of the machine to be started with the other end of black (-) cable (2, Figure 12). 12). When making lastend connection to upper frame, be sure to connect the the cable as far away from the machine batteries as possible. DO NOT CONNECT DIRECTLY TO THE NEGATIVE BATTERY TERMINAL.

4.

Start th the en engine.

Disconnecting the Booster Batteries 1.

Disc Discon onnec nectt b bla lack ck ne nega gati tive ve (-) (-) c cab able le (2, (2, Figure 12 12)) from the machine frame (5) first.

2.

Discon Disconnect nect the other other end end of black black nega negativ tive e (-) (-) cabl cable e (2, (2, Figure 12) 12) from the booster batteries (3).

3.

Disc Discon onne nect ct red red pos posit itiv ive e (+) (+) ca cabl ble e (1, (1, Figure 12) 12) from the

4.

booster batteries (3). Disc Discon onne nect ct red red pos posit itiv ive e (+) (+) ca cabl ble e (1, (1, Figure 12) 12) from the machine batteries (4).

1 RED

3

4 BLACK

2

5 ARO0440L

Figure 12

Operation  3-10

DX220A-2/DX220LCA-2

 

Hydraulic System Warm-up

 WARNING AVOID DEATH OR SERIOUS INJURY If a problem or abnormal operation occurs, immediately stop engine. Allow excavator to reach normal operating temperature before starting work, especially in cold weather. The correct operating temperature of the hydraulic oil is 50° 80°C (120° - 175°F). Make sure to follow the procedures listed here for hydraulic fluid warm-up. 1.

Run Run engi engine ne for for a app ppro roxi xima matel tely y five five minu minute tes s se sett at the the middle of the speed range, without a load.

HAOB410L

Figure 13 2.

Move safety lever (1, (1, Figure 14 14)) to "UNLOCK" position.

Unlock

Lock

EX1300566

Figure 14 3.

Slowly Slowly cyc cycle le boom, boom, arm and bucket bucket cyl cylind inders ers about about fiv five e times without a load to circulate the oil through the system. Do this for five minutes.

4.

Check Check for cle clearan arance ce and fully fully rais raise e tthe he front front atta attachm chment. ent. Swing clockwise 3 revolutions. Swing counterclockwise 3 revolutions.

5.

Trave Travell fo forw rward ard an and d reve revers rse e at lo low w spee speed d for for two two revolutions of the drive sprocket. FG000380

Figure 15

Operation  Operation  3-11

DX220A-2/DX220LCA-2

 

Hydraulic System Warm-up – Cold Weather 1.

Run Run engi engine ne at at "LOW "LOW IIDL DLE" E" ((no no loa load) d) for for ffiv ive e minu minutes tes (Figure 16). 16).

HAOB290L

Figure 16 2.

Run Run engi engine ne for for a app ppro roxi xima matel tely y five five minu minute tes s se sett at the the middle of the speed range, without a load (Figure ( Figure 17). 17).

HAOB410L

Figure 17 3.

Move safety lever (1, (1, Figure 18 18)) to "UNLOCK" position.

Unlock

Lock

EX1300566

Figure 18 4.

Slowly Slowly cyc cycle le boom, boom, arm and bucket bucket cyl cylind inders ers about about fiv five e times without a load to circulate the oil through the system. Do this for five minutes.

FG000380

Figure 19

Operation  3-12

DX220A-2/DX220LCA-2

 

5.

Set Set engi engine ne spee speed dc con ontr trol ol dial dial to "H "HIG IGH H IIDL DLE" E" (Figure 20). 20).

6.

Repeat Step 4 for five minutes. If working speeds continue to be slow, continue to operate, but use extreme caution because the machine function may be erratic.

7.

Check Check for cle clearan arance ce and fully fully rais raise e tthe he front front atta attachm chment. ent. Slowly swing clockwise 3 revolutions. Slowly swing counterclockwise 3 revolutions.

8.

Trave Travell fo forw rward ard an and d reve revers rse e at lo low w spee speed d for for two two revolutions of the drive sprocket.

HAOB550L

Figure 20

Stopping Engine NOTE:

Allow engine to idle for three - five minutes before shutting down the engine. If not allowed to idle, heat surge may develop which will damage the engine. Allowing the engine to idle will dissipate heat.

1.

Park Park ex exca cava vato torr on on lev level el and and fir firm mg gro roun und. d.

2.

Lowe Lowerr fr fron ontt end end atta attach chme ment nt to to grou ground nd a and nd mak make e sure sure all all operating controls are in "NEUTRAL". EX1300684

Figure 21 3.

Mo Move ve saf safet ety y le leve verr to "LOC "LOCK" K" po posi siti tion on (Figure (Figure 22 22). ).

Unlock

Lock

EX1300566

Figure 22 4.

Set Set eng engin ine e speed speed cont contro roll dial dial to "L "LOW OW IDLE IDLE"" ((Figure Figure 23). 23). Allow engine to idle for three - five minutes.

HAOB290L

Figure 23

Operation  Operation  3-13

DX220A-2/DX220LCA-2

 

5. 6.

Stop Stop engi engine ne b by y turn turnin ing g key key to "O "O"" (OFF (OFF)) posi positi tion on ((Figure Figure   24). 24).

O   ACC I

Re Remo move ve ke key y from from star starte terr swi switc tch. h.

EX1402155

Figure 24

Check and Confirmation After Stopping Engine 1.

Repa Repair ir exc excav avat ator or,, if tthe here re are are any any cool coolan antt or oil oil le leak aks. s.

2.

Inspec Inspectt fron frontt atta attachm chment ent and under under car carriag riage e for for abn abnorm ormal al appearances. Correct any problems.

3.

Fill fu fuel ta tank.

4.

Get Get ri rid d of any any accum accumul ulate ated d flam flamma mabl ble e ma mater teria ials ls suc such h as leaves and paper etc. in engine compartment.

5.

Clean Clean all mud, mud, etc. etc. from from u unde nderca rcarria rriage ge and tracks. tracks. Make Make sure that all steps and hand holds are clean, and that the operator's cabin is clean.

Operation  3-14

DX220A-2/DX220LCA-2

 

SAFETY LEVER  WARNING AVOID DEATH OR SERIOUS INJURY When stopping engine or leaving the operator's seat, "LOCK" the safety lever, otherwise, a serious accident can occur by accidental movement of travel and work levers. Whenever leaving the operator's seat, make sure the engine is stopped and the safety lever is "LOCKED". Especially, when adjusting the seat, control stands, or raising the front window, lower window, or ceiling cover, never forget to lock the safety lever in its "LOCKED" position. Be careful not to move the work levers (joysticks) when moving safety lever. 1.

Push safety lever (Figure 25) 25) down into "LOCKED" position. When safety lever is in the "LOCKED" position, the front attachment, swing and travel movement will be disabled even though a lever is moved. NOTE:

2.

Lower bucket (front attachment) to ground. Place all control levers in "NEUTRAL" and stop engine, before using the safety lever.

Unlock

Move safety lever (Figure 25 25)) to "RELEASE/UNLOCK" position, by pulling it up before starting work. NOTE:

When the engine is not running, but the safety lever is "RELEASED" and the starter key is tuned "ON", moving the work levers (joysticks) can result in movement. The charged accumulators in the system will provide pilot pressure for control valve spool movement.

Lock

Figure 25

EX1300566

Operation  Operation  3-15

DX220A-2/DX220LCA-2

 

TRAVEL  WARNING AVOID DEATH OR SERIOUS INJURY 1.

Bef Befor ore e op oper erati ating ng the the tra travel vel lever levers, s, make make su sure re tha thatt you you know in which direction the machine is pointing. Look at the end of the track assemblies. If the drive motors are visible while sitting in the operator's seat, you are looking at the back end of the track assembly (therefore, you are looking backwards). In this case, the response of the travel levers will be the reverse of normal operation.

2.

Bef Befor ore e mo movin ving, g, make make sur sure e that that ther there e are are no perso personn nnel el in in the way or on the machine. Sound the horn to alert workers that you are about to move the machine.

3.

Be sure sure the the pat path h is is cle clear ar du duri ring ng tr trav avel el..

4.

Use extre extreme me cau cautio tion n when when reve reversi rsing ng travel travel.. Be su sure re there is a clear path behind the machine.

5.

Ma Make ke sure sure to to op opera erate te the the trave travell cont contro roll lever levers s smoo smoothl thly y to avoid sudden starts or stops.

6.

Bef Befor ore e lea leavin ving g the the opera operator tor's 's seat, seat, make make sure sure to lock lock out out all control systems and stop engine to avoid accidental activation.

Automatic Travel Speed Control

 WARNING AVOID DEATH OR SERIOUS INJURY Do not change the travel mode while traveling. Always use speed mode "O" when traveling down a slope. It is very dangerous to change to speed modes indicated "O" or "I" while going down a slope. coming to a complete stop. Only change travel mode after Two travel speed ranges can be selected by using the travel speed selector switch on the control panel (Figure ( Figure 26 26). ). "O" (LOW) - In this position low travel speed and a higher torque are selected. "I" (HIGH) - In this position high travel speed and a lower torque are selected.

O I

DS1703979

Figure 26

Operation  3-16

DX220A-2/DX220LCA-2

 

Travel Control Lever Operation 1.

To tr travel st straight ((Figure Figure 27), 27), push both travel control levers/pedals fully forward or backwards. The farther the levers/pedals are pressed, the faster the travel speed. NOTE:

"X" is the sprocket end of the track.

"X" FG000303

Figure 27 2.

Pivot turns (Figure 28) 28) are made by rotating only one track forward or backward. The machine will pivot on the nonmoving track. NOTE:

"X" is the sprocket end of the track.

"X" FG000304

Figure 28 3.

Spin turns (Figure 29 29)) are made by rotating one track forward and one track backward. The machine will spin around its center point, thus counterrotating. NOTE:

"X" is the sprocket end of the track.

"X" FG000305

Figure 29 4.

Stopping tr travel (Figure (Figure 30 30)) - Returning travel levers to "NEUTRAL" position will automatically apply brakes and stop excavator. NOTE:

"X" is the sprocket end of the track.

"X"

Figure 30

FG000306

Operation  Operation  3-17

DX220A-2/DX220LCA-2

 

General Travel Instructions 1.

Set Set en engi gine ne sp spee eed d co cont ntro roll dial dial (Figure 31) 31) on desired speed.

HAOB550L

Figure 31 2.

Move Move s safe afety ty lever lever to "UN "UNLOC LOCK" K" pos positi ition, on, and foldin folding g the the front, raise it 40 ~ 50 cm (16 ~ 20 in) above ground. See Figure 32. 32.

40 - 50 cm

EX1300696

Figure 32 3.

When When poss possib ible le,, trave travell on ffir irm m and lev level el grou ground nd.. Avoi Avoid d sudden movements and sharp turns.

4.

When When tra trave veli ling ng on on roug rough h grou ground nd,, trav travel el at at a sl slow ow spee speed d [1.0 ~ 1.5 km/h (0.62 ~ 0.93 MPH)]. Reduced engine speed, to avoid shock loading the equipment. Be careful that an excessive force is not added to equipment by touching or climbing on rocks.

5.

On rou rough gh,, fr froz ozen en or or unev uneven en ter terra rain in,, trav travel el slo slowl wly. y. EX1300697

Figure 33

Operation  3-18

DX220A-2/DX220LCA-2

 

 WARNING AVOID DEATH OR SERIOUS INJURY When traveling, keep bucket from 20 ~ 30 cm (8 ~ 12 in) above ground. Do not travel backward on a slope. Never turn or travel crosswise on a slope. Choose a safe alternate route before climbing a slope.

EX1300682

Figure 34

If excavator starts to slip or becomes unstable, lower the bucket immediately into the ground, using it as a brake. Avoid working on slopes, because there is a danger of overturning by becoming unbalance while swinging and performing front attachment operations. It is very dangerous to swing towards bottom of slope with a loaded bucket.

2 0  0 -  3  0 c m  0  m  ( 8  8 -  1  2 i n  2  n )   

In unavoidable cases level the slope with fill soil, to make the vehicle as horizontal as possible. See Figure  Figure  EX1300698

34. 34. Do not travel on slopes more than 30° because of turnover danger. 6.

7.

Figure 35

Travel Travel str straig aight ht up up or or down down s slop lopes, es, never never diag diagonal onally ly across across the slope. See Figure 35  35  and Figure 36 36.. Extend the arm and lower the boom to keep the bucket about 20 ~ 30 cm (8 ~ 12 in) off the ground. If the machine starts to slide or becomes unstable, lower the bucket to regain control. If the engine stalls, lower the bucket, make sure that all controls are in the neutral position and restart the engine. NOTE:

Even though engine stops on a slope, do not operate swing control. The hydraulic accumulators can cause the unit to swing.

NOTE:

Do not open or close operator's door on a slope. Make sure door is latched.

 c m  c  3 3 0       2 0

Figure 36

  )  in  i n  1 2   1     8  (   ( 

EX1300699

If dirt dirt or mud mud b build uilds su up p in the track track frame frame,, raise raise eac each h track track and rotate and clean that track.

CAUTION AVOID INJURY When using the boom and arm to lift any portion of the machine, roll the bucket until round base is against the ground. The angle of the arm to the boom must be at 90°.

EX1300700

Figure 37

Operation  Operation  3-19

DX220A-2/DX220LCA-2

 

Make sure that the material buildup has been cleared. See Figure 37 and 37 and Figure 38. 38. 8.

Th The e excav excavat ator or can can trav travel el in in wate waterr that that come comes s up to to cente centerr of upper carriage rollers. Make sure that footing is solid so that the machine will not sink. See "Working in Water" on on   page 3-31. NOTE:

If the machine is submerged to the point that water or mud gets into the swing bearing or center joint, stop machine operation. Remove machine from the submerged location to firm, dry ground. Do not operate until proper inspection and maintenance have been completed. Refer to the Shop Manual or contact your distributor.

90  - 1  11 10

EX1300534

Figure 38

Operation  3-20

DX220A-2/DX220LCA-2

 

OPERATING INSTRUCTIONS Engine Speed Control Engine speed can be manually adjusted using the engine speed control dial, Increase engine speed by rotating the control knob clockwise. Decrease engine speed by rotating the control knob counterclockwise.

IMPORTANT The engine speed control system has been set at the factory and should not require adjustment as part of routine maintenance.

HAOA690L

Figure 39

If the engine speed control system should have an electrical malfunction, the engine throttle system can be set for manual operation.

Mode Selection

More efficient work can be done by choosing a proper power and work mode combination, suitable to type of work and conditions. Use the mode selection according to following guide. Power Mode 1.

Press Press the the righ rightt butto button n the the top top o off th the e ri right ght-ha -hand nd w work ork lev lever er (joystick) to use power mode.

DS1703698

Figure 40 2.

Wh When en po powe werr m mod ode e is is sel selec ecte ted, d, sy symb mbol ol (Figure 41) 41) shows on screen.

DS1703713

Figure 41

Operation  Operation  3-21

DX220A-2/DX220LCA-2

 

Economy Mode 1.

No specif specific ic comman command d iis s requi required red to ente enterr into into the economy economy mode.

2.

When When the the eng engin ine e spee speed d dial dial ind indic icat ates es 1,6 1,600 00 rpm rpm o orr less less during travel, the machine enters into the economy mode automatically.

3.

This This symbo symboll ligh lights ts up up on the gauge gauge panel panel upo upon n shift shifting ing int into o the economy mode. DS1703714

Figure 42 Mode

Selection Point

Power Mode

Standard Mode

Economy Mode

•

Requ Requir ired ed to perfo perform rm he heav avy y wor work k iin n a sh shor ortt p peri eriod od of ti time me..

•

Fast speed loading.

•

Fast speed travel.

•

General work.

•

Minimize fu fuel c co onsumption.

•

Light work.

•

Minimize fu fuel c co onsumption.

•

Reduce noise.

Auto Idle Mode 1.

Press Press the lef leftt butto button n the the top of the rig right-h ht-hand and work work lleve everr (joystick) to use auto Idle mode.

DS1703699

Figure 43 2.

When When Auto Auto idle idle mode mode is selec selected ted,, sym symbol bol (Figure 44) 44) shows on screen.

 WARNING AVOID DEATH OR SERIOUS INJURY Turn "OFF' auto idle function when performing work in close operating area, i.e., work in a narrow area and loading/unloading on or off a trailer.

DS1703715

Figure 44

Operation  3-22

DX220A-2/DX220LCA-2

 

Work Mode and Breaker Operation 1.

Press Press the the u uppe pper-ri r-right ght button button on the the left left wor work k lever lever to ente enterr into the breaker mode, and press the lower button on the right work lever to activate the breaker.

DS1703718

Figure 45 2.

Wh When en Bre Break aker er mod mode e is se sele lect cted ed,, symb symbol ol (Figure (Figure 46) 46) shows on screen.

DS1703716

Figure 46

Operation  Operation  3-23

DX220A-2/DX220LCA-2

 

Work Levers (Joysticks) (ISO Pattern)

5

1 3

4

8

7

WARNING 6

2

AVOID DEATH OR SERIOUS INJURY Check surrounding area before swinging. When operating a lever while in auto idle, do it carefully, because the engine speed will increase rapidly. NOTE:

When starting work, move work levers (joysticks) slowly and check movement of swing and front attachment.

FG018404

Figure 47

This equipment is manufactured using the lever configuration described in ISO standards. Do not change valving, hoses, etc., that would change this standard. The boom, arm and bucket movements and swing direction of work levers (joysticks)  levers (joysticks)  are  are as follows: Left-hand Work Lever (Joystick) (Figure (Figure 47 and 47 and Figure 48) 48) 1.

Arm dump

2.

Arm crowd

3.

Left swing

4.

Right swing

NOTE:

NOTE:

4

1

3 2

The swing brake is spring applied and hydraulically released. It is always engaged when the work lever (joystick) is in "NEUTRAL" or the engine is stopped. Figure 48

EX1300701

Figure 49

EX1300702

When operating the arm, it may stop momentarily. When the arm is operated, the weight of the arm can cause it to move faster than the amount of oil being supplied.

Right-hand Work Lever (Joystick) (Figure ( Figure 47 47 and  and Figure 50) 50) 5.

Boom down

6.

Boom up

7.

Bucket crowd

8.

Bucket dump

NOTE:

Even after stopping the engine, the front can be lowered to the ground by operating work lever (joystick), by setting safety lever on "UNLOCK"

6

7

5

8

EX1300703

position and turning starter switch ON .

Figure 50

Operation  3-24

DX220A-2/DX220LCA-2

 

OPERATING PRECAUTIONS  WARNING AVOID DEATH OR SERIOUS INJURY Do not rest your feet on the travel pedals during normal machine operation. Unexpected machine travel can occur. If levers or pedals are operated when the auto idle is being actuated, the engine rpm will suddenly increase so be careful during operation. It is possible that boom, arm, or bucket may come into contact with the upper or lower structure of the machine. There are digging conditions which could allow this to happen. 1.

Before Before starti starting ng w work ork,, inspe inspect ct terrain terrain and soil soil co condi nditio tions. ns. Level ground and drain area if necessary.

2.

Instal Installl wind window ow gua guards rds for add additi itiona onall oper operator ator protec protectio tion n when working if there is a possibility of falling rocks or other objects. See Figure 51 51..

EX1300709

Figure 51 3.

Check Check str streng ength th of suppor supported ted str structu uctures res bef before ore working working on them to avoid collapse of the structure caused by the weight of the excavator. If insufficient, reinforce it. See Figure 52. 52.

EX1300710

Figure 52

Operation  Operation  3-25

DX220A-2/DX220LCA-2

 

4.

When When wor worki king ng clo close se tto o the the ex exca cavat vated ed edg edge e or drop drop-o -off, ff, make sure that the machine is sitting on solid ground. Keep the travel motors (1, Figure 53 53)) to the rear. See Figure 53. 53. 1

EX1300711

Figure 53 5.

Do not not all allow ow b bot ottom tom side side o off the the boom boom to to inter interfe fere re wit with h or touch the ground or track when digging a deep hole. See Figure 54. 54.

EX1300712

Figure 54 6.

Do not not exc excav avat ate e un under derne neat ath h th the e machi machine ne.. The The grou ground nd under the machine can collapse and cause the machine to fall and roll-over. See Figure 55. 55.

Figure 55 7.

EX1300687

Make Make sur sure e ther there e is ade adequ quate ate clea clearan rance ce ffro rom m over overhea head d electrical supply lines. Check for underground utility lines before excavating. Call before you dig. See Figure 56. 56.

EX1300688

Figure 56

Operation  3-26

DX220A-2/DX220LCA-2

 

8.

If the the exc excav avat atio ion n is in in an und under ergr grou ound nd loca locati tion on or or in a building, make sure there is adequate overhead clearance and there is adequate ventilation. See Figure 57. 57.

EX1300689

Figure 57 9.

Do not contin continual ually ly "botto "bottom m out" out" the hydraul hydraulic ic cylind cylinders. ers. Machine damage can occur if the cylinders are fully extended or retracted. For example: arm cylinder fully retracted and the bucket cylinder is extended to rotate the bucket into the ground. See Figure 58 58..

Figure 58 10.

EX1300713

Do not not dig dig wi with th the the excavato excavatorr tracks tracks raised. This can result in structural and mechanical failures. See Figure 59 59   and Figure 60. 60.

EX1300714

Figure 59

EX1300715

Figure 60

Operation  Operation  3-27

DX220A-2/DX220LCA-2

 

11. Do not not use the the bucket bucket as a hamme hammerr or rammi ramming ng de devic vice. e. This can cause damage to the front attachment. See Figure 61. 61.

EX1300716

Figure 61 12. Do not not move dirt dirt or or objects objects by swin swingin ging g the excav excavator ator into into them. This can result in structural and mechanical failures. See Figure 62. 62.

Figure 62

EX1300717

13. Do not not use mach machine ine trave travell when when the the bucket bucket iis s in the the ground to provide additional breakout force. See Figure 63 63..

EX1300718

Figure 63 14. Do not not operate operate travel travel leve levers rs quickl quickly y or jerk jerk them w when hen traveling in high range. See Figure 64. 64. •

Avoid su sudden st starts.

•

When When tra trave veli ling ng iin n one one dire direct ctio ion, n, com come e to a co comp mple lete te stop before reversing directions. Do not rock excavator back and forth with levers.

•

Av Avoi oid d sud sudde den n sto stops ps.. Ret Retur urn n llev ever ers s to to neu neutr tral al by hand. Do not let them snap back to neutral on their own. FG018422

Figure 64

Operation  3-28

DX220A-2/DX220LCA-2

 

15. To protec protectt undercar undercarria riage ge of the machi machine ne whe when n travelin traveling g on rough ground or on rocks, set the idler (1, Figure 65) 65) facing in travel direction. The idler and track spring are spring cushioned to absorb direct impacts.

1

EX1300719

Figure 65 16. Do not trav travel el at highhigh-spe speed ed over over rough rough grou ground nd or rocks rocks.. This can result in structural and mechanical failures and can reduce the service life of the machine. See Figure 66 66..

EX1300720

Figure 66 17.

Do not not travel travel continuously continuously for a long time. The lubrica lubricating ting oil temperatures inside the track rollers will rise, and this will cause damage to the oil seal or leakage of oil. If traveling continuously for a long time, it is recommended to stop the machine for 15 minutes every 2 hours to allow the lubricating oil inside the track rollers to cool down. See Figure 67. 67.

FG018452

Figure 67

Operation  Operation  3-29

DX220A-2/DX220LCA-2

 

18.

If optional optional long fronts (arm extensions) extensions) or attachmen attachments ts or heavy-duty front end attachments are used, the machine balance will be altered. Follow these additional operating precautions. See Figure 68. 68.

WARNING

2 0  0 -  3  0 c m  0  m  ( 8  8 -  1  2 i n  2  n )   

AVOID DEATH OR SERIOUS INJURY Do not travel downhill with front end attachments raised. Do not travel across slopes. Travel straight up or down slopes. Use extreme caution when swinging the upper frame when positioned on a slope. Keep bystanders away from swing area.

 cc m 3 0   -  3   0  2

Allow extra swing stopping room. The additional momentum generated by the longer or heavier front end equipment will increase the amount of time needed to stop the swing motion.

  )  in  i n  1 2   1     8  (   ( 

Make sure that all optional equipment has been authorized and installed properly.

EX1300691

Figure 68

Operation  3-30

DX220A-2/DX220LCA-2

 

Working in Water

IMPORTANT When working in water, do not exceed a slope of more than 15°. If the slope is over 15°, the rear part of the upper structure will be immersed in water, resulting in radiator fan and engine damage. EX1300721

Figure 69 When working in water, do not operate in water higher than the center of upper track roller(s) (1, Figure 70 70). ). If swing bearing gets wet, immediately grease it until all the old grease is purged from bearing. If water gets into swing gear housing, drain water immediately by removing lower inspection cover. Apply new grease. After working in water, purge old grease from bucket pins. 1

EX1300690

Figure 70

Escaping From Mud Be very careful to avoid getting stuck in mud. Track On One Side Stuck  NOTE:

When using the boom or arm to raise the machine, always have the bottom of the bucket in contact with the ground. The angle between the boom and arm must be 90° ~ 110°. The same applies when using the bucket installed in the reverse direction.

EX1300722

Figure 71

When only one side is stuck in mud, use the bucket to raise the track and then lay boards or logs and drive the machine out. Tracks On Both Sides Stuck  When the tracks on both sides are stuck in mud and slipping, making it impossible for the machine to move, lay boards or logs as explained above and dig the bucket into the ground in front. Then pull in the arm as in normal digging operations and put the travel levers in the FORWARD position to pull the machine out.

EX1300723

Figure 72

Operation  Operation  3-31

DX220A-2/DX220LCA-2

 

PARKING EXCAVATOR WARNING

12 0

AVOID DEATH OR SERIOUS INJURY Park excavator on firm and level ground. Avoid parking on slopes. If excavator must be parked on a slope, block tracks and place bucket teeth in ground. See Figure 73. 73.

Block

EX1300724

Figure 73 1.

Park Park exca excavat vator or on firm firm and lev level el ground. ground. Lower Lower buc bucket ket or work tool to ground as shown in Figure 74 74..

EX1300684

Figure 74 2.

Set Set engi engine ne spee speed dc con ontro troll dia diall on on ""LO LOW W IDL IDLE" E"..

HAOB290L

Figure 75 3.

If you touc touch h th the e oper operati ation on lleve everr un unint intenti entiona onally lly,, itit ma may y create a serious accident. Before leaving operator's seat, move safety lever to "LOCK" position.

Unlock

Lock

Figure 76

EX1300566

Operation  3-32

DX220A-2/DX220LCA-2

 

TOWING PROCEDURE

Cloth

WARNING AVOID DEATH OR SERIOUS INJURY Never use a damaged wire rope or chain. They could brake and cause a serious accident.

Towing Wire

Always wear gloves when handling a chain or wire rope. When towing excavator use a wire rope or chain capable of handling the load. Attach chain or wire rope to track frame as shown in Figure  Figure  77 Insert protective material such as thick cloths between track frame and wire rope to prevent the wire rope from being damage.

Towing Wire

IMPORTANT Use shackle hook on track frame to only haul objects that weigh less than 5 metric tons (5.51 U.S. Tons). Never use it to haul objects over 5 metric tons (5.51 U.S. Tons).

Towing Wire EX1400132

Figure 77

Operation  Operation  3-33

DX220A-2/DX220LCA-2

 

ATTACHMENTS Bucket Replacement and Reversal

 WARNING AVOID DEATH OR SERIOUS INJURY Wear eye protection, hard hat, gloves, and other protective equipment when tools are being used and flying objects are possible. Striking pins with a hammer can cause flying objects, keep bystanders clear of the area. When removing pins, stand to the side of the bucket and do not place feet or body under a raised attachment. When removing, inserting, or aligning pins, never insert your fingers into the pinholes. When the bucket is removed, place it in a stable condition. Stop the machine on a firm and flat surface. When performing work with more than one person, appoint a lead and follow that person's instructions and signals.

Replacement 1.

Place Place the the buck bucket et iin n cont contac actt with with a flat flat sur surfac face. e.

IMPORTANT When removing the pins, place the bucket so it is resting slightly on the ground. If down pressure is applied to the bucket, the resistance will be increased and it will be difficult to remove pins. After removing the pins, make sure they are clean and do not allow mud, sand, or other debris to get on them. Dust seals are fitted at both ends of the bushings. Be careful not to damage them.

Operation  3-34

DX220A-2/DX220LCA-2

 

2.

Remov Remove e dou doubl ble e nut nut from from bo bolt lt fo forr arm arm pin pin (A, (A, Figure 78) 78) and link pin (B, Figure 78), 78), remove bolt, pull out arm pin (A) and link pin (B, Figure 78), 78), and then remove bucket.

5 A

6

B

FG020108

Figure 78 3.

Align th the a arrm ((5 5, Figure 78) 78) with holes (1, Figure 79) 79) of the replacement bucket and the link (6, Figure 78) 78) with holes (2, Figure 79), 79), then insert grease coated pins (A, Figure  Figure  78) 78) and (B, Figure 78) 78) into hole (1, Figure 79) 79) and hole (2, Figure 79) 79) respectively.

1 2

FG018432

Figure 79 4.

When When ins insta tall llin ing g the the buck bucket et,, for for arm arm pi pin n port portio ion n (A, (A, Figure Figure   78), 78), fit O-rings (3, Figure 80) 80) on bucket (4, Figure 80) 80) in the position shown in the diagram on the right. After inserting the pin, position them in the standard groove.

5.

Inst In stal alll the the stop stopper per bolts bolts and and n nut uts s fo forr each each p pin ins. s.

6.

Lubric Lubricate ate wit with h grea grease se thorou thoroughl ghly y until until grea grease se comes comes out from the end face.

IMPORTANT

4

3

5

3 FG019639

When replacing the bucket, replace the dust seal if it has been damaged. If a damaged seal is used without being replaced, sand and dirt may enter the pin portion and cause abnormal wear of the pin.

Figure 80

Operation  Operation  3-35

DX220A-2/DX220LCA-2

 

Reversal (If Applicable) 1.

Plac Place e the the bu buck cket et on a fla flatt s sur urfa face ce..

IMPORTANT When removing the pins, place the bucket so it is in resting slightly on the ground. If down pressure is applied to the bucket, the resistance will be increased and it will be difficult to remove pins. After removing the pins, make sure they are clean and do not allow mud, sand, or other debris to get on them. Dust seals are fitted at both ends of the bushings. Be careful not to damage them. 2.

Remov Remove e do doubl uble e nut nut on the the sto stopp pper er bol boltt for for ar arm m pin pin (A, (A, Figure 81) 81) and link pin (B, Figure 81), 81), remove bolt, pull out arm pin (A, Figure 81) 81) and link pin (B, Figure 81), 81), and then remove bucket.

3.

Afte Afterr re remo movi ving ng the the buc bucke ket, t, rev rever erse se it. it.

4.

Align arm (5, Figure 81 81)) with replacement bucket hole (1, Figure 82), 82), then align link (6, Figure 81 81)) with hole (2, Figure 82), 82), then insert greased coated pins (A, Figure 81) 81) and (B, Figure 81) 81) into hole (1, Figure 82) 82) and hole (2, Figure 82) 82) respectively.

5 A

6

B

FG020108

Figure 81

IMPORTANT When reversing, do not install an O-ring. Keep the O-ring in a safe place until using it next. 5.

Inst In stal alll the the stop stopper per bolts bolts and and n nut uts s fo forr each each p pin in..

6.

Lubric Lubricate ate wit with h grea grease se thorou thoroughl ghly y until until grea grease se comes comes out from the end face.

2

IMPORTANT

FG018433

Figure 82 When replacing the bucket, replace the dust seal if it has been damaged. If a damaged seal is used without being replaced, sand and dirt may enter the pin portion and cause abnormal wear of the pin.

1

Operation  3-36

DX220A-2/DX220LCA-2

 

HYDRAULIC ATTACHMENT ATTACHMENTS S (OPTIONAL) Breaker Operation

IMPORTANT If a hydraulic breaker and piping is installed without DOOSAN's authorization, it may create a serious malfunction which will not be covered under the excavator warranty.

Selection of Hydraulic Breaker If a hydraulic breaker is installed, consider equipment's stability and suitability for such modification. Also, consider hydraulic oil pressure and quantity. When selecting a hydraulic breaker consult with a DOOSAN distributor or sales agency. Hydraulic Hoses and Tubing for Breaker 1.

When When iinst nstall alling ing hyd hydrau raulic lic breaker breaker,, a asse ssembl mble e a acco ccordi rding ng to drawings provided with kit.

2.

If brea breaker ker is take taken n off off excav excavator ator,, be sur sure e to plu plug g and and cap cap al alll hoses and tubing to prevent contamination from entering hydraulic system.

3.

Plug Plug and and cap a all ll c conn onnec ector tors s and and fitti fitting ngs s on b bre reake akerr to prevent contamination.

4.

Check Check all hyd hydrau raulic lic connec connectio tions ns ffor or sign signs s of leaks leaks or or lo loose ose components before starting operation.

Operation  Operation  3-37

DX220A-2/DX220LCA-2

 

Breaker Operating Precautions NOTE:

Hydraulic pressure and flow settings may need to be changed. Refer to the Maintenance Section of this manual for further information.

1.

Make Make sur sure e to rea read d and and unde underst rstand and the break breaker er use user' r's s manual.

2.

Insp In spec ectt all m mec echa hani nica call and hyd hydrau rauli lic c co conn nnec ecti tion ons. s.

3.

Do no nott use use the the brea breake kerr as a ham hamme mer. r. See See Figure 83. 83. Do not drop breaker from extreme heights. The breaker is relatively heavy and drops fast. Do not drop breaker from extreme heights or damage to upper structure can result.

EX1300725

Figure 83 4.

Do not not ope opera rate te the the brea breake kerr with with tthe he boom boom or or arm arm cyli cylinde nders rs fully extended (bottomed out). See Figure 84. 84. Leave over 100 mm (4 in) of clearance between rod end of cylinder and cylinder head. This will help prevent damage to cylinders during breaker operation.

EX1300726

Figure 84 5.

Do not not use use the the brea breake kerr if tthe he hyd hydra raul ulic ic hos hoses es vib vibra rate te excessively. See Figure 85. 85. If excavator is operated under this condition, structural and hydraulic components can be damaged.

EX1503209

Figure 85

Operation  3-38

DX220A-2/DX220LCA-2

 

6.

Do not not all allow ow the the bre break aker er bod body y to go int into o wate waterr if not not equipped for underwater operation. The breaker seal can be damaged and allow rust, foreign material or water to enter the hydraulic system and cause damage. Only insert the breaker tool into water. See Figure 86. 86.

EX1502480

Figure 86 7.

Do not not any any lif lifti ting ng or or towi towing ng w wit ith hab bre reak aker er.. See See Figure 87 87..

EX1300729

Figure 87 8.

Oper Operate ate th the e break breaker er onl only y to th the e fron frontt and and rear rear o off th the e excavator. Do not use the breaker to either side of the excavator. Do not swing the breaker from side to side when operating it. See Figure 88. 88.

WARNING AVOID DEATH OR SERIOUS INJURY Operating a breaker with the upper body turned 90° to the tracks can result in tipping over the machine or reduction in service life. 9.

HAOB990L

Figure 88

Do not not cur curll the the brea breaker ker to tool ol tip tip in into to the the arm or b boo oom m when when traveling or parking the excavator. See Figure 89. 89.

EX1300730

Figure 89

Operation  Operation  3-39

DX220A-2/DX220LCA-2

 

To activate breaker 1.

Press Press the the uppe upper-ri r-right ght button button on on the the left left jjoys oystic tick k to enter enter into into the breaker mode.

DS1703720

Figure 90 2.

Pres Press s lo lowe werr bu butt tton on o on n top top of rig right ht-h -han and d work work lev lever er (joystick) or electric pedal to activate hydraulic breaker.

3.

Rele Releas ase e lowe lowerr bu butt tton on o on n top top of rrig ight ht-h -han and d work work llev ever er (joystick) or electric pedal to deactivate hydraulic breaker.

O I DS1703719

Figure 91

Operation  3-40

DX220A-2/DX220LCA-2

 

Hydraulic Oil and Filter Service Intervals When using a hydraulic breaker, the viscosity breakdown and contamination of hydraulic oil is faster because the work condition is more severe than during normal digging work. To prevent the hydraulic components (especially pump) from having a shortened life cycle, replace the hydraulic oil and main hydraulic oil return filter using the following schedule. Attachment

Operation Rate

Hydraulic Oil

Bucket Work

100%

2,000 Hours

Hydraulic Breaker Work

100%

500 Hours

*

Filter 250 Hours (First Replacement)  1,000 Hours (After First Replacement) 100 Hours

These These se servi rvice ce interv intervals als only only appl apply, y, when when a genuin genuine e DOOSAN DOOSAN oil oil and and filter filter are are used. used. If any any other other brands brands are used, the guaranteed changed interval must be reduced in half.

100 105 10 5

   )    %    (    E    T    A    R    N    O    I    T    P    O    R    E    K    A    E    R    B

80

106

614

144

112

60

551

116 11 6

FILTER 692 (First Replacement)

171

119

214

128

782

893

275

HYDRAULIC OIL 40

137

335

156

20

175

1028

FILTER (After First Replacement)

412

0

1400

500

206

1196

1658

635

500

1000

1500

2000

MACHINE OPERATING HOURS FG000767

Figure 92 NOTE:

The replacement intervals of hydraulic oil and filter depend upon the amount of time the hydraulic breaker is being used. These intervals must be followed as opposed to regularly scheduled maintenance.

Operation  Operation  3-41

DX220A-2/DX220LCA-2

 

LIFTING OBJECTS IMPORTANT There may be local or government regulations, about the use of excavators for the lifting of heavy loads. Always contact your local and government agencies in regards to these regulations. When this machine is used in object handling applications, the machine must be properly configured and operated properly. Ensure the following safety working devices equipped and operated. •

Lifting eye eye fo forr load hooking.

•

Hose Hose bu burs rstt prot protec ecti tion on on bo both th bo boom om an and d arm. arm.

To prevent injury, do not exceed the rated load capacity of the machine. If the machine is not on level ground, load capacities will vary. Short slings will prevent excessive load swing. Use the lifting eye on the bucket that is provided to lift objects. Always try to maintain the lifting eye (Figure ( Figure 93 93)) straight below the center line of the arm and bucket pin. In this manner the weight of the load is being primarily held only by the pin, and not by the bucket cylinder, link, and link pins. When a lifting eye is used, the sling/lifting device must be fastened to the eye in a manner that will not allow it to come loose. The most stable position is over the corner of the machine. For best stability, carry a load as close to the ground and machine as possible. Lift capacity decreases as the distance from the machine swing center line is increased.

HAAD3830

Figure 93

Operation  3-42

DX220A-2/DX220LCA-2

 

Lifting Unknown Weight When loads are not accurately known are to be lifted, the person responsible for the job shall ascertain that the weight of the load does not exceed the machine LOAD RATING CHART at the radius at which it is to be lifted. It is recommended that you feel your way into any lift as a precaution against tip-over. One method is to position the boom at 90° over the side of the machine. Slowly lift the load until it clears the ground. A lift over the side is the most unstable, and as the load is swung into the front zone of the excavator it will become more stable. DO NOT INCREASE SWING RADIUS AFTER THE LOAD IS LIFTED.

FRONT LIFT ZONE

SIDE LIFT

SIDE LIFT

ZONE

ZONE

REAR LIFT

DANGER

ZONE HAAD3842

AVOID DEATH If a load is picked up from the front zone and swung into the side zone, a tip-over could result causing a deadly or fatal injury.

Lifting Known Weight The load chart is the governing factor when lifting known weights. It is recommended that you feel your way into any lift as a precaution against tip-over. Whenever possible, lift and swing payloads between the front idler area. Pick and Carry The machine can pick and carry payloads without added labor. We recommend when traveling with a suspended payload, you evaluate the prevailing conditions and determine the safety precautions required in each case. The following factors must be considered before attempting to pick and carry a load. Align the boom with the forward direction of machine travel. Maintain this boomatposition when turning Turn on ly only when necessary, the slowest speed, the andmachine. at a wide turning radius. 1.

Use Use the the short shortes estt lifti lifting ng ra radi dius us d dis istan tance ce pos possi sibl ble. e.

2.

Keep Keep the the lloa oad d as clo close se to to the the gr groun ound d as cond condit itio ions ns wil willl permit.

3.

Prov Provid ide e tag line lines s to pre preve vent nt lo load ad fro from m pend pendul ulat atin ing. g. Pendulating can cause a change in radius. A change in radius could exceed the load chart rating or cause a tip over condition.

4.

Gove Govern rn trave travell spee speed d to suit suit cond condit itio ions ns..

5.

Avoi Avoid d su sudd dden en star starts ts an and d stop stops. s.

Figure 94

Operation  Operation  3-43

DX220A-2/DX220LCA-2

 

OPERATION UNDER UNUSUAL CONDITIONS NOTE:

See "Maintenance in Special Conditions" on page 4-  88   for for other recommendations.

Operation In Extreme Cold In extremely cold weather, avoid sudden travel movements and stay away from even slight slopes. The machine could slide down the slope. Snow accumulation could hide potential hazards and slippery surfaces. Warming up engine for a short period may be necessary to avoid operating with sluggish or reduced working capacity. The  jolting shocks and impact loads caused by bumping or bottoming boom or attachment could cause severe stress in very cold temperatures. Reducing work cycle rate and workload may be necessary. If machine is to be operated in extremely cold weather temperatures, certain precautions musttobebetaken. The following paragraphs detail checks to be made certain machine is capable of operating at these temperatures. 1.

Preh Prehea eatt the the en engi gine ne be befo fore re star startu tup. p. •

2.

Pr Preh ehea eatt the the en engi gine ne be befo fore re star startu tup. p. Wait Wait 3 to to 4 seconds after preheating until voltage of the battery return, and then actuate the key switch.

Keep Keep batter batteries ies fully fully c charg harged ed tto o preve prevent nt free freezin zing. g. IIff di disti stille lled d water is added to batteries, run engine at least one hour to mix electrolyte solution. When temperature drops below -10°C, efficacy of the battery is reduced accordingly. Insulation of the battery prevents reduction of efficacy, and supports improvement of starting power of the starter.

 WARNING AVOID DEATH OR SERIOUS INJURY Explosion of the battery can cause serious injury or death. Never attempt to directly heat the battery with open fire. 3.

Keep Keep engi engine ne in good good mech mechani anical cal condit condition ion for eas easy y star startin ting g and good performance during adverse weather.

4.

Use engine engine oil wit with h prop proper er specifi specificat cation ions s for for expect expected ed temperatures.

Refer

to

"Table

of

Recommended  Recommended 

Lubricants on page 4-8, 4-8, in this manual or Shop Manual for details. Operation  3-44

DX220A-2/DX220LCA-2

 

5.

Always Always keep keep the the fuel fuel tank tank full fully y fille filled d af after ter com comple pletio tion n of the operation. Always drain water from the fuel tank before and after the operation. In addition, check the water separator, and drain it if required. The fuel filter, if frozen, may interrupt the flow of fuel. Periodically remove water from the fuel tank, drain water from the filter, and replace the filter upon regular basis. To prevent fuel from being clogged due to formation of wax in fuel, make sure that wax formation point of fuel is lower than atmospheric temperature.

 WARNING AVOID DEATH OR SERIOUS INJURY Explosion of the fuel tank may cause serious injury or death. Never attempt to directly heat the fuel tank with open fire  6.

Lubr Lubric icat ate e enti entire re mach machin ine e ac acco cord rdin ing g to "Lubrication and and   Service Chart" on page 4-12, 4-12 , in this manual or lubrication chart on machine.

7.

Star St artt engin engine ebefore and and operating. allo allow w it to to reac reach h norm normal al o ope pera rati ting ng temperature •

If mud mud and and ice ice co coll llec ects ts an and d free freeze zes s on on any any of of mov movin ing g parts while machine is idle, apply heat to thaw frozen material before attempting to operate machine.

•

Oper Operat ate e h hyd ydra raul ulic ic un unit its s wit with h c car are e unt until il th they ey hav have e reached a temperature which enable them to operate normally.

•

Chec Check k all all mach machin ine e cont contro rols ls and and fun funct ctio ions ns to to be sur sure e they are operating correctly.

8.

An extr extra a ou outer ter air filter filter must must be kept kept in ope operat rator' or's s cabin cabin to replace element that could become iced and cause restricted airflow to engine.

9.

Clean Clean off off all mud, snow snow and and ice to prevent prevent freezin freezing. g. Cover Cover machine with a tarp if possible, keep ends of tarp from freezing to ground.

Operation in Extreme Heat Continuous operation of the machine in high temperatures can cause the machine to overheat. Monitor engine and transmission temperatures and stop machine for a cooling-off period whenever necessary. 1.

Make Make freq freque uent nt ins inspe pect ctio ions ns and and ser servi vices ces of of the the fan fan and and radiator. Check coolant level in radiator. Check grills and radiator fins for accumulation of dust, sand and insects

radiator fins block for accumulation of dust, sand and insects which could the cooling passages.

Operation  Operation  3-45

DX220A-2/DX220LCA-2

 

2.

A.

Formati Formation on of scale scale and rust in coo coolin ling gs syst ystem em occurs occurs more rapidly in extremely high temperatures. Change antifreeze each year to keep corrosion inhibitor at full strength.

B.

If necess necessary ary,, flus flush h c cool ooling ing system system peri periodi odical cally ly to keep passage clear. Avoid use of water with a high alkali content which increases scale and rust formation.

Check Check leve lplates evell of preventing bat batter tery y elect electrol rolyte yte daily. dai Keep Keep elect electrol rolyte yte above damage toly.batteries. Use a slightly weaker electrolyte solution in hot climates. Dilute 1.28 specific gravity electrolyte as issued to 1.20 - 1.24 specific gravity readings at full charge. Recharge batteries whenever they reach a 1.16 specific gravity reading. Batteries self-discharge at a higher rate if left standing for long periods at high temperatures. If machine is to stand for several days, remove batteries and store in a cool place.

 WARNING AVOID DEATH OR SERIOUS INJURY Do not store acid type storage batteries near stacks of tires; the acid fumes have a harmful affect on rubber. 3.

Servic Service e fuel fuel system system as dir direct ected ed in "Engin "Engine e Fuel Fuel Sys System tem"" Section 5, of this manual. Check for water content before filling fuel tank. High temperatures and cooling off cause condensation in storage drums.

4.

Lubric Lubricate ate as specif specified ied in "Perio "Periodic dic Servic Service e Char Chartt a and nd Table" Section 4, in this manual or Lubrication Decal on the machine.

5.

Do not park park m machi achine ne in sun for lon long g perio periods ds of time time.. When When practical park machine under cover to protect it from sun, dirt and dust. A.

Cover Cover ina inacti ctive ve machin machine e with with tarpau tarpaulin lin if no suitab suitable le shelter is available. Protect engine compartment, transmission and hydraulics from entrance of dust.

B.

In hot, hot, damp, damp, clim climate ates s corro corrosiv sive e actio action n will will o occu ccurr on all parts of the machine and will be accelerated during the rainy season. Rust and paint blisters will appear on metal surfaces and fungus growth on other surfaces.

C.

Protect Protect all unf unfini inishe shed, d, expo exposed sed sur surfac faces es with with a film film of of preservative lubricating oil. Protect cables and terminals with ignition insulation compound. Apply paint or suitable rust preventive to damaged surfaces to protect them from rust and corrosion.

Operation  3-46

DX220A-2/DX220LCA-2

 

Operation in Dusty or Sandy Areas Operation of the machine can cause dust in almost any area. However, when in predominantly dusty or sandy areas, additional precautions must be taken. 1.

Keep Keep cool cooling ing system system fin fins s and and coolin cooling g a area reas s c clea lean. n. Blo Blow w out with compressed air, if possible, as often as necessary.

 WARNING AVOID DEATH OR SERIOUS INJURY Wear goggles when using compressed air. 2.

Use Use care care whe when n serv servic icin ing g fuel fuel sys syste tem m to prev preven entt dust dust and and sand from entering the tank.

3.

Servic Service e the the air cleane cleanerr at at ffreq requen uentt iinte nterval rvals, s, check check air restriction indicator daily and keep dust cup and dust valve clean. Prevent dust and sand from entering engine parts and compartments as much as possible.

4.

Lubr Lubric icate ate and and perf perfor orm m servi service ces s out outli line ned d on curre current nt lubrication chart 4. on Clean machine "Lubrication Chart and Table" Section alland lubrication fittings before applying lubricant. Sand mixed with lubricant becomes very abrasive and speeds wear on parts.

5.

Prot Protec ectt machi machine ne from from dus dustt and san sand d as much much as as possi possibl ble. e. Park machine under cover or protect with tarpaulin to keep dust and sand from damaging unit.

Operation in Rainy or Humid Conditions Operation under rainy conditions is similar to that as in extreme heat procedures listed previously. 1.

Keep Keep all all e exp xpos osed ed sur surfa face ces s coat coated ed wit with h prese preserv rvat ativ ive e lubricating oil. Pay particular attention to damaged or unpainted surfaces. Cover all paint cracks and chip marks as soon as possible to prevent corrosive effects.

DX220A-2/DX220LCA-2

 

Operation in Salt Water Areas The corrosive effect of salt water and salt water spray is very extensive. When operating in salt water areas, observe the following precautions. 1.

When When expo expose sed d to sal saltt wate water, r, dr dry y ma mach chin ine e th thoro oroug ughl hly y and and rinse with fresh water as soon as possible.

2.

Keep Keep all all e exp xpos osed ed sur surfa face ces s coat coated ed wit with h prese preserv rvat ativ ive e lubricating oil. Pay particular attention to damaged paint surfaces.

3.

Keep Keep al alll p pai aint nted ed surfa surface ces s in in g goo ood d rep repai air. r.

4.

Lubric Lubricate ate mac machin hine e as as p pres rescri cribed bed on lub lubric ricati ation on cha chart rt on machine or "Periodic Service Table and Chart" Section 4, in this manual. Shorten lubricating intervals for parts subject to exposure to salt water, if found necessary.

Operation at High Altitudes Normally, operation of machine at high altitudes will be as outlined in extreme cold. Before operating at high altitudes, engine fuel and air mixture may have to be adjusted according to appropriate engine manual. 1.

Check Check engin engine e opera operati ting ng tem tempe pera ratur ture e for for evid eviden ence ce of of overheating. The pressure cap on radiator must make a perfect seal to maintain coolant pressure in the system.

Operation During Electrical Storms During electrical storms, do not enter or exit machine. •

If you you are are off off mac machi hine ne,, kee keep p awa away y fro from m mac machi hine ne unti untill s stor torm m passes.

•

If you are in cabi cabin, n, rema remain in seat seated ed with with mach machin ine es sta tati tion onar ary y until storm passes. Do not touch controls or anything metal.

Operation  Operation  3-47

Operation  3-48

DX220A-2/DX220LCA-2

 

LONG TERM STORAGE When a machine is taken out of service and stored for a time exceeding 30 days, steps must be taken to protect the machine. Leaving equipment outdoors exposed to the elements will shorten its life. An enclosure will protect the machine from rapid temperature changes and lessen the amount of condensation that forms in hydraulic components, engine, fuel tank, etc. If it is not possible to put the machine in an enclosure, cover it with a tarpaulin. Check that storage site is not subject to flooding or other natural disasters. After the machine has been positioned for storage and the engine stopped, perform the following operations:

Before Storage Keep the excavator in the position shown in Figure 95 to 95 to prevent rust of the hydraulic piston rods. •

In Insp spec ectt for for da dama mage ged, d, loos loose e or or mis missi sing ng pa part rts. s.

• •

Repa Repain intt nec neces essa sary ry area areas s to to p pre reve vent nt ox oxid idat atio ion. n. Wash Wash an and d clea clean n al alll pa part rts s of ma mach chin ine. e.

•

Stor Store e the the mach machin ine e iin n an an ind indoo oor, r, stabl stable e pla place ce.. IIff sto store red d outside, cover with a waterproof tarp.

•

Perf Perfor orm m lu lubri brica cati tion on proc proced edur ures es on all all gre grease ase poin points ts..

•

Appl Apply y a coat coatin ing g of of ligh lightt oil oil to the ex expo pose sed d pla plate ted d m met etal al surfaces (such as hydraulic cylinder rods, etc.) and to all the control linkage and control cylinders. (Control valve spools, etc.)

•

Remo Remove ve ba batt tter ery y fro from m the the exca excava vator tor to be fu full lly y cha charge rged da and nd stored.

•

Inspec Insp ectt the the cool coolan antt rec recov over ery y tan tank k and and radi radiat ator or to make make sure the antifreeze level in the system is correct. Make sure that antifreeze concentration is enough for the lowest temperature anticipated during storage.

•

Seal Seal all all ext exter erna nall ope openi ning ngs s (i. (i.e. e. engi engine ne exha exhaus ustt out outle let, t, crankcase and hydraulic breather, fuel vent line, etc.) with tape wide enough to cover the opening, regardless of size. NOTE:

When sealing with tape, be sure to extend tape approximately one inch (25 mm) beyond opening to insure a good seal.

EX1300542

Figure 95

DX220A-2/DX220LCA-2

 

Operation  Operation  3-49

Operation  3-50

DX220A-2/DX220LCA-2

 

4Inspection,

Maintenance and Adjustment

MAINTENANCE INFORMATION This section deals with information for proper maintenance of the machine. Therefore, ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Operational Hour Meter Reading Check operational hour meter reading every day to see if necessary maintenance is scheduled to be performed. DOOSAN Genuine Replacement Parts Use DOOSAN genuine parts specified in Parts Book as replacement parts. DOOSAN Genuine Lubricants For lubrication of the machine, use DOOSAN genuine lubricants. Use oil of specified viscosity according to ambient temperature. Windshield Washer Fluid Use automobile window washer fluid, and be careful not to let any dirt get into it. Fresh and Clean Lubricants Use clean oil and grease. Keep containers of oil and grease containers clean and keep foreign materials away. Check Drained Oil and Used Filter After oil is changed or filters are replaced, check oil and filters for metal particles and foreign materials. If large quantities of metal particles or foreign materials are found, take corrective action.

Fuel Strainer If your machine is equipped with a fuel strainer, do not remove it while fueling. Inspection, Maintenance and Adjustment  Adjustment  4-1

DX220A-2/DX220LCA-2

 

Welding Instructions •

Cut Cut o off ff power. power. Wait Wait for for a appr pprox oxim imat atel ely y o one ne mi minu nute te af afte terr turning off engine starter switch key, and then turn battery disconnect switch to "OFF" position.

•

Do no nott ap appl ply y more more than than 20 200 0 V co cont ntin inuo uous usly ly..

•

Conn Connec ectt g gro roun undin ding g cab cable le with within in 1 m (3.3 (3.3 ft) ft) of of a are rea a to to b be e welded. If grounding cable is connected near instruments, connectors, etc., instruments can be damaged.

•

If a sea seall or or b bea eari ring ng happe happens ns to come come be betw twee een n par partt bei being ng welded and grounding point, change grounding point to avoid these types of parts.

•

Do not not use use ar area ea arou around nd wo work rk eq equi uipm pmen entt pin pins s o orr hyd hydra rauli ulic c cylinders as grounding point.

Do Not Drop Things Inside Machine •

When When open openin ing g iins nspe pect ctio ion n win windo dows ws or oi oill fil fille lerr port port of ta tank nk to perform inspection, be careful not to drop nuts, bolts, or tools inside the machine. If parts are dropped inside machine, it can cause damage and/or improper operation of the machine. If you drop anything inside immediately.

the

machine,

always

remove

it

Dusty Work Site When working at a dusty work site, do the following: •

Clea Clean n radi radiat ator or fin fins s and and othe otherr part parts s of hea heatt exch exchan ange ge equipment more frequently, and take care not to let fins become clogged.

•

Repl Replac ace e fue fuell fil filte terr mor more e ffre requ quen entl tly. y.

•

Clea Clean n ele electr ctric ical al c com ompon ponent ents, s, esp espec ecial ially ly sta starti rting ng mot motor or and and alternator, to avoid accumulation of dust.

•

When When chec checki king ng an and d repl replac acin ing g oil oil or filt filter ers, s, move move the the machine to a place where there is no dust and take care to prevent dust from entering system.

Avoid Mixing Lubricants If a different brand or grade of oil has to be added, drain all old oil before adding new brand or grade of oil. Never mix different brands or grades of oil. Locking Inspection Covers Lock inspection cover securely into position with lock bar. If inspection or maintenance is performed with inspection cover not locked in position, it could fall and cause injury.

Inspection, Maintenance and Adjustment  4-2

 

Hydraulic System - Air Bleeding When hydraulic equipment has been repaired or replaced, or hydraulic piping has been removed and installed again, air must be bled from circuit. For details, see "Venting and Priming Priming   Hydraulic System" on page 4-84. 4-84. Hydraulic Hose Installation •

When When rem removi oving ng pa part rt at locat locatio ions ns with with O-rin O-rings gs or gask gasket et seals, clean mounting surface and replace with new parts. When doing this, be careful not to forget to assemble O-rings and gaskets.

•

When When inst instal alli ling ng ho hose ses, s, do no nott ttwi wist st them them or be bend nd th them em sharply. This will extend service life and prevent damaging hoses.

Checks After Inspection and Maintenance Works Perform checks after inspection and maintenance to prevent operation problems. Always do the following: •

•

Chec Checks ks afte afterr o ope pera rati tion on (w (wit ith h eng engin ine e sto stopp pped ed). ). –

Have Have any in insp spec ectio tion n an and d m mai aint nten enan ance ce po poin ints ts been been forgotten?

–

Have Have all inspe inspecti ction on and and mai maint nten enan ance ce item items s bee been n performed correctly?

–

Have Have an any y tool tools s or pa part rts s been been dro dropp pped ed ins insid ide e the the machine? If parts are dropped inside the machine and get caught in lever linkage mechanism, and this could cause improper operation of the machine.

–

Are Are tthe here re an any y coo coola lant nt or oil oil lea leaks ks? ?H Have ave al alll n nuts uts and and bolts been tightened?

Checks whe when no op perating en engine. –

– –

Fo Forr deta detail ils s of of c che heck cks s when when opera operati ting ng en engi gine ne,, see see "Safety Precautions" on page 4-4  4-4   and pay careful attention to safety. Ar Are e insp inspec ecti tion on and and mai maint nten enan ance ce ite items ms wor worki king ng properly? Is there there any any lea leaka kage ge of fu fuel el or oil oil w whe hen ne eng ngin ine e spe speed ed is raised?

DX220A-2/DX220LCA-2

DX220A-2/DX220LCA-2

 

Safety Precautions 1.

Make Make sure sure to lloc ock k ou outt hydra hydraul ulic ic con contro trols ls and and pla place ce a "DO "DO NOT OPERATE" Warning Tag on the machine to indicate that the machine is being serviced and to prevent any unauthorized operation.

2.

Clea Clean n up a any ny flu fluid id spi spill lls, s, e espe speci cial ally ly aro aroun und d en engi gine ne..

3.

Inspec Inspectt all all fuel fuel line lines s to make make su sure re that that fittin fittings, gs, lines, lines, filters filters,, O-rings, etc. or aredamage. tight and are not showing signs of leakage, wear

4.

If inspec inspectio tion n or or test test proc procedu edure re requir requires es that that engi engine ne be running, make sure to keep all unauthorized personnel away from the machine.

Inspection, Maintenance and Adjustment  Adjustment  4-3

Inspection, Maintenance and Adjustment  4-4

DX220A-2/DX220LCA-2

 

MACHINE SETUP POSITION FOR MAINTENANCE Before beginning any service work, park the machine using the following procedure (except for service work requiring the machine to be positioned differently). 1.

Posi Positi tion on tthe he mac machi hine ne on on even, even, firm firm a and nd lev level el g gro roun und. d.

2.

Put at atta tach chme ment nt on gr grou ound nd..

EX1300684

Figure 1 3.

Mo Move ve saf safet ety y le leve verr to "LOC "LOCK" K" po posi siti tion on..

Unlock

Lock

EX1300566

Figure 2 4.

Allow Allow en engin gine e to run run at at "LOW "LOW IDL IDLE" E" ffor or a min minim imum um o off five five minutes to allow engine to cool, If this is not done, heat surge can occur.

Figure 3

HAOB290L

Inspection, Maintenance and Adjustment  Adjustment  4-5

DX220A-2/DX220LCA-2

 

5.

Stop Stop e eng ngin ine e by tur turnin ning g key to to "O "O"" (OFF) (OFF) pos posit itio ion. n. Aft After er releasing hydraulic system and tank pressure, remove starter switch key.

O   ACC

I

EX1402155

Figure 4 6.

Befo Before re sta starti rting ng mai maint nten enan ance ce work work,, plac place e a "DO "DO NOT NOT OPERATE" Warning Tag on cabin door or work lever.

 WARNING AVOID DEATH OR SERIOUS INJURY If engine must be running while performing maintenance, use extreme care. Always have one person in cabin at all times. Never leave cabin with engine running.

EX1300740

Figure 5

Inspection, Maintenance and Adjustment  4-6

DX220A-2/DX220LCA-2

 

MAINTENANCE HANDLING ACCESS A

Entering/Leaving/Climbing Entering/Leaving/Climb ing On Machine

WARNING AVOID DEATH OR SERIOUS INJURY

Figure 6

DS1703958

Do not jump ON/OFF a machine. Never get ON/OFF when the machine is running. Never grasp control lever to get ON/OFF. Use handholds and steps when entering, leaving or climbing the machine. Use three-point grip, i.e. two hands and one foot or two feet and one hand. Always face machine. Always wipe mud and oil off all footboards, handrails, guardrails and your footwear, especially when cleaning windows, rearview mirrors and lights.

EX1301111

Figure 7

Clean your boots and wipe your hands before getting on the machine. Always wear proper footgear. Do not use hand grip (A, Figure 6) 6) of cabin door as a support when entering, leaving or climbing the machine. It is not strong enough to be used as a support. It should only be used for closing the door.

Figure 8

EX1301112

DS1703773

Figure 9

Inspection, Maintenance and Adjustment  Adjustment  4-7

DX220A-2/DX220LCA-2

 

TABLE OF RECOMMENDED LUBRICANTS IMPORTANT It is highly recommend to use the DOOSAN Genuine Products, or products which meet the specification below. Using other products can damage the equipment. NOTE:

Refer to the Maintenance Intervals Table for application points. Ambient Temperature

Reservoir

Kind of of Flu Fluid id

-58

-40

-22

-4

14

32

50

68

86

104

122 °F

-50

-40

-30

-20

-10

0

10

20

30

40

50 °C

2)

 SAE 5W-40

SAE 10W-30 5) Engine

Engine Pan Oil

Oil 3)

 SAE 10W-40 4)

 SAE 15W-40

SAE 90 and API GL5

Swing Drive Case 1)

Gear Oil

 SAE 80W-90 and API GL5

Final Drive Case

SAE 140 and API GL5

ISO VG. 15

Hydraulic Oil Tank

ISO VG. 32 6)

 Hydraulic Oil ISO VG. 46 ISO VG. 68

1)

 ASTM D975 No. 2

Fuel Tank

Diesel Fuel

ASTM D975 No. 1

Inspection, Maintenance and Adjustment  4-8

DX220A-2/DX220LCA-2

 

Grease Fitting

Grease

Cooling System

Coolant

1) Multipurpose

Lithium Grease NLGI No. 2

Add Antifreeze  (50% antifreeze - 50% distilled water)

1)

1)

Installed at factory.

2)

(5W40) - Recommended for use at extremely low temperature below -20°C.

3) 4)

(10W40) - Filled at factory. Doosan genuine engine oil is recommended for use. (15W40) - Doosan genuine engine oil is recommended for use.

5)

(Engine oil) - Engine oil must meet ACEA-E5 or API-CI-4.

6)

Hydraulic oil change interval is 4,000 hours, only when DOOSAN Genuine Oil is used. If other brands of oil is used, guaranteed change interval is 2,000 hours. Note that mixing ratio is for reference purpose only, and is not an absolute standard.

API: American API:  American Petroleum Institute. ACEA: Association ACEA:  Association des Constructeurs Europens d'Automobiles. ASTM: American Society of Testing and Materials. ISO: International ISO:  International Organization for Standardization. NLGI: National NLGI:  National Lubricating Grease Institute. SAE: Society of Automotive Engineers.

IMPORTANT Do not mix oils from different manufacturers. DOOSAN does not endorse specific brands but recommends that owners select quality oils whose manufacturers provide assurance   that required standards will always be met or assurance exceeded.

IMPORTANT Fluctuating or weekly of temperature, operation indaily subzero freezingextremes temperatures, may make or it impractical to use straight weight lubricants. Select lubricants that are appropriate for climate conditions.

DX220A-2/DX220LCA-2

 

Coolant and Water for Dilution •

Th The e coo coola lant nt ha has s the the impo importa rtant nt fu func ncti tion on of prev preven enti ting ng corrosion and preventing freezing.  Even in areas where freezing is not an issue, use of antifreeze coolant is essential.  DOOSAN machines are supplied with DOOSAN coolant. DOOSAN coolant has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 1 year or 2,000 hours. Therefore, it is recommended authorized genuine DOOSAN antifreeze solution.  to use When using DOOSAN coolant, there is no need to use a corrosion resistor. For details, see "Engine Cooling Cooling   System" on page 4-78. 4-78.

•

When When di dilu luti ting ng anti antifr free eeze ze cool coolan ant, t, us use e dis disti till lled ed wate water. r.  Natural water, such as a river water or well water (hard water), contains large amounts of minerals (calcium, magnesium, etc.), and this makes it easier for scale to form inside engine or radiator. Once scale is deposited inside engine or radiator, it is extremely difficult to remove.  If tap water needs to be used, refer to "Engine Cooling  Cooling  System" on page 4-78 for 4-78 for further information on standards and precautions.

•

When When us usin ing g ant antif ifre reez eze, e, alw alway ays s obs obser erve ve preca precaut utio ions ns gi give ven n in this manual.

•

Anti Antifr free eeze ze coo coola lant nt is is fla flamm mmab able le,, so so be be sure sure to kee keep p itit awa away y from any flame.

•

Th The e rati ratio o of of DOO DOOSA SAN N coo coola lant nt tto ow wate aterr diffe differs rs acco accordi rding ng to ambient temperature.  For details of ratio when mixing, see "Antifreeze  "Antifreeze  Concentration Tables" on page 4-80. 4-80.  DOOSAN coolant may be supplied premixed. Never add distilled water.

•

If en engi gine ne ov over erhe heat ats, s, wait wait for en engi gine ne to cool cool befo before re ad addi ding ng coolant.

•

If cool coolan antt leve levell iis s low low,, itit wil willl cau cause se ov overh erhea eati ting ng and and corrosion problems because of air entering coolant.

•

Neve Neverr m mix ix lime lime (har (hard d wat water er), ), salt salt or wate waterr c con onta tain ined ed me metal tal material with coolant.

Inspection, Maintenance and Adjustment  Adjustment  4-9

Inspection, Maintenance and Adjustment  4-10

DX220A-2/DX220LCA-2

 

FLUID CAPACITIES Component Oil Pan with Filter

26 L (6.9 U.S. gal.)

Cooling System

26 L (6.9 U.S. gal.)

Engine

400 L (105 U.S. gal.)

Fuel Tank

Hydraulic Oil

Capacity

Tank Level

141 L (37.2 U.S. gal.)

Full

195 L (51.5 U.S. gal.)

System

270 L (71.3 U.S. gal.)

Travel Reduction Gear (Each)

3L (0.8 U.S. gal.)

Swing Reduction Gear

5L (1.3 U.S. gal.)

Inspection, Maintenance and Adjustment  Adjustment  4-11

DX220A-2/DX220LCA-2

 

LUBRICATION AND SERVICE LUBRICATION CHART Lubrication and service chart is on the inside of battery box cover. The symbols shown here are used in the lubrication and service chart on the next page. Symbol

Description

Symbol

Description

Lubrication

Coolant

Gear Oil (Swing Device, Travel Device)

Air Cleaner Element

Engine Oil

Fuel Filter, Water Separator

Engine Oil Filter

Air Conditioner Filter

Hydraulic Oil

Drain Water

Hydraulic Oil Return Filter

Fuel Cap Filter

Hydraulic Oil Tank Breather

Level Check

Inspection, Maintenance and Adjustment  4-12

DX220A-2/DX220LCA-2

 

Description of Lubrication and Service Chart

20

6

23

5

21

 

15

4

7

10

16 2 9

12

11

19

18

3 17 3 13

10h 50h 250h 500h 1000h 2000h

24

14

22

8

1

DS1703961

Figure 10

DX220A-2/DX220LCA-2

Inspection, Maintenance and Adjustment  Adjustment  4-13

 

 SERVICE DATA No.

Items to Check

Service

1 2 3 4

Arm, Bucket Joint Pin Swing Bearing Boom, Arm Joint Pin Breaker Filter (Opt)

5

Engine Oil

Grease Grease Grease Cartridge Engine Oil  (10W40)

6

Water Separator and Pre Fuel Filter (Fuel Prefilter)

7 8 9 10 11 12 13 14

Engine Oil Filter Track Spring Pinion Gear (Swing) Main Fuel Filter Swing Reduction Gear Hydraulic Oil Return Filter Pilot Filter Travel Reduction Gear Air Conditioner Filter

15

(Outer) Air Conditioner Filter (Inner) Swing Reduction Gear Air Breather Filter* Fuel Cap Filter Hydraulic Oil Tank** Radiator Air Cleaner (Outer) Air Cleaner (Inner) Fuel Tank Additional Water Separator

16 17 18 19 20 21 22 23

Qty. 6 2 11 1

10 F100 F100

Service Interval (hr) 50 250 500 1000 W10 W10 W10

28 28 L  L

V

Cartridge

1

D, V

Cartridge Grease Grease Cartridge Gear Oil Element Element Gear Oil

1 2 1 1 5 L 1 1 2 x 3 L

Element

1

C

Element

1

C

Grease Element Element Hydraulic Oil Coolant Element Element Diesel Strainer

2000

F

W10

V

F F F F,V

1 1 1 195 L 26 L 1 1 400 L

W10

V

1

D, V

V V C D C

Hydraulic Oil Suction Strainer 1 C Strainer V: Maintenance and Refill. C: Cleaning. D: Drain Water. F: First Time Exchange Only. F100:: Every 10 Hours For First 100 Hours. F100 W10:: Every 10 Hours If Operating In Water. W10 EG:: Ethylene Glycol - Doosan Genuine Antifreeze Solution (Drain and replace using this interval.) See "Engine  EG "Engine  Cooling System" on page 4-78, 4-78, for further explanation. 24

: Replacement On Every Interval. NOTE:

For additional service items see list of "Maintenance Intervals" on page 4-15 .

*: When the machine is operated dusty work sites, thedate. air breather filter needs to be cleaned or replaced on a regular basis even before under the expected replacement ** **:: If DOOSAN Genuine Oil used, hydraulic oil change interval is 4,000 hours. Inspection, Maintenance and Adjustment  4-14

DX220A-2/DX220LCA-2

 

MAINTENANCE INTERVALS SERVICE ITEM

PAGE

10 Hour / Daily Service Grease Boom, Arm and Front Attachment Pins (for first 100 hours)

4-17

Check Engine Oil Level

4-17

Check Level of Hydraulic Oil Tank

4-18

Check for Leaks in Hydraulic System Check Fuel Level

4-19 4-19

Check for Leaks in Fuel System

4-20

Check Additional Water Separator

4-20

Check W Wa ater Se Separator & Pre Fu Fuel F Fiilter (F (Fuel P Prrefilter) an and D Drrain Wa Water a as s Re Required

4-21

Check Oil Level of Swing Reduction Device

4-22

Clean Dust Net in Front of Oil Cooler and Intercooler

4-23

Check Cooling System and Refill as Required

4-23

Check Level of Window Washer Liquid (Optional)

4-24

Inspect the Bucket Teeth and Side Cutters for Signs of Wear

4-24

Inspect Cooling Fan Blade

4-24

Check Air Intake System

4-25

Inspect Seat Belt for Proper Operation Inspect the Structure for Cracks and Faulty Welds

4-25 4-25

Check the Operation of All Switches

4-25

Pilot Cutoff Switch

4-26

Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights

4-27

Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds

4-27

Check Operation of All Controls

4-27 50 Hour / Weekly Service

Perform All Daily Service Checks

4-28

Grease Arm and Bucket Joint Pins

4-28

Grease Swing Bearing Drain Water and Sediment from Fuel Tank

4-29 4-29

Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)

4-30

Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers)

4-30

250 Hour / Monthly Service Perform All Daily and 50 Hour Service Checks

4-31

Grease Boom and Arm Joint Pins

4-31

Clean Additional Water Separator

4-33

Change Breaker Filter (Optional)

4-34

Check Engine Fan Belt Wear

4-35

Check Engine Fan Belt Tension

4-36

Replace Hydraulic Oil Return Filter (After First 250 Hours) Change Pilot Filter (After First 250 Hours)

4-36 4-36

Inspect Pins and Bushings of the Front End Attachments for Signs of Wear

4-36

Inspection, Maintenance and Adjustment  Adjustment  4-15

DX220A-2/DX220LCA-2

 

SERVICE ITEM

PAGE

Check Fluid Levels in Batteries

4-36

Inspect for Any Loose or Missing Nuts and Bolts

4-36

Inspect Fuel System Hose Clamps

4-36 500 Hour / 3 Month Service

Perform All Daily, 50 and 250 Hour Service Checks

4-37

Grease Swing Gear and Pinion

4-37

Clean Air-Conditioning Outer Filter Check and Clean Air-Conditioning Inner Filter

4-39 4-40

Cl Clea ean nR Rad adia iato tor, r, Oil Oil C Coo oole ler, r, Inte Interc rcoo oole ler, r, Fuel Fuel Cool Cooler er an and d Air Air Cond Condit itio ione nerr Con Conde dens nser er Core Core

44-41 41

Clean Outer Filter of Air Cleaner

4-42

Change of Water Separator & Pre Fuel Filter (Fuel Prefilter)

4-44

Change Main Fuel Filter

4-45

Check Oil Level in Travel Reduction Device (One on Each Side of Unit)

4-46

Chang hange eO Oil il in Trav Travel el Redu Reduct ctio ion n Dev Devic ice e ((On One e on on Eac Each h Sid Side e of of Uni Unit) t) (A (Aft fter er Fi Firs rstt 5 500 00 Hour Hours) s)

44-46 46

Change Swing Reduction Device Oil (Drain and Refill After First 500 Hours)

4-46

1,000 Hour / 6 Month service Perform All Daily, 50, 250 and 500 Hour Service Checks

4-47

Grease Swing Reduction Device

4-47

Change Air Breather Filter Replace Hydraulic Oil Return Filter

4-47 4-48

Change Pilot Filter

4-49

Change Oil in Travel Reduction Device (One on Each Side of Unit)

4-50

Change Swing Reduction Device Oil

4-51

Change Air-Conditioning Outer Filter

4-52

Change Air-Conditioning Inner Filter

4-53

Check and Adjust Engine **

4-53

Change Fuel Cap Filter

4-54 2,000 Hour / Yearly Service

Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks

4-56

Replace Outer and Inner Air Cleaner Elements

4-56

Change Radiator Coolant Hydraulic Oil Exchange and Suction Strainer Cleaning

4-57 4-58

Check Alternator and Starter**

4-60

Check All Rubber Antivibration Shock Mounts

4-60

Perform and Record the Results of the Cycle Time Tests

4-60

Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage

4-60

Check, Adjust Valve Clearance **

4-60

Check Head Bolt Torques

4-60 4,000 Hour / Biennial Service

Major Parts - Periodic Replacement

4-61 12,000 HOUR / SIX YEAR SERVICE

Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN)

4-62

** These checks need to be completed by an authorized DOOSAN dealer.

Inspection, Maintenance and Adjustment  4-16

DX220A-2/DX220LCA-2

 

10 HOUR / DAILY SERVICE Grease Boom, Arm and Front Attachment Pins (for first 100 hours) Grease every 10 hours for first 100 hours and every 50 or 250 hours thereafter (See page 4-17). 4-17). NOTE:

If the unit has been running or working in water the front attachment must be greased on a 10 hour/daily basis.

FG000500

Figure 11

Check Engine Oil Level

 

2

1

WARNING AVOID DEATH OR SERIOUS INJURY Allow the engine to cool before checking the oil level to avoid burns by touching hot engine parts. NOTE:

When checking level using a dipstick always remove and wipe it clean before making final level check.

1.

Stop Stop engine engine and wait wait for for fifte fifteen en m minu inutes tes.. This This w will ill all allow ow all all oil to drain back to oil pan.

2.

Remove ove dipstick (1, Figure 12) 12) and wipe the oil off with a clean cloth.

3.

Insert Insert dipstic dipstick k full fully y in the oil gauge gauge tube tube,, then then take take it out out again.

4.

Engi Engine ne oil oil lev level el mus mustt be bet betwe ween en ""HI HIGH GH"" and and "LOW "LOW"" marks on dipstick. NOTE:

5.

FG001377

Figure 12

  H

If oil is above "HIGH" mark on dipstick, some must be drained to return oil to proper level.

  L

Add Add oil oil thro throug ugh h eng engin ine e oil oil fill fill cap cap ((2, 2, Figure 12 12), ), if the oil level is below the "LOW" mark.

FG000616

Figure 13

Inspection, Maintenance and Adjustment  Adjustment  4-17

DX220A-2/DX220LCA-2

 

Check Level of Hydraulic Oil Tank 

WARNING AVOID DEATH OR SERIOUS INJURY The hydraulic oil will be hot after normal machine operation. Allow the system to cool before attempting to service any of the hydraulic components. The hydraulic tank is pressurized. Turn the breather cap slowly to allow the pressurized air to vent. After the pressure has been released, it is safe to remove either the fill cap or service covers. 1.

Park Park mac machi hine ne o on n firm firm a and nd lev level el gro groun und. d. Low Lower er b boo oom m an and d position bucket on ground as shown in Figure 15. 15.

2.

Mo Move ve en engi gine ne sp spee eed d to to "LO "LOW W IDL IDLE" E"..

ARO1760L

Figure 14

EX1300541

Figure 15 3.

Mo Move ve saf safet ety y le leve verr to "LOC "LOCK" K" po posi siti tion on..

4.

Check Check leve levell gauge gauge by open opening ing rig right ht acces access s door. door. Oil level level must be between marks on sight gauge. H L

FG006442

Figure 16 5.

If th the e llev evel el is be belo low w "L" "L" mark mark ad add d oil oil.. A.

Stop engine.

B.

The hydrau hydraulic lic tank is pres pressur surize ized. d. Lif Liftt the the brea breathe therr cap slowly to allow the pressurized air to vent.

C.

Re Remov move e up uppe perr cove coverr of the the hydra hydrauli ulic c tank tank a and nd ad add d oil.

FG013199

Figure 17

Inspection, Maintenance and Adjustment  4-18

DX220A-2/DX220LCA-2

 

IMPORTANT Do not fill above "H" mark on sight gauge. Overfilling can result in damage to equipment and oil leaking from hydraulic tank because of expansion. 6.

If oil oil lev level el is above above th the e ""H" H" mark mark d dra rain in oi oil. l. A.

Stop Stop e eng ngine ine an and d wait wait for for tthe he hyd hydra raul ulic ic oil oil to to co cool ol down.

B.

Drai Drain n the the exce excess ss oil oil from from drai drain n plu plug g (Figure (Figure 18) 18) at the bottom of the tank into a suitable container, using a hose at the port (plug).

NOTE:

Dispose of drained fluids in compliance with all applicable environmental laws and regulations. FG013200

Figure 18

Check for Leaks in Hydraulic System 1.

Perfor Perform m a daily daily walk walk-ar -aroun ound d inspe inspecti ction on to make make sure sure that that hoses, piping, fittings, cylinders and hydraulic motors are not showing any signs of leakage. If any is noted, determine the source of the leak and repair.

Check Fuel Level

1

 WARNING AVOID DEATH OR SERIOUS INJURY Use extreme safety precautions while refueling to prevent explosions or fire. Immediately clean up any split fuel. 1.

At end end o off each each work work day, day, fill fill fuel fuel tank. tank. Add Add fuel fuel thro through ugh fuel fuel fill tube (1, Figure 19). 19). When working at a temperature of 0°C (32°F) or higher, use ASTM No. 2-D or its equivalent. At temperatures below 0°C (32°F) use ASTM No. 1-D or its equivalent.

2.

Make Make su sure re that that fue fuell fill fill hose is groun grounded ded to tthe he e exca xcavat vator or before fueling begins.

3.

Check Check the amount amount of fuel fuel in in tthe he tank tank by observ observing ing the fue fuell

DS1703722

Figure 19

gauge of display monitor. NOTE: 4.

See "Fluid Capacities" on page 4-11 for 4-11 for capacity.

Add Add ffue uel. l. Do no nott o ove verf rfil illl the the ta tank nk..

DX220A-2/DX220LCA-2

Inspection, Maintenance and Adjustment  Adjustment  4-19

 

5.

Secu Secure rely ly tigh tighte ten nc cap ap afte afterr fue fueli ling ng.. NOTE:

If breather holes (3, Figure 20   ) in cap are clogged, a vacuum may form in the tank preventing proper fuel flow to engine. Keep holes in fuel cap clean.

3

3

FG000317

Figure 20

Check for Leaks in Fuel System 1.

Perfor Perform m an an insp inspect ection ion of the engine engine compart compartmen mentt to to veri verify fy that fuel system is not leaking. If any is noted, determine the source of the leak and repair.

Check Additional Water Separator

1.

A addi addition tional al w wate aterr separa separator tor is insid inside e the the left left rear rear si side de access door.

2.

Open Open the the acc acces ess s door door o on n left left rea rearr si side de of of the the mach machin ine. e.

DS1703723

Figure 21 3.

It is is neces necessar sary y to dra drain in tthe he coll collect ected ed water water if the the b bowl owl is full full of water or sediment.

4.

Posi Positio tion n a small small con conta tain iner er unde underr ad addit ditio iona nall wate waterr separator. Drain water or sediment by opening drain valve (2, Figure 22) 22) on bottom of bowl (1). NOTE:

5.

1

Dispose of drained fluids in compliance with all applicable environmental laws and regulations.

Close drain valve.

2

open

Figure 22

close DS1602385

Inspection, Maintenance and Adjustment  4-20

DX220A-2/DX220LCA-2

 

Check Water Separator & Pre Fuel Filter (Fuel Prefilter) and Drain Water as Required 1.

A ffuel uel pre prefil filter ter is ins inside ide the lef leftt rear rear sid side ea acce ccess ss doo door. r.

2.

Open Open the the acc acces ess s door door o on n left left rea rearr si side de of of the the mach machin ine. e.

EX1402656

Figure 23 3.

It is is neces necessar sary y to dra drain in tthe he coll collect ected ed water water if the the b bowl owl is full full of water or sediment.

4.

Positi Position on a small small c conta ontaine inerr under under fuel fuel prefi prefilte lter. r. D Drai rain n w wate aterr or sediment by opening drain valve (2, Figure 24 24)) on bottom of bowl (1). NOTE:

5.

1

Dispose of drained fluids in compliance with all applicable environmental laws and regulations.

2

Close drain valve.

open

close FG000438

Figure 24

Inspection, Maintenance and Adjustment  Adjustment  4-21

DX220A-2/DX220LCA-2

 

Check Oil Level of Swing Reduction Device

 WARNING AVOID DEATH OR SERIOUS INJURY The gear oil is very hot after the machine has been operating. Shut all systems down and allow them to cool. Before fully removing any motor case inspection port plug, etc., loosen the plug slightly to allow pressurized air to escape. NOTE:

When checking level using a dipstick always remove and wipe it clean before making final level check.

1.

Remove ove dipstic tick (1, Figure 25 25)) and wipe the oil from the dipstick with a cloth.

2.

Insert dipstick (1, Figure 25) 25) fully into dipstick tube.

2

1

FG001384

Figure 25 3.

When When d dips ipstic tick k is is p pull ulled ed out, out, oil oil lev level el must must b be e betw between een "HIGH" and "LOW" marks on dipstick. NOTE:

4.

If oil is above "HIGH" mark on dipstick, some must be drained to proper level.

If tthe he oil oil does does not reach reach the the "L" "L" mark mark o on n the the dipst dipstick ick,, add add oil oil through fill port (2, Figure 25 25). ).

  H   L

FG000419

Figure 26 5.

If tthe he oil oil leve levell excee exceeds ds the the ""H" H" mark mark on the the dips dipstic tick, k, rrele elease ase the drain plug. Drain the excessive oil into a suitable container. NOTE:

Dispose of drained fluids in compliance with all applicable environmental laws and regulations.

FG013201

Figure 27

Inspection, Maintenance and Adjustment  4-22

DX220A-2/DX220LCA-2

 

Clean Dust Net in Front of Oil Cooler and Intercooler

IMPORTANT If running excavator in dusty area, check dust net everyday and clean it if dirty.

 WARNING AVOID DEATH OR SERIOUS INJURY If using compressed air or water to clean the dust net, make sure that proper eye protection is worn. 1.

Loos Loosen en the wing wing bolt bolt(s (s)) and and remo remove ve dust dust net. net.

2.

Clea Clean nw wit ith hc com ompr pres esse sed d air air or wa wate ter. r.

FG013202

Figure 28

Check Cooling System and Refill as Required

 WARNING AVOID DEATH OR SERIOUS INJURY Allow the engine to cool before releasing the radiator cap. Make sure to loosen the cap slowly to release any remaining pressure. Radiator cleaning is performed while the engine is running. Take extreme caution when working on or near a running engine. Make sure to lock out and tag the controls notifying personnel that service work is being performed. Do not remove the radiator cap unless it is required. Observe the coolant level in the coolant recovery tank. NOTE:

Do not mix ethylene glycol and propylene glycol antifreeze together.

1.

When When the the eng engin ine e is cold cold,, re remo move ve the the rad radia iator tor cap cap an and d check the coolant level inside the radiator. Do not rely on the level of coolant in the coolant recovery tank. Refill radiator as required. Refer to coolant concentration table. (See page 4-80)

2.

Check Check to m make ake sure sure that that tthe he coo coolan lantt trans transfer fer line line from from the coolant recovery tank to the radiator is free and clear of obstructions, or not pinched.

3.

Observ Observe e the the le level vel of cool coolant ant in the coo coolan lantt recov recovery ery tan tank. k.

DS1703724

The normal cold engine fluid level must be between "FULL" and "LOW" marks on tank. 4.

Figure 29

If the coolant coolant is bel below ow the "LOW" "LOW" mark, mark, add genuin genuine e part part of 50% concentration coolant to the tank. Inspection, Maintenance and Adjustment  Adjustment  4-23

DX220A-2/DX220LCA-2

 

Check Level of Window Washer Liquid (Optional) 1.

Open Open left left access access door door and and check check fluid fluid level level in windsh windshiel ield d washer tank.

2.

Open Open fill fill ca cap pa and nd ad add d fflu luid id.. NOTE:

Use a washer liquid that is rated for all seasons. This will prevent freezing during cold weather operation. DS1703725

Figure 30

Inspect the Bucket Teeth and Side Cutters for Signs of Wear 1. 2.

2 1

Dail Daily, y, ins inspe pect ct the the b buc ucke kett teeth teeth tto o make make sur sure e that that to tooth oth wear or breakage has not developed.

3

Do not all allow ow the replac replaceabl eable e buck bucket et teeth teeth to to w wear ear dow down n tto o the point that bucket adapter is exposed. See Figure 31 31.. NOTE:

These instructions are only for DOOSAN OEM buckets. If you are using other manufacturers' buckets, refer to their specific instructions.

FG000420

Figure 31

Reference Number

Description

1

Point

2

Adapter

3

Pin

Inspect Cooling Fan Blade

WARNING AVOID DEATH OR SERIOUS INJURY Personal injury can result from a fan blade failure. Never pull or pry on the fan. This can damage the fan blade(s) and cause fan failure. 1.

An insp inspecti ection on of the the cool cooling ing fan is requ require ired d daily daily.. Chec Check k for for cracks, loose bolts, bent or loose blades, and for contact between the blade tips and the fan shroud. Check the fan to make sure it is securely mounted. Tighten the bolts if necessary. Replace any fan that is damage.

Figure 32

Inspection, Maintenance and Adjustment  4-24

DX220A-2/DX220LCA-2

 

Check Air Intake System

CAUTION AVOID INJURY Hot engine components can cause burns. Avoid contact with hot engine components c omponents 1.

Park Park the the machin machine e on on a lev level el surfac surface, e, low lower er the attach attachment ment to the ground, move safety lever to "LOCK" position, and stop engine.

2.

Chec Check k the e eng ngin ine e int intak ake e hose hose,, an and d hose hose band bands s for for dam damag age e and tightness.

3.

If dama damaged ged,, wrin wrinkl kled ed,, or loos loose, e, repl replac ace e or reti retigh ghte ten n or contact your nearest DOOSAN dealer.

HAOA050L

Figure 33

IMPORTANT Severe engine damage will result from running with unfiltered air. Do not operate engine if any leaks or defects are found on air intake system.

Inspect Seat Belt for Proper Operation See "Seat Belt" on page 1-32 1-32 for  for further information.

Inspect the Structure for Cracks and Faulty Welds 1.

Durin During g th the e da dail ily y wa walklk-ar arou ound nd iinsp nspec ectio tion n an and d when when greasing the machine, look for any visible damage to the machine. Repair or replace any damaged parts before operating the machine.

Check the Operation of All Switches 1.

Verify Verify the wor workin king g co condi ndition tion of all all s swit witche ches s before before startin starting g the engine.

FG001386

Figure 34

Inspection, Maintenance and Adjustment  Adjustment  4-25

DX220A-2/DX220LCA-2

 

Pilot Cutoff Switch The pilot cutoff switch is equipped with a pivoting safety lever that disables the swing, travel, and front operations. Putting the safety lever in the "LOCK" position disables the swing, travel, and front operations. Putting the safety lever in the "UNLOCK" position enables the swing, travel, and front operations.

WARNING AVOID DEATH OR SERIOUS INJURY If the machine operations are not disabled with the safety lever in the "LOCK" position, contact your local DOOSAN dealer. Never tune the system yourself.

Check for Operation of Pilot Cutoff Switch 1.

Make Make s sure ure no per person son access accesses es your your worki working ng pla place. ce. Sit on the driver's seat and tighten the seat belt.

2.

Star Startt up th the e engi engine ne and and put put the the saf safety ety le leve verr in th the e "UNLOCK" position.

3.

Move Move the the joys joystic tick k in in all all dire directi ctions ons to check check tha thatt the the bo boom, om, arm, bucket (or the installed attachment), and swing operations are all normal. Also, move the travel lever to check that the machine travels normally. NOTE:

You must heat the hydraulic system up to the operating temperature.

4.

Rais Raise e the boo boom m an and d arm w with ith the the bu buck cket et lif lifted ted 1 m (3 ft ft.) .) above the ground.

5.

Put the safety safety lev lever er in the "UNLOC "UNLOCK" K" pos positi ition on and move move the joystick. The front and swing operations must not be performed.

6.

Operate Operate the travel travel lever lever under under the the c cond onditi ition on of Step Step 5. The machine must not travel.

7.

Put the safety safety lleve everr in the "relea "release" se" pos positi ition, on, and raise raise the boom and arm with the bucket (or the installed attachment) lifted 1 m (3 ft.) above the ground. Using the joystick, lower the boom slowly. While the boom is lowering, put the safety lever in the "LOCK" position. The boom then must stop moving. Repeat the steps above with the arm, bucket (or the installed attachment), swing, and travel operations to check if the safety lever works normally with them.

8.

Lowe Lowerr th the e buck bucket et ((or or att attac achm hmen ent) t) to th the e grou ground nd and and sto stop p the engine.

Unlock

Lock

Figure 35

EX1300566

Inspection, Maintenance and Adjustment  4-26

DX220A-2/DX220LCA-2

 

Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights 1.

Turn Turn engin engine e star starter ter swi switch tch to "I" (ON (ON)) posit position ion and observ observe e all of the indicator lights.

2.

Restore Restore operati operation on of of an any y lilight ght bul bulbs bs that that do n not ot tturn urn "ON" "ON" now.

3.

Soun Sound d tthe he horn horn.. R Rep epai airr or repl replac ace e iiff requ requir ired ed..

4.

Turn Turn "ON" "ON" and inspec inspectt a allll exteri exterior or work work lights lights.. Repl Replace ace any monitors, burned out bulbs or cracked or broken housings or lenses.

Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds Check Operation of All Controls

IMPORTANT Cold weather operation requires that operator fully warm up the hydraulic oil before beginning machine operation. Follow all warm up instructions listed in the Operating Instruction section of this manual. Make sure to cycle oil through all of the components, including all cylinders, both travel motors and the swing motor. Cold hydraulic oil in the lines and components needs to be warmed before beginning full operation. If this is not done, damage to the cylinders or hydraulic motors can occur. 1.

With With th the e engi engine ne at rate rated ds spee peed, d, oper operate ate all of the contro controls. ls.

2.

Fo Foll llow ow col cold d procedures.

3.

Note Note a any ny s slow low op oper erat ation ions s or un unus usual ual move moveme ment nts. s. Determine the cause and repair the fault before operating.

weat weathe herr

hydr hydrau auli lic c

sy syst stem em

w war arm-u m-up p

Inspection, Maintenance and Adjustment  Adjustment  4-27

DX220A-2/DX220LCA-2

 

50 HOUR / WEEKLY SERVICE Perform All Daily Service Checks Grease Arm and Bucket Joint Pins Grease every 10 hours for first 100 hours and every 50 hours thereafter. NOTE:

If the unit has been running or working in water, the front attachment must be greased on a 10 hour/daily basis.

•

Posi Positio tion n mac machi hine ne on firm firm and and llev evel el grou ground nd as show shown nb bel elow ow and lower the front attachment to the ground and stop engine.

•

Pres Press s tthe he greas grease e ffit itti ting ng an and d iinj njec ectt gre greas ase e wit with h tthe he grea grease se gun on the marked point.

•

Afte Afterr gre greas asin ing, g, clea clean n off off the old old gre greas ase e tha thatt has has bee been n purged.

D

B, E

C

A

EX1300742

Figure 36 Reference Number

Description

Reference Number

Description

A

Arm Link Joint Pin (1 Point)

D

Bucket Link Joint Pin (1 Point)

B

Link Joint Pin (2 Points)

E

Bucket Cylinder Rod Pin (1 Point)

C

Arm Bucket Joint Pin (1 Point)

Inspection, Maintenance and Adjustment  4-28

DX220A-2/DX220LCA-2

 

A.

Arm lin ink k jjoi oint nt pin pin ((1 1 poi point nt))

B.

Link Link jo join intt pin pin (2 po poin ints ts))

C.

Arm Arm buc bucke kett joi joint nt pin pin ((1 1p poi oint nt))

D.

Buck Bucket et link link join jointt p pin in (1 po poin int) t)

A B C

D

FG019633

Figure 37 E.

Buck Bucket et cy cyli lind nder er ro rod dp pin in (1 po poin int) t)

E

FG019634

Figure 38

Grease Swing Bearing 1.

Park Park mac machi hine ne on on firm firm and and llev evel el grou ground nd.. Lowe Lowerr th the e fron frontt attachment to the ground and stop engine.

2.

There There are are thre three e g greas rease e fitt fitting ings s ffor or the swing swing bearin bearing. g. Do not over lubricate. Purge old grease with new. Remove all purged grease.

EX1403881

Figure 39

Drain Water and Sediment from Fuel Tank  1.

Perfo Perform rm this this proc proced edur ure e before before ope opera ratin ting g the mac machi hine ne..

2.

Drain Drain water water and sedime sediment nt from bot bottom tom of fuel tank into an approved container. NOTE:

Dispose of drained fluids in compliance with all applicable environmental laws and regulations.

NOTE:

Always completely fill fuel tank at end of each workday to prevent condensation from forming on the inside walls of the tank.

DX220A-2/DX220LCA-2

 

Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours) 1.

Inspec Insp ectt af after ter fir first st 5 50 0 ho hours urs of op oper erat atio ion n and and ever every y 250 250 hours thereafter. For details, See "Check Engine Fan Belt Belt   Tension" on page 4-36

Inspect Assemblies for Proper Tensionthe andTrack Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers) 1.

Do a dai daily ly wal walkk-aro around und iins nspe pecti ction on of of all com compo pone nent nts s including the track assemblies. Look for missing, damaged or excessively worn parts. See "Track Tension" on page 482

2.

Jack Jack up up each each trac track k and per perfo form rm the the two two speed speed tra travel vel mot motor or test.

DS1703726

Figure 40

Inspection, Maintenance and Adjustment  Adjustment  4-29

Inspection, Maintenance and Adjustment  4-30

DX220A-2/DX220LCA-2

 

250 HOUR / MONTHLY SERVICE Perform All Daily and 50 Hour Service Checks

Grease Boom and Arm Joint Pins Grease every 10 hours for first 100 hours and every 250 hours thereafter. NOTE:

If the unit has been running or working in water, the front attachment must be greased on a 10 hour/daily basis.

•

Posi Positio tion n mac machi hine ne on firm firm and and llev evel el grou ground nd as show shown nb bel elow ow and lower the front attachment to the ground and stop engine.

•

Pres Press s tthe he greas grease e ffit itti ting ng an and d iinj njec ectt gre greas ase e wit with h tthe he grea grease se gun on the marked point.

•

Afte Afterr gre greas asin ing, g, clea clean n off off the old old gre greas ase e tha thatt has has bee been n purged.

B, C, D

E F

G

A

EX1300743

Figure 41 Reference Number

Description

Reference Number

Description

A

Boom Cylinder Head Pin (2 Points)

E

Boom Arm Joint Pin (2 Points)

B

Boom Foot Pin (2 Points)

F

Arm Cylinder Rod Pin (1 Point)

C D

Boom Cylinder Rod Pin (2 Points) Arm Cylinder Head Pin (1 Point)

DX220A-2/DX220LCA-2

G

Bucket Cylinder Head Pin (1 Point)

Inspection, Maintenance and Adjustment  Adjustment  4-31

 

A.

Boom Boom cyli cylind nder er he head ad pin pin ((2 2 poi point nts) s)

A

A

Figure 42 B.

Boo oom m foot foot pi pin n (2 po poin ints ts))

C.

Boom Boom cyli cylind nder er ro rod d pin pin (2 po poin ints ts))

D.

Arm Arm cyl cylin inde derr h hea ead d pin pin (1 po poin int) t)

EX1403883

C D C B

FG019635

Figure 43 E.

Boom Boom arm arm join jointt pin pin (2 po poin ints ts))

F.

Arm cy cyli lin nder der rod rod pin pin (1 (1 po poin int) t)

G.

Buck Bucket et cyli cylinde nderr hea head d pin pin (1 poin point) t)

F

E G

EX1403396

Figure 44

Inspection, Maintenance and Adjustment  4-32

DX220A-2/DX220LCA-2

 

Clean Additional Water Separator 1.

Open Open the the llef eftt rear rear side side doo doorr to acc acces ess s addi additi tion onal al wat water er separator.

2.

Posi Positio tion n a small small con conta tain iner er unde underr ad addit ditio iona nall wate waterr separator. Drain fuel by opening drain valve on bottom of filter. NOTE:

Dispose of drained fluids in compliance with all applicable environmental laws and regulations.

DS1602459

Figure 45 3.

Re Remo move ve bo bowl wl us usin ing g sup suppl plie ied d too tool. l.

DS1602460

Figure 46 4.

Remove the the strain ainer (1 (1, Figure 47) 47) from the head and remove any foreign material from it using fuel. NOTE:

5.

Make sure to use fuel only to clean it.

Aft After er moun mountin ting g the the strai strainer ner on the head, head, coat coat the surfac surface e of seal (2, Figure 47) 47) with fuel and tighten the bowl with tool.

2

1

3

DS1602461

Figure 47

Inspection, Maintenance and Adjustment  Adjustment  4-33

DX220A-2/DX220LCA-2

 

Change Breaker Filter (Optional)

WARNING AVOID DEATH OR SERIOUS INJURY The hydraulic oil will be hot after machine operation. Allow the system to cool down before changing breaker filter. 1.

Park Park mac machi hine ne on on firm firm and and llev evel el grou ground nd.. Lowe Lowerr th the e fron frontt attachment to the ground and stop engine.

2.

Tip the Tip the hy hydr drau auli lic c oil oil tank tank bre breat athe herr cap cap up tto o rele releas ase e pressure.

3.

Lo Loca cate te brea breake kerr fil filte terr ass assem embl bly. y.

4.

Posi Positi tion on a cont contain ainer er und under er the the ffil ilte terr as asse semb mbly ly..

5.

Using Using a 32 mm wren wrench, ch, uns unscre crew w filte filterr housi housing ng ffrom rom filter filter bottom (Figure (Figure 48 48). ).

6.

Remov Remove e O-ri O-ring ng,, and and back back-u -up p ri ring ng fro from m filt filter er hea head. d.

7.

Repl Replac ace e ffil ilte terr e ele leme ment nt (1, (1, Figure 49). 49).

8.

Appl Apply y a small small amou amount nt of of oil oil ar aroun ound d the the enti entire re O-r O-rin ing g an and d back-up ring and then install the filter housing on the filter head.

9.

•

Tool: 32 mm (

)

•

Torque: 30 3 0 N.m (3 ( 3 kg.m, 22 ft lb) and turn 1/4 counterclockwise

Aft After er chan changin ging g break breaker er filter, filter, ven ventt air air from from p pump ump and check check level of hydraulic oil tank.

DS1702323

Figure 48

1

DS1603612

Figure 49

Inspection, Maintenance and Adjustment  4-34

DX220A-2/DX220LCA-2

 

Check Engine Fan Belt Wear

WARNING AVOID DEATH OR SERIOUS INJURY Keep clear of engine fan and fan drive belts when the engine is running. Rotating fan and belt contact can cause injury. DS1702861

Figure 50

 WARNING AVOID DEATH OR SERIOUS INJURY When checking, adjusting or replacing drive belts, care must be taken to prevent accidental cranking of the engine. Be sure the starter switch is in the "OFF" position and the controls are tagged. 1.

Repla Replace ce badl badly y worn, worn, grea greasy sy or or sever severel ely y crack cracked ed be belts lts immediately. These conditions prevent proper belt function. Visually inspect the belt. Check the belt for intersecting cracks. Transverse (across the belt width) cracks are acceptable. Longitudinal (direction of belt length) cracks that intersect with transverse cracks are not acceptable. Replace the belt if it is frayed or has pieces of material missing.

2.

Before Before ins instal tallin ling g n new ew belts, belts, make make sur sure e all all pulle pulley y g groov rooves es are clean and not worn. Replace pulley, if damaged, or if the grooves are worn.

3.

All pulley pulley suppor supportt be beari arings ngs,, shafts shafts,, and and brack brackets ets mus mustt be in working order.

4.

When When rrepl eplaci acing ng belts belts and and pulley pulleys, s, pul pulley ley ali alignm gnment ent must must be checked with belts tensioned and brackets securely clamped. A misalignment that can be detected by the eye is detrimental to belt performance.

5.

Do not force force the belts belts into the pulley pulley groove grooves s by prying prying wit with h a screwdriver or pry bar. This will damage the belt side cords which will cause the belts to turn and result in complete destruction of the belts in operation.

6.

Belt Belts s on ne new w machi machine nes s and rep repla lacem cement ent b belt elts s lose lose thei theirr tension as they seat into the pulley grooves. Check the tension of new belts at 50 hour intervals until tension is stabilized and thereafter, every 250 hours. If the tension falls below the required minimum, the belt slips damaging the belts and pulley grooves.

NOTE:

When operating in abrasive conditions, check tension every 100 hours.

DX220A-2/DX220LCA-2

Inspection, Maintenance and Adjustment  Adjustment  4-35

 

Check Engine Fan Belt Tension

10mm/10kg

FAN

IMPORTANT A loose fan belt can cause engine overheating, poor charging, and/or premature belt wear. A belt that is too tight can cause damage to the water pump, alternator bearing or

COMPRESSOR

ALTERNATOR

belt.

CRANKSHAFT

1.

Inspec Inspectt ever every y 250 250 hou hours. rs. (In (Inspe spect ct after after firs firstt 5 50 0 h hour ours s o off operation.)

2.

With With th the e en engin gine e shut shut off, off, check check the ten tensio sion n of the fan bel beltt by pressing downwards on the belt, midway between the fan pulley and alternator pulley. The belt should flex approximately 10 mm (0.4 in). See Figure 51. 51. To adjust the belt, loosen the alternator adjustment plate bolts, adjust the belt tension and retighten the bolts.

Replace Hydraulic Oil Return Filter (After First 250 Hours) NOTE:

Replace hydraulic oil return filter after first 250 hours of operation or rebuild, then every 1,000 hours thereafter (See page 4-48) .

Change Pilot Filter (After First 250 Hours) NOTE:

Change pilot filter after first 250 hours and every 1,000 hours thereafter (See page 4-49) .

Inspect Pins and Bushings of the Front End Attachments for Signs of Wear Check Fluid Levels in Batteries See "Inspection of Battery Electrolyte Level" on page 4-75 4-75   for further information.

Inspect for Any Loose or Missing Nuts and Bolts

Figure 51

FG000353

Inspect Fuel System Hose Clamps

Inspection, Maintenance and Adjustment  4-36

DX220A-2/DX220LCA-2

 

500 HOUR / 3 MONTH SERVICE Perform All Daily, 50 and 250 Hour Service Checks

Grease Swing Gear and Pinion

 WARNING AVOID DEATH OR SERIOUS INJURY Greasing swing gear and pinion must be serviced by only one person. 1.

Remove Remove inspec inspection tion cover cover and ins inspec pectt the the conditi condition on of tthe he grease. Make sure that water or other contaminants are not noticeable. NOTE:

The upper structure must be rotated a little at a time so that the entire face of the swing gear can be lubricated. Use extreme caution when performing this operation.

DS1703962

Figure 52 2.

If water water or othe otherr c cont ontami aminat nation ions s are are found, found, remove remove low lower er access cover so the gear teeth can be thoroughly cleaned and lubricated.

3.

Inst In stal alll acce access ss c cov over ers s afte afterr lubri lubricat catin ing g gear gear teet teeth. h.

FG000148

Figure 53

Inspection, Maintenance and Adjustment  Adjustment  4-37

DX220A-2/DX220LCA-2

 

Change Engine Oil and Filter NOTE:

Change engine oil and filter after first 50 hours of operation or rebuild, then every 500 thereafter.

 WARNING AVOID DEATH OR SERIOUS INJURY DO NOT change oil on a hot engine. Allow the engine to cool down before attempting to change the engine oil and filter to avoid burns by touching hot engine parts. 1.

Positi Position on a large largerr cont contain ainer er under under the engi engine. ne. Remove Remove cap (1, Figure 54) 54) and install hose (2) to drain the engine oil. Remove hose (2) and install cap (1). 1

NOTE:

Dispose of drained fluids in compliance with all applicable environmental laws and regulations.

2 FG001393

Figure 54 2.

Replac Replace e en engin gine e oil oil filte filterr by using using fi filte lterr wr wrenc ench. h. The eng engine ine oil filter is a spin-on type. See Figure 55 55.. Remove and discard filter.

3.

Instal Installl new new filt filter. er. Apply Apply a sma smallll amount amount of oil oil arou around nd ffilt ilter er gasket. Screw filter on head until gasket contacts head, turn filter 1/2 turn more.

FG001394

Figure 55 4.

Refill Refill the eng engine ine wit with h the the co correc rrectt oi oill throu through gh tthe he oil oil fill fill port port (Figure 56). 56). Refer to the Lubrication Table of this manual for the recommended oil for the operating conditions. NOTE:

See "Fluid Capacities" on page 4-11  4-11  for capacity.

5.

Start Start eng engine ine.. Run Run engine engine for fiv five e minu minutes tes at "LOW "LOW IDLE IDLE", ", and check engine oil pressure light.

6.

Stop Stop engin engine. e. Look Look for signs signs o off leaks leaks at filt filter. er. Rechec Recheck k oil oil

level after fifteen minutes. FG003365-1

Figure 56

Inspection, Maintenance and Adjustment  4-38

DX220A-2/DX220LCA-2

 

Clean Air-Conditioning Outer Filter The unit is equipped with an air filtration system which filters out dirt and dust particles from air being circulated into operator's cabin. This filter must be cleaned out. NOTE:

In the unit is being operated in a dusty environment, the cleaning and replacement must be performed more frequently. If filter is damaged, replace damaged filter with a new one.

 WARNING AVOID DEATH OR SERIOUS INJURY

1  TOP

 Donaldson.

All service and inspection of air-conditioning system must be performed with the starter switch in the "O" (OFF) position.

FG000440

 WARNING

Figure 57

AVOID DEATH OR SERIOUS INJURY If using compressed air to clean the element, make sure that proper eye protection is worn. NOTE:

All right and left call outs are based on the operator being seated in the operator's seat facing the front.

1.

Open Open tthe he door in the left front front o off the the machin machine, e, then then remov remove e the cover (1, Figure 57) 57) by loosening the four wing bolts.

2.

Op Open en th the e co cove verr by turn turnin ing g the the kno knob b (1, (1, Figure 58) 58) in the rear of the cabin.

1

FG000441

Figure 58 3.

Remove filter ((Figure Figure 59) 59) and inspect for any damage.

4.

Use compre compresse ssed d air air to clea clean n filte filter. r. If If filter filter is stil stilll dirty dirty,, then then change to new one.

5.

Reas Reasse semb mble le in reve revers rse e ord order er..

FG000342

Figure 59

Inspection, Maintenance and Adjustment  Adjustment  4-39

DX220A-2/DX220LCA-2

 

Check and Clean Air-Conditioning Inner Filter

 WARNING AVOID DEATH OR SERIOUS INJURY All service and inspection of air-conditioning system must be performed with the starter switch in the "O" (OFF) position.

 WARNING

FG000422

Figure 60 AVOID DEATH OR SERIOUS INJURY If using compressed air to clean the element, make sure that proper eye protection is worn. 1.

Remo Remove ve the the fil filte terr by pul pulli ling ng o out ut war ward d th the e kn knob ob whi while le pressing the upper part and lower part of the filter handle which is inside of the left rear part of the cabin.

2.

Use compre compresse ssed d air air in the cle clean an ffilt ilter. er. If the the filter filter is damaged replaced by a new one.  If the filter is very dirty use a mild soap or detergent and water to clean it.

IMPORTANT If water was used to clean filter, be certain it is completely dry before installing.

Inspection, Maintenance and Adjustment  4-40

DX220A-2/DX220LCA-2

 

Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Core

WARNING AVOID DEATH OR SERIOUS INJURY If compressed air, steam or water hit your body directly, there is danger of injury. Always wear protective glasses, mask and safety shoes during the cleaning precess. Make sure that all extra personnel are clear of the work area. 1.

Open Open th the e rear rear le left ft do door or an and d eng engin ine e cov cover er..

2.

Loosen Loosen the win wing g bolt bolt(s) (s) and rem remove ove dust dust net net from in front front of oil cooler and intercooler.

3.

Clean Clean the the outs outside ide of the radiat radiator or and and o oilil cooler cooler,, inter intercoo cooler ler and fuel cooler with compressed air, steam or water. Wash from the outside of the engine compartment inwards. Repeat the cleaning process from the inside of the engine

FG013205

Figure 61

compartment outwards to remove all dirt and debris. NOTE: Clean dust net and install it after cleaning radiator, oil cooler, intercooler and fuel cooler. 4.

Clean Clean air condit condition ioner er con condens denser er c core ore wit with h comp compress ressed ed air air,, steam or water.

IMPORTANT To prevent damage to the cores, apply compressed air from an appropriated distance. Damaged core can cause water leakage or overheating. In a dusty site, check the core daily, irrespective of the maintenance interval.

FG013202

Figure 62

Inspection, Maintenance and Adjustment  Adjustment  4-41

DX220A-2/DX220LCA-2

 

Clean Outer Filter of Air Cleaner NOTE:

Clean outer filter every 500 hours/3 months of service.

NOTE:

If air cleaner clogged warning light ( F Figure igure 63   ) on instrument panel comes "ON" the air cleaner must be serviced.

NOTE:

When working in severely dusty conditions, the service interval must be shortened. DS1703727

 WARNING

Figure 63

AVOID DEATH OR SERIOUS INJURY Never clean or attempt to remove the air cleaner filter if the engine is running.

2

If using compressed air to clean the filter, make sure that proper eye protection is worn. 1.

Lo Loca cate te the the air air clea cleane nerr ass assem embl bly. y. NOTE:

NOTE: 2.

When it reaches every 500 hours or If indicator light ( F Figure igure 63   ) on instrument panel comes "ON" the air cleaner must be serviced.

1 FG000297

Figure 64

Replace outer filter after cleaning 5 times or every 2,000 hours/1 year of service.

Remo Remove ve and clea clean n rub rubbe berr eva evacu cuato atorr val valve ve (1, Figure 64) 64) from bottom of air cleaner housing cover (2). Inspect seal lips for wear or damage. Replace valve if necessary. NOTE:

Install evacuator valve with lips parallel to the cover.

3.

Remo Remove ve the the acc acces ess s cov cover er (2, (2, Figure 66 66)) by loosening the latches (3).

4.

Remo Remove ve ou oute terr filt filter er (4, (4, Figure 66 66)) from the housing. Do not remove inner filter (5).

5 4

2 3 1

Figure 65

DS1703728

Inspection, Maintenance and Adjustment  4-42

DX220A-2/DX220LCA-2

 

5.

Cl Clea ean n the the ou oute terr fifilter lter (4, (4, Figure 66 66)) by blowing compressed air from the inside of the filter towards the outside. Do not use more than 205 kPa (30 psi) air pressure.

DS1703108

Figure 66 6.

Check Check oute outerr filte filterr by shi shinni nning ng a light light thro through ugh it. If smal smalll holes or thinner parts are found on the element after cleaning it, replace the filter.

7.

Clean Clean the the inside inside of the air cle cleane anerr body body and the ins inside ide of the air cleaner cover. Do not use compressed air.

8.

Prop Proper erly ly inst instal alll the the air air fil filte terr and and cove cover. r.

9.

Aft After er filt filter er servic service e be be sure sure to instal installl c cover over wit with h arrow arrows s pointing "UP". NOTE:

If after cleaning the outer filter, the air cleaner clogged indicator remains "ON", replace the outer and inner filters. Do not clean inner filter.

DS1703109

Figure 67

DX220A-2/DX220LCA-2

Inspection, Maintenance and Adjustment  Adjustment  4-43

 

Change of Water Separator & Pre Fuel Filter (Fuel Prefilter) 1.

Open Open the the left left rear rear sid side e door door to to ac acce cess ss ffue uell pref prefil ilte ter. r.

2.

Positio Position n a sma smallll c cont ontain ainer er unde underr prefi prefilte lter. r. Drai Drain n fu fuel el by opening drain valve on bottom of filter. NOTE:

Dispose of drained fluids in compliance with all applicable environmental laws and regulations. EX1402656

Figure 68 3.

Re Remo move ve bo bowl wl us usin ing g sup suppl plie ied d too tool. l.

4.

Remove cartridge.

FG005878

Figure 69 5.

Coat Coat su surf rfac ace e of of pac packi king ng (2, (2, Figure 70) 70) with fuel on new cartridge (1).

6.

Tighte Tigh ten n the car cartr trid idge ge by by hand hand until until pac packi king ng com comes es int into o contact with the surface of the filter housing head.

7.

When When iitt reach reach the sur surfac face, e, tigh tighten ten the cart cartrid ridge ge about about 3/4 of a turn more.

8.

Coat surf urface ace o off sea seall (3 (3, Figure 70 70)) with fuel, and tighten the bowl with tool.

2

1

3

FG000428

Figure 70

Inspection, Maintenance and Adjustment  4-44

DX220A-2/DX220LCA-2

 

Change Main Fuel Filter

WARNING AVOID DEATH OR SERIOUS INJURY Exchange filter after waiting for engine to cool. Be careful of fire hazards. Do not smoke. 1.

Loca Locate te ffue uell filt filter er ins insid ide e en engi gine ne com compa partm rtmen ent. t.

2.

Posi Positi tion on a smal smalll cont contai ainer ner unde underr fuel fuel filt filter er..

3.

Unscrew Unscrew fuel fuel filter filter from from head head asse assembl mbly. y. D Disc iscard ard fue fuell filte filter. r. NOTE:

4.

FG000773

Figure 71

Dispose of drained fluids in compliance with all applicable environmental laws and regulations.

Aft After er clea cleanin ning g filter filter h head ead,, insta installll new new fu fuel el filt filter. er. S Scre crew w filte filterr on head until gasket contacts head, and turn filter 1/2 turn more with a filter wrench. NOTE:

Coat fuel filter gasket with fuel.

FG000478

Figure 72

Fuel System Priming If air remains in the fuel inlet line to the engine, it can cause the engine to run in an abnormal condition. Air may impact the starting capability of the engine, and may also result in surging engine speeds. If the machine happens to have run out of fuel, or if the fuel filter has been replaced, air may need to be bleed using the following procedure: 1. 2.

Loosen plug (Figure 73) 73) on top of fuel filter head. Unsc Unscre rew w and and pump pump the the hand hand op opera erated ted pr prim imer er pum pump p (Figure 74) 74) by the fuel injection pump. Pump primer until fuel is present at plug hole in fuel filter head.

3.

Tigh Tighte ten n plu plug g in in fue fuell fil filte terr hea head. d.

4.

Contin Continue ue to pump pump prim primer er pump pump until until a stro strong ng res resist istanc ance e is felt. Screw the primer pump knob back into housing.

5.

Star Startt eng engin ine ea and nd look look for sign signs s of of lea leaks ks..

6.

Re Repe peat at proc proced edur ure e if ne nece cess ssar ary. y.

FG003468

Figure 73

FG014219

Figure 74

Inspection, Maintenance and Adjustment  Adjustment  4-45

DX220A-2/DX220LCA-2

 

Check Oil Level in Travel Reduction Device (One on Each Side of Unit) 3

WARNING

1

AVOID DEATH OR SERIOUS INJURY

2

The gear oil is very hot after the machine has been operating. Shut all systems down and allow them to cool. Before removing the motor case, loosen the plug slightly to allow pressurized air to escape. Residual pressure in the travel reduction device can cause the plug to be dislodged and oil to squirt out suddenly. Reference Number

Description

1

Oil Level Plug

2

Drain Plug

3

Fill Plug

1.

Make Make sur sure e that that the the mac machi hine ne is is on ffir irm m and and leve levell gr grou ound nd..

2.

Ro Rota tate te the the ttra rack ck un unti till por ports ts (1 thr thru u 3, Figure 75) 75) are in their proper positions as shown.

3.

Loosen fill plug (3, Figure 75 75)) slightly to allow pressurized air to escape.

4.

Remo Remov ve oi oill le leve vell plu plug g (1, (1, Figure 75 75). ).

5.

Check Check oil oil level level.. The The oil oil mu must st b be e ne near ar the the b bott ottom om of of the the level level plug opening.

6.

Add Add o oil il thro throug ugh h the the fill fill plug plug (3 (3,, Figure 75) 75) opening, if necessary.

7.

Clea Clean n an and d inst instal alll oil oil le leve vell an and d fi fill ll p plu lugs gs ((1 1 and and 3, Figure 75). 75).

8.

Repeat Repeat thi this s proce procedur dure e on the other other trave travell reduc reductio tion n devic device. e.

Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 500 Hours) NOTE:

Drain and refill oil after first 500 hours of operation or rebuild, and every 1,000 hours thereafter (See page   4-50) .

FG028838

Figure 75

Change Swing Reduction Device Oil (Drain and Refill After First 500 Hours) Change swing reduction device oil after first 500 hours on a new machine and every 1,000 hours thereafter (See page 4-51) . Inspection, Maintenance and Adjustment  4-46

DX220A-2/DX220LCA-2

 

1,000 HOUR / 6 MONTH SERVICE Perform All Daily, 50, 250 and 500 Hour Service Checks Grease Swing Reduction Device 1.

Park Park mac machi hine ne on on firm firm and and llev evel el grou ground nd.. Lowe Lowerr th the e fron frontt attachment to the ground and stop engine.

2.

Remov move ai air v ve ent pl plug (1, (1, Figure 76) 76) from swing reduction device.

1

FG001403

Figure 76 3.

Inj Inject ect grease grease wit with h the the gr greas ease e gun gun ((2, 2, Figu Figure re 77) 77) unti untill new new grease comes out from air vent port (1, Figure 76).

4.

In Inst stal alll ai airr ve vent nt pl plug ug (1, (1, Figure 76) 76) in swing reduction device.

2

DS1703963

Figure 77

Change Air Breather Filter 1.

Park Park mac machi hine ne on on firm firm and and llev evel el grou ground nd.. Lowe Lowerr th the e fron frontt attachment to the ground and stop engine.

2.

Lift Lift the the br brea eath ther er ca cap( p(2. 2. Figure 78) 78) slightly to release the internal pressure.

3.

Unscrew the bolt (1, Figure 78) 78) and take off the breather cap (2, Figure 78). 78).

4.

Ch Chan ange ge a filt filter er cart cartri ridg dge e (3 (3,, Figure 78 78)) and assemble the breather cap by tighting the bolt. NOTE:

Used filter should always be disposed of according to local regulations.

1

2

3

NOTE:

When the machine is operated under to dusty work sites, the air breather filter needs be cleaned or replaced on a regular basis even before the expected replacement date.

FG013207

Figure 78

Inspection, Maintenance and Adjustment  Adjustment  4-47

DX220A-2/DX220LCA-2

 

Replace Hydraulic Oil Return Filter NOTE:

Change hydraulic oil return filter after first 250 hours of operation or rebuild, and every 1,000 hours thereafter.

WARNING AVOID DEATH OR SERIOUS INJURY The hydraulic oil will be hot after normal machine operation. Allow the system to cool before attempting to service any of the hydraulic components. The hydraulic tank is pressurized. Lift the hydraulic breather cap slightly to allow the pressurized air to vent. After the pressure has been released, it is safe to remove either the fill cap or service covers or drain water from the tank.

2

FG013210

Figure 79

3

IMPORTANT Make sure to clean any dirt or water from the top of the hydraulic tank, especially around the fill port and filter ports. 1.

Park Park mac machi hine ne on on firm firm and and llev evel el grou ground nd.. Lowe Lowerr th the e fron frontt attachment to the ground and stop engine.

2.

Lift Lift the the br brea eath ther er ca cap p (1, (1, Figure 79) 79) slightly to release the internal pressure.

3.

Remove bo bolts (2 (2, Figure 79) 79) and service cover (3). Remove spring (4), valve (5) O-ring (6), and bypass strainer (7), and then filter (8).

4.

Remo Remove ve filt filter er and disc discar ard. d. NOTE:

Instal Installl new new filter filter and a new new OO-rin ring. g. Inst Install all bypass bypass str straine ainer, r, valve and spring. Install service cover plate.

6.

Tigh Tighte ten n tthe he br brea eath ther er ca cap p ((1, 1, Figure 79). 79).

7.

Run eng engine ine for ten ten m minu inutes tes at low low idle idle to purg purge e air air from from c circ ircuit uit..

8.

Ch Chec eck k llev evel el in hy hydr drau auli lic c oil oil tank tank (See page 4-18). 4-18). Add oil if necessary.

4

6

7 5

8

Used filter should always be disposed of according to local regulations.

5.

3

1

FG000761

Figure 80

Inspection, Maintenance and Adjustment  4-48

DX220A-2/DX220LCA-2

 

Change Pilot Filter NOTE:

Change pilot filter after first 250 hours of operation or rebuild, and every 1,000 hours thereafter.

WARNING AVOID DEATH OR SERIOUS INJURY The hydraulic oil will be hot after normal machine operation. Allow the system to cool down before changing pilot filter. 1.

Park Park mac machi hine ne on on firm firm and and llev evel el grou ground nd.. Lowe Lowerr th the e fron frontt attachment to the ground and stop engine.

2.

Lift Lift the the breat breathe herr cap s sli ligh ghtl tly y to rele releas ase e the int inter erna nall pressure.

3.

Loca Locate te pi pilo lott s sys yste tem m fil filte terr ass assem embl bly. y. See See Figure 81. 81.

4.

Unscrew rew canister (2 (2, Figure 82 82)) and remove O-ring (3) and filter cartridge (4). NOTE:

5.

DS1703794

Figure 81

1

The canister will be filled with oil. Use caution when removing this assembly.

3

Insert Insert a n new ew filter filter cart cartrid ridge ge and O-ring O-ring.. Appl Apply y a small small amount of oil around the entire O-ring and install the canister assembly onto the filter head (1, Figure 82). 82). NOTE:

4

Used filter should always be disposed of according to local regulations.

2 DS1703795

6.

Aft After er changi changing ng pil pilot ot filter, filter, ven ventt a air ir ffrom rom pum pump p and and check check level of hydraulic oil tank.

Figure 82

Inspection, Maintenance and Adjustment  Adjustment  4-49

DX220A-2/DX220LCA-2

 

Change Oil in Travel Reduction Device (One on Each Side of Unit) 3

WARNING

1

AVOID DEATH OR SERIOUS INJURY

2

The gear oil is very hot after the machine has been operating. Shut all systems down and allow them to cool. Before removing the motor case, loosen the plug slightly to allow pressurized air to escape. Residual pressure in the travel reduction device can cause the plug to be dislodged and oil to squirt out suddenly. Reference Number

Description

1

Oil Level Plug

2

Drain Plug

3

Fill Plug

NOTE:

Drain oil after first 500 hours of operation or rebuild, and every 1,000 hours thereafter.

1.

Make Make sur sure e that that the the mac machi hine ne is is on ffir irm m and and leve levell gr grou ound nd..

2.

Ro Rota tate te the the ttra rack ck un unti till por ports ts (1 thr thru u 3, Figure 83) 83) are in their proper positions as shown.

3.

Plac Place e a con conta tain iner er und under er dra drain in plu plug g (2, (2, Figure 83) 83) and remove plugs (1 thru 3) to drain the travel reduction gear oil. NOTE:

4.

Dispose of drained fluids in compliance with all applicable environmental laws and regulations.

Install d drrain ain pl plug (2 (2, Figure 83). 83). Refill the travel reduction gear case with fluid through fill port (3) until fluid level is at port (1). Install level plug (1) and fill plug (3). NOTE: See "Fluid Capacities" on page 4-11  4-11  for capacity.

5.

Repeat Repeat thi this s proce procedur dure e on the other other trave travell reduc reductio tion n devic device. e.

FG028838

Figure 83

Inspection, Maintenance and Adjustment  4-50

DX220A-2/DX220LCA-2

 

Change Swing Reduction Device Oil NOTE:

2

Change swing reduction device oil after first 500 hours of operation or rebuild and every 1,000 hours thereafter. 1

WARNING AVOID DEATH OR SERIOUS INJURY The gear oil is very hot after the machine has been operating. Shut all systems down and allow them to cool. 1.

Set Set a co cont ntai aine nerr und under er ex exca cava vato tor. r.

2.

Relea Release se the the dra drain in plu plug g and and drai drain n the the swin swing g redu reduct ctio ion n device oil into a container. NOTE:

3.

FG001384

Figure 84

Dispose of drained fluids in compliance with all applicable environmental laws and regulations.

Afte Afterr d dra rain inin ing g oil oil,, tig tight hten en the drai drain n plu plug. g.

FG013201

Figure 85 4.

Re Remo move ve brea breath ther er/f /fil illl ca cap p (2 (2,, Figure 84 84)) and add oil to "H" mark on dipstick (1).   H   L

FG000419

Figure 86

Inspection, Maintenance and Adjustment  Adjustment  4-51

DX220A-2/DX220LCA-2

 

Change Air-Conditioning Outer Filter The unit is equipped with an air filtration system which filters out dirt and dust particles from air being circulated into operator's cabin. This filter must be cleaned out. NOTE:

In the event that the unit is being operated in a dusty environment, the cleaning and replacement must be performed more frequently. If filter is damaged, replace damaged filter with a new one.

 WARNING AVOID DEATH OR SERIOUS INJURY

1  TOP

All service and inspection of air-conditioning system must be performed with the starter switch in the "O" (OFF) position. NOTE: 1.

2.

 Donaldson.

All right and left call outs are based on the operator being seated in the operator's seat facing the front.

Open Open tthe he door in the left front front o off the the machin machine, e, then then remov remove e four wing bolts and washers, and access cover (1, Figure  Figure 

FG000440

Figure 87

87). 87). Open Open th the e c cov over er by un unsc scre rewi wing ng th the e k kno nob b (1, (1, Figure 88) 88) in the rear of the cabin.

1

FG000441

Figure 88 3.

Remove filter ((Figure Figure 89) 89) and replace with new one.

4.

Reas Reasse semb mble le in reve revers rse e ord order er..

FG000342

Figure 89

Inspection, Maintenance and Adjustment  4-52

DX220A-2/DX220LCA-2

 

Change Air-Conditioning Inner Filter

 WARNING AVOID DEATH OR SERIOUS INJURY All service and inspection of air-conditioning system must be performed with the starter switch in the "O" (OFF) position. 1.

Remo Remove ve the the fil filte terr by pul pulli ling ng o out ut war ward d th the e kn knob ob whi while le pressing the upper part and lower part of the filter handle which is inside of the left rear part of the cabin.

2.

Replace with new new one.

3.

Re Reas asse semb mble le filt filter er in rrev ever erse se orde order. r.

Check and Adjust Engine ** Contact your nearest DOOSAN dealer. Engine dealer for checking and adjusting the following items: • Engine gine Compres ression Pr Press essure. re. •

Injection Pr Pressure.

•

Injection Timing.

FG000422

Figure 90

Inspection, Maintenance and Adjustment  Adjustment  4-53

DX220A-2/DX220LCA-2

 

Change Fuel Cap Filter

WARNING AVOID DEATH OR SERIOUS INJURY External shock or damages to fuel cap may lead to permanent damage to filter.

FG015720

Figure 91 1.

See See u und nder er the the fue fuell c cap ap as show shown n o on n (Figure (Figure 92 92). ). Rotate bolt to CCW direction to loosen.

FG015684

Figure 92 2.

Afte Afterr dis disen enga gagi ging ng it as show shown no on n (Figure (Figure 93 93), ), carefully lay it on floor.

FG015685

Figure 93 3.

After di disengaging (Figure (Figure 93), 93), disengage rubber as shown on (Figure (Figure 94). 94).

FG015686

Figure 94 Inspection, Maintenance and Adjustment  4-54

DX220A-2/DX220LCA-2

 

4.

Afte Afterr dise diseng ngag agin ing g as sh show own n o on n (Figure 94), 94), you may now exchange it to a new filter as shown on (Figure (Figure 95). 95).

FG015687

Figure 95 5.

Afte Afterr excha exchang ngin ing g to a n new ew fil filte ter, r, you you may may now now a ass ssem embl ble e back in reverse order.

FG015688

Figure 96

Inspection, Maintenance and Adjustment  Adjustment  4-55

DX220A-2/DX220LCA-2

 

2,000 HOUR / YEARLY SERVICE Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks Replace Outer and Inner Air Cleaner Elements 3

 WARNING AVOID DEATH OR SERIOUS INJURY Never clean or attempt to remove the air cleaner element if the engine is running. NOTE:

Replace outer element after cleaning 5 times or every 2,000 hours of service.

NOTE:

Replace inner element whenever a new outer element is installed.

If there is clogged filter signal on the gauge panel, use the following procedure. 1.

Open Open th the e acc acces ess s door door at the the rear rear of th the e cabi cabin. n.

2.

Re Remo move ve the the ev evac acua uato torr va valv lve e (1 (1,, Figure 98) 98) and air cleaner cover (2). NOTE:

Inspect evacuator valve seal lips for wear or damage. Replace valve if necessary. Install evacuator valve with lips parallel to the cover.

3.

Remov move ou outer fifilter (4 (4, Figure 98 98)) from the air cleaner housing.

4.

Clean Clean the air cleane cleanerr cover cover and the inside inside of tthe he air air cleaner cleaner housing.

5.

Remo Remov ve in inne nerr filt filter er (5, (5, Figure 99 99). ).

6.

Clean Clean ou outt insi inside de of of air air cl clea eane nerr hous housin ing. g. D Do o not not use use compressed air to blow out housing.

7.

Inst In stal alll new new inne innerr filt filter er.. Do not not cl clea ean n and and reuse reuse iinn nner er element.

8.

In Inst stal alll ne new w oute outerr fifilter lter..

9.

Inst In stal alll air air cl clean eaner er cov cover er and and e eva vacu cuat ator or v val alve ve.. NOTE:

Make sure that all gaskets and cover are

FG000414

Figure 97

2

4 1 DS1703729

Figure 98

5 4

properly installed and seated. DS1703730

Figure 99

Inspection, Maintenance and Adjustment  4-56

DX220A-2/DX220LCA-2

 

Change Radiator Coolant NOTE:

Do not mix ethylene glycol and propylene glycol antifreeze together. See "Engine Cooling System" on   page 4-78 , for further details.

 WARNING AVOID DEATH OR SERIOUS INJURY ARO1760L

Allow the engine to cool before releasing the radiator cap. Make sure to loosen the cap slowly to release any remaining pressure.

Figure 100

Radiator cleaning is performed while the engine is running. Take extreme caution when working on or near a running engine. Make sure to lock out and tag the controls notifying personnel that service work is being performed. Do not remove radiator cap unless it is required. Check the coolant level in the coolant recovery tank.

IMPORTANT Do not mix up the antifreeze from different makers. Mixing the two compounds can cause generation of foreign material which can damage the system. Therefore, it Is recommended to use authorized DOOSAN genuine antifreeze solution. To achieve the best cooling performance, keep the mixing ratio of the antifreeze and water by 50 5 0 : 50. Using water only can corrode the coolant circuit. In bitterly cold working conditions, the customer should frequently check the performance of the coolant for appropriateness for the weather and then t hen determine change cycle of the coolant. 1.

Slow Slowly ly o ope pen n the the radi radiato atorr cap cap to all allow ow a any ny pre press ssur ure e to escape.

2.

Plac Place e a conta contain iner er unde underr the rad radia iato torr and ope open n the drai drain n valve (2, Figure 101). 101). NOTE:

Dispose of drained fluids in compliance with all applicable environmental laws and regulations. 2

FG001407

Figure 101

Inspection, Maintenance and Adjustment  Adjustment  4-57

DX220A-2/DX220LCA-2

 

3.

Re Remo move ve co cool olan antt drai drain n plug plug (1 (1,, Figure 102) 102) from engine.

4.

Instal Installl drain drain plu plug, g, and and clos close e dr drain ain val valve ve a after fter coolan coolantt has has completely drained from system.

5.

Fill Fi ll coo cooli ling ng sys syste tem m wi with th a flus flushi hing ng sol soluti ution on..

6.

Run engine engine at low idl idle e unti untill the the cool coolant ant tempera temperature ture gau gauge ge reaches the "WHITE ZONE".Run engine for another ten minutes.

7.

Allow engi ngine to cool.

8.

Drai Drain n flus flushi hing ng flu fluid id and and ffil illl syst system em wit with h wate water. r.

9.

Run engine engine again again to all allow ow water water to comp complet letely ely cir circul culate. ate.

1

FG001409

Figure 102

10. Aft After er allowi allowing ng engine engine to cool, cool, drain drain water water and and fill system system with proper antifreeze mixture for ambient temperature. Refer to coolant concentration table. See "Antifreeze  "Antifreeze  Concentration Tables" on page 4-80 11.

Run engine without without radiator radiator cap install installed, ed, s so o tha thatt all air will will be purged from system. Fill radiator to fill neck.

12. Drain Drain and fill fill rradi adiato atorr coolan coolantt recove recovery ry tank. tank.

Hydraulic Oil Exchange and Suction Strainer Cleaning

 WARNING AVOID DEATH OR SERIOUS INJURY The hydraulic oil will be hot after normal machine operation. Allow the system to cool before attempting to service any of the hydraulic components. The hydraulic tank is pressurized. Lift the breather cap to allow the pressurized air to vent. After the pressure has been released, it is safe to remove either the fill cap or service covers.

IMPORTANT Make sure to clean any dirt or water from the top of the hydraulic tank, especially around the fill port and filter ports. Hydraulic oil change interval is 2,000 hours. NOTE:

Based on the type of excavating being completed, the working conditions (extremely hot or dusty) and

ARO1760L

Figure 103

the extra front end attachments being used (hydraulic breaker, etc.), the hydraulic fluid will need to be changed more frequently.

Inspection, Maintenance and Adjustment  4-58

DX220A-2/DX220LCA-2

 

1.

Park Park mac machi hine ne o on n firm firm and and llev evel el gro groun und. d. Swi Swing ng upp upper er structure parallel to tracks. Lower boom and position bucket on ground as shown in Figure 104. 104.

2.

Mo Move ve saf safet ety y le leve verr to "LOC "LOCK" K" po posi siti tion on..

3.

Stop engine.

4.

Releas Release e press pressuri urized zed air from hydrau hydraulic lic tan tank k by by llift ifting ing breather cap (1, Figure 107). 107).

EX1300542

Figure 104 5.

Drain Drain hydrau hydraulic lic oil from from ttank ank int into o a con contai tainer ner cap capabl able e of holding 280 liters (74 U.S. gal.). After draining tank, install drain plug.

IMPORTANT Be careful of squirting oil when removing drain plug. NOTE:

Used filter and used oil should always be disposed of according to local regulations.

6.

Ca Care refu full lly y remo remove ve bol bolts ts and and cov cover er (2, (2, Figure 107) 107) from top of hydraulic oil tank. There is a spring (3) under the cover that will force the cover up.

7.

Remove spring (3, Figure 107 107)) and strainer (5), by pulling on rod (4).

8.

Clean Clean insi inside de a and nd outs outside ide of s stra traine iner. r. Repl Replace ace str strain ainer er ifif it is broken.

9.

Posi osition st strainer (5 (5, Figure 107) 107) on boss portion of suction pipe (6). NOTE:

FG013200

Figure 105

A

Measurement "A" is 650 mm (25.59 in).

HAOC411L

Figure 106

DX220A-2/DX220LCA-2

Inspection, Maintenance and Adjustment  Adjustment  4-59

 

10.

Fill the hydrauli hydraulic c oil tank. Check level using sight gauge on side of tank.

1 2

11. 11.

Pla lace ce spr sprin ing g (3, (3, Figure 107) 107) on rod (4) and assemble cover (2).

12. Aft After er replac replacing ing an and d cleanin cleaning g the hydrau hydraulic lic oi oil, l, filter filter an and d strainer, vent the system. See "Venting and Priming Priming   Hydraulic System" on page 4-84

3

IMPORTANT

4

When the hydraulic breaker is being used, because of the higher heat generated by this unit, use replacement intervals recommended under the "Hydraulic Oil and Filter Service Intervals" on page 341. 41.

5

6

13. Check Check leve levell of hyd hydraul raulic ic oil tank tank.. (See page 4-18)

ARO1720L

Figure 107

Check Alternator and Starter** **These checks need to be completed by an authorized DOOSAN dealer.

Check All Rubber Antivibration Shock Mounts Perform and Record the Results of the Cycle Time Tests Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage

Check, Adjust Valve Clearance Check Head Bolt Torques Inspection, Maintenance and Adjustment  4-60

DX220A-2/DX220LCA-2

 

4,000 HOUR / BIENNIAL SERVICE Major Parts - Periodic Replacement To

ensure

safe

operation

and

work,

perform

periodic

inspections. Also, to increase safety, replace the following parts. These parts are the ones most often subjected to abrasion, heat and fatigue. Exchange these parts with new ones at the designated time intervals, even if the old parts look good. Always replace all related parts such as gaskets and O-rings. Use only original equipment manufacturers parts. Major Component Engine

Parts Name to be Exchanged Periodically

Time to Exchange

Fuel hose (Tank to water separator) Fuel hose (Water separator to fuel injection pump) Fuel hose (Tank to fuel injection pump) Heater hose (Heater to engine) Heater hose (Heater to engine) Heater hose (Heater to radiator) Air Conditioner hose

Hydraulic System

Body

Pump suction hose Pump discharge hoses Pump side branch hoses Swing motor hoses Travel motor hoses

Work Device

Boom cylinder line hoses Arm cylinder line hoses Bucket cylinder line hoses

2 years or 4,000 hours

Inspection, Maintenance and Adjustment  Adjustment  4-61

DX220A-2/DX220LCA-2

 

12,000 HOUR / 6 YEAR SERVICE Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN) European regulations state that the in-service life of any hydraulic hose may not recommends the following;

exceed

six

years.

DOOSAN

•

Hose Hoses s a att tthe he cust custom omer er prem premis ises es cann cannot ot be stor stored ed more more than 2 years before being discarded or installed on a machine.

•

In-serv In-se rvic ice e li lifet fetim ime e of of hose hoses s fit fitted ted on a mac machi hine ne can can ne neve verr exceed 6 years, but replace hoses described in "Major  "Major  Parts - Periodic Replacement" on page 4-61, 4-61 , every 2 years. Always replace hoses having exceeded the allowed in-service lifetime irrespective of the external appearance/  wear.

•

Alwa Always ys stor store e hos hoses es in in a dar dark k pl plac ace e at a ma maxi ximu mum m of of 65 65% % relative humidity, between 0°C (32°F) and 35°C (95°F) but as close as possible to 15°C (59°F) and away from copper, manganese or tube generating Ozone.

Inspection, Maintenance and Adjustment  4-62

 

AIR-CONDITIONING AIR-CONDITIO NING SYSTEM NOTE:

See "Clean Air-Conditioning Outer Filter" on page 4-  39 

Check Control Panel When a function switch is pushed, the last setting has to be displayed on the LCD display. When the light switch is turned to "I" position, the LED for illumination in the control panel has to turn "ON".

Check Air Conditioner Hoses Check the hose for cracking and damage.

 CAUTION AVOID INJURY When a leak occurs, dirt will accumulate in the area where the leak is. Consult a DOOSAN distributor or sales agency.

Check Condenser Inspect the condenser for dust and debris. Clean if necessary. NOTE:

See "Clean Radiator, Oil Cooler, Intercooler, Fuel   Cooler and Air Conditioner Condenser Core" on page   4-41

Check Magnetic Clutch Check the magnetic clutch for dirt and interference. Push the "A/C" switch in order to energize magnetic clutch and check the magnetic clutch.

Check Belt Tension NOTE:

See "Check Engine Fan Belt Tension" on page 4-36 

DX220A-2/DX220LCA-2

Inspection, Maintenance and Adjustment  Adjustment  4-63

DX220A-2/DX220LCA-2

 

BOLT AND NUT INSPECTION Inspect ALL fasteners after the first 50 hours of operation and every 250 hours thereafter. If any are loose or are missing tighten them or install new hardware. Always use a calibrated torque wrench.

IMPORTANT Always clean fasteners before tightening. If counterweight is loose, contact a DOOSAN distributor or sales agent.

No.

Point to be Inspected

Bolt Dia. mm

Qty.

Bolt Head Size

Torque N.m

kg.m

ft lb

1

Joint bolt with engine mounting bracket and engine

pump side

16

8

19

108

11

80

fan side

10

8

17

64

6.5

47

pump side

20

2

30

539

55

398

2

Joint bolt and nut between engine mounting bracket and frame

fan side

20

2

30

539

55

398

3

Radiator mounting bolt

16

4

24

265

27

195

4

Tightening bolt for hydraulic oil tank

16

6

24

265

27

195

5

Tightening bolt for fuel tank

16

6

24

265

27

195

6

Tightening bolt for pump

20

4

17

539

55

398

10

12

17

64

6.5

47

7

Tightening bolt for control valve

16

4

24

265

27

195

8

Tightening bolt for swing reduction device

20

11

30

539

55

398

9

Tightening bolt for swing motor

12

12

10

141

14.4

105

10

Tightening bolt for battery

10

2

17

64

6.5

47

Joint bolt with cabin mounting rubber and frame

10

20

17

64

6.5

47

Joint nut with cabin mounting rubber and cabin

16

5

24

206

21

152

Joint bolt with swing bearing and upper frame

20

36

30

539

55

398

Joint bolt with swing bearing and bottom frame

20

36

30

539

55

398

Tightening bolt for travel device

16

60

24

294

30

217

Tightening bolt for sprocket

16

60

22

294

30

217

14

Tightening bolt for upper roller

20

4

30

539

55

398

15

Tightening bolt for bottom roller

16

72

24

265

27

195

16

Tightening bolt for track guard

16

16

24

265

27

195

17

Bolt for track shoes

20

392

27

765

78

564

11

12

13

18

Fixing bolt for front pin

19

Breaker Filter (Optional)

16

10

24

265

27

195

-

1

32

30

3

22

Inspection, Maintenance and Adjustment  4-64

DX220A-2/DX220LCA-2

 

1.

Join Jointt bolt bolt wit with h engi engine ne mou mounti nting ng bra brack cket et a and nd eng engin ine e 1) Pump side •

Tool: 19 mm (

)

•

Torque: que: 108 N N..m (1 (11 k kg g.m, 8 80 0 ft ft lb lb)

FG001416

Figure 108 2) Fan side •

Tool: 17 mm (

)

•

Torque: que: 64 N. N.m (6 (6.5 kg kg.m, 4 47 7 ft ft lb lb)

FG001417

Figure 109 2.

Join Jointt bolt bolt and n nut ut betw betwee een n engin engine e mount mountin ing g brack bracket et an and d frame 1) Pump side •

Tool: 30 mm (

)

•

Torq Torqu ue: 53 539 9 N. N.m m (55 (55 kg kg.m .m,, 39 398 8 ft lb lb))

FG001418

Figure 110 2) Fan side •

Tool: 30 mm (

)

•

Torq Torqu ue: 53 539 9 N. N.m m (55 (55 kg kg.m .m,, 39 398 8 ft lb lb))

FG001419

Figure 111

Inspection, Maintenance and Adjustment  Adjustment  4-65

DX220A-2/DX220LCA-2

 

3.

Radiator mo mounting bo bolt •

Tool: 24 mm (

)

•

Torq Torqu ue: 26 265 5 N. N.m m (27 (27 kg kg.m .m,, 19 195 5 ft lb lb))

FG001420

Figure 112 4.

Tigh Tighte teni ning ng bol boltt for for hydr hydrau auli lic c oil oil tank tank •

Tool: 24 mm (

)

•

Torq Torqu ue: 26 265 5 N. N.m m (27 (27 kg kg.m .m,, 19 195 5 ft lb lb))

FG006450

Figure 113 5.

Tigh Tighte teni ning ng bo bolt lt fo forr fue fuell tan tank k •

Tool: 24 mm (

)

•

Torq Torqu ue: 26 265 5 N. N.m m (27 (27 kg kg.m .m,, 19 195 5 ft lb lb))

Figure 114 6.

Tighte teni nin ng bo bolt fo for pu pump 1) Main Pump •

Tool: 17 mm (

)

•

Torq Torqu ue: 53 539 9 N. N.m m (55 (55 kg kg.m .m,, 39 398 8 ft lb lb))

FG001422

FG001423

Figure 115

Inspection, Maintenance and Adjustment  4-66

DX220A-2/DX220LCA-2

 

2) Pump Cover •

Tool: 17 mm (

)

•

Torque: que: 64 N. N.m (6 (6.5 kg kg.m, 4 47 7 ft ft lb lb)

DS1703731

Figure 116 7.

Tigh Tighte teni ning ng bo bolt lt for for con contr trol ol va valv lve e •

Tool: 24 mm (

)

•

Torq Torqu ue: 26 265 5 N. N.m m (27 (27 kg kg.m .m,, 19 195 5 ft lb lb))

FG001425

Figure 117 8.

Tigh Ti ghte teni ning ng bolt bolt for for swin swing g red reduc ucti tion on devi device ce •

Tool: 30 mm (

)

•

Torq Torqu ue: 53 539 9 N. N.m m (55 (55 kg kg.m .m,, 39 398 8 ft lb lb))

FG001426

Figure 118 9.

Tigh Tighte teni ning ng bo bolt lt for for swin swing g mo moto torr •

Tool: 10 mm (

)

•

Torq Torqu ue: 14 141 1 N.m N.m (14 (14.4 kg kg.m .m,, 105 105 ft lb)

FG001427

Figure 119

Inspection, Maintenance and Adjustment  Adjustment  4-67

DX220A-2/DX220LCA-2

 

10. Ti Tigh ghte teni ning ng bolt bolt for for batte battery ry •

Tool: 17 mm (

)

•

Torque: que: 64 N. N.m (6 (6.5 kg kg.m, 4 47 7 ft ft lb lb)

FG000453

Figure 120 11. Joint Joint bolt bolt with with ca cabin bin m moun ounting ting rub rubber ber a and nd frame frame •

Tool: 17 mm (

)

•

Torque: que: 64 N. N.m (6 (6.5 kg kg.m, 4 47 7 ft ft lb lb)

FG000454

Figure 121 Joint nut with cabin mounting rubber and cabin •

Tool: 24 mm (

)

•

Torq Torqu ue: 20 206 6 N. N.m m (21 (21 kg kg.m .m,, 15 152 2 ft lb lb))

FG000455

Figure 122 12. Joint Joint bo bolt lt with with sw swing ing b bear earing ing a and nd up upper per fram frame e •

Tool: 30 mm (

)

•

Torq Torqu ue: 53 539 9 N. N.m m (55 (55 kg kg.m .m,, 39 398 8 ft lb lb))

FG001429

Figure 123

Inspection, Maintenance and Adjustment  4-68

DX220A-2/DX220LCA-2

 

Joint bolt with swing bearing and bottom frame •

Tool: 30 mm (

)

•

Torq Torqu ue: 53 539 9 N. N.m m (55 (55 kg kg.m .m,, 39 398 8 ft lb lb))

FG001430

Figure 124 13. 13.

Tigh Ti ghte teni ning ng bolt bolt for for tra trave vell dev devic ice e •

Tool: 24 mm (

)

•

Torq Torqu ue: 29 294 4 N. N.m m (30 (30 kg kg.m .m,, 21 217 7 ft lb lb))

FG001431

Figure 125 Tightening bolt for sprocket •

Tool: 22 mm (

)

•

Torq Torqu ue: 29 294 4 N. N.m m (30 (30 kg kg.m .m,, 21 217 7 ft lb lb))

FG001432

Figure 126 14. Ti Tigh ghte teni ning ng bolt bolt for for up uppe perr rolle rollerr •

Tool: 30 mm (

)

•

Torq Torqu ue: 53 539 9 N. N.m m (55 (55 kg kg.m .m,, 39 398 8 ft lb lb))

FG000460

Figure 127

Inspection, Maintenance and Adjustment  Adjustment  4-69

DX220A-2/DX220LCA-2

 

15. 15.

Tigh Ti ghte teni ning ng bolt bolt for for bot botto tom m rolle rollerr •

Tool: 24 mm (

)

•

Torq Torqu ue: 26 265 5 N. N.m m (27 (27 kg kg.m .m,, 19 195 5 ft lb lb))

FG000461

Figure 128 16. 16.

Tigh Ti ghte teni ning ng bolt bolt fo forr trac track k gu guar ard d •

Tool: 24 mm (

)

•

Torq Torqu ue: 26 265 5 N. N.m m (27 (27 kg kg.m .m,, 19 195 5 ft lb lb))

FG000462

Figure 129 17 17..

Bolt Bolt fo forr tra track ck sh shoe oes s •

Tool: 27 mm (

)

•

Torq Torqu ue: 76 765 5 N. N.m m (78 (78 kg kg.m .m,, 56 564 4 ft lb lb))

FG000463

Figure 130

Inspection, Maintenance and Adjustment  4-70

DX220A-2/DX220LCA-2

 

18. Fi Fixi xing ng bolt bolt fo forr fro front nt pi pin n •

Tool: 24 mm (

)

•

Torq Torqu ue: 26 265 5 N. N.m m (27 (27 kg kg.m .m,, 19 195 5 ft lb lb))

FG000464

Figure 131 19. 19.

Brea Breaker ker filt filter er (Opti (Option onal al)) •

Tool: 32 mm (

)

•

Torque: 30 3 0 N.m (3 ( 3 kg.m, 22 ft lb) and turn 1/4 counterclockwise

DS1702323

Figure 132

Inspection, Maintenance and Adjustment  Adjustment  4-71

DX220A-2/DX220LCA-2

 

BUCKET Bucket Tooth Replacement

 WARNING AVOID DEATH OR SERIOUS INJURY Due to the possibility of flying metal objects, always wear safety helmet, protective gloves and eye protection when changing bucket teeth. Curl the bucket upwards and place the round rear surface of the bucket firmly on the ground. Shut the engine off and lock out the hydraulic controls before working on the bucket. NOTE:

These instructions are only for DOOSAN OEM buckets. If you are using other manufacturers buckets, refer to their specific instructions.

HAOC680L

Figure 133 1.

On a routi routine ne bas basis, is, ins inspec pectt b buck ucket et teeth teeth tto o make make sure sure that that tooth wear or breakage has not developed. Do not allow replaceable bucket teeth to wear down to a point that bucket adapter is exposed. See Figure 133 133..

2.

To re replace a tooth oth (1, Figure 134), 134), use a hammer and punch to drive locking pin (2) and lock washer (3) out of tooth adapter (4).

3.

Once Once wor worn n toot tooth h ha has s been been rrem emov oved ed,, use use a putt putty y knif knife e to scrape adapter as clean as possible.

4 3

4.

Slid Slide e new new tooth tooth int into o posi positi tion on and and ins inser ertt loc lock k wash washer er..

5.

Insert Insert loc lockin king g pi pin n in into to ttoot ooth h and and with with a hammer hammer,, drive drive pin in until lock washer seats in locking groove.

2

1

FG000346

Figure 134

Inspection, Maintenance and Adjustment  4-72

DX220A-2/DX220LCA-2

 

Bucket O-ring Replacement

 WARNING AVOID DEATH OR SERIOUS INJURY Because of possibility of flying metal objects, always wear safety helmet, protective gloves and eye protection when changing pins. 1.

Inspec Insp ectt bu buck cket et O-r O-rin ings gs o on n a routi routine ne bas basis is.. If wor worn n or damaged, replacement is necessary.

2.

Roll o olld OO-ring (1 (1, Figure 135 135)) onto boss (2) around bucket pin (3). Remove bucket pin and move arm or bucket link (4) out of way. 1

3 2

4

DS1703964

Figure 135 3.

Remove Remove old O-r O-ring ing and tempora temporaril rily y inst install all new O-ring O-ring (1, Figure 136) 136) onto bucket boss (2). Make sure that O-ring groove on both bucket link (4) and boss have been cleaned.

4.

Realig Realign n ar arm m or or link link with with bucket bucket pin hole hole and and ins insert ert bucket bucket pin (3, Figure 135). 135).

3

1

2

4

DS1703965

Figure 136 5.

Roll n ne ew OO-ring ((1 1, Figure 137) 137) into O-ring groove.

1

DS1703966

Figure 137 Inspection, Maintenance and Adjustment  Adjustment  4-73

DX220A-2/DX220LCA-2

 

ELECTRICAL SYSTEM NOTE:

Never disassemble electrical or electronic parts. Consult with a DOOSAN distributor or sales agency before servicing.

Battery

 WARNING AVOID DEATH OR SERIOUS INJURY Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water. Battery acid could cause blindness if splashed into the eyes. If acid gets into the eyes, eye s, flush them immediately with large quantities of water and see a doctor at once. If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or vegetable oil. Call a doctor or poison prevention center immediately. When working with batteries, always wear safety glasses or goggles. Battery generates hydrogen gas, so there is danger of an explosion. Do not bring lighted cigarettes near the battery, or do anything that will cause sparks. Before working with batteries, stop engine and turn the starter switch to "O" (OFF) position. Avoid short circuiting the battery terminals through accidental contact with metallic objects, such as tool. When removing or installing, check which is the positive (+) terminal and negative (-) terminal. When removing the battery, first disconnect the negative (-) terminal. When installing the battery, first connect the positive (+) terminal. If the terminals are loose, there is danger that the defective contact may generate sparks that will cause an explosion. When installing the terminals, install them tightly.

Batteries in Cold Weather In colder weather a greater drain is placed on the batteries when

they are used for the preheat cycle and when starting a cold engine. Battery performance decreases as the temperature gets lower. In extremely cold weather, remove batteries at night and move them to a warm location. This will help to keep them at a higher power level. Inspection, Maintenance and Adjustment  4-74

DX220A-2/DX220LCA-2

 

Inspection of Battery Electrolyte Level This machine has two maintenance free batteries. They never require the addition to water. When the charge indicator becomes transparency, it means low electrolyte state because of the leakage or charging system error. Determine the cause of problem and replace the batteries immediately. Check Charging State Check charging state through the charging indicator. •

GREEN: S Su ufficiently ch charged.

•

BLACK: In Insuffi fficient ent ch charged.

•

TRANSPARENT: Replace ba batte ttery.

DS1703732

Figure 138

Check the Battery Terminals Be certain that battery is held securely in its compartment. Clean the battery terminals and the battery cable connectors. A solution of baking soda and water will neutralize acid on the battery surface, terminals, and cable connectors. Petroleum jelly or grease can be applied to the connectors to help prevent corrosion. Battery Replacement When the charging indicator indicates transparency state, replace the battery. The batteries should always be replaced in pairs. Using an old battery with a new one will shorten the life span of the new battery.

DS1703733

Figure 139

Inspection, Maintenance and Adjustment  Adjustment  4-75

DX220A-2/DX220LCA-2

 

Fuses 1.

Th The e fuses fuses in in the the fus fuse e box box ar are e us used ed to to pr prote otect ct the the v var ario ious us electrical circuits and their components from being damaged. See Figure 140. 140. The fuses used are standard automotive type fuses.

2.

The se section on on "Fuse Identification" on page 4-77, 4-77, lists the circuits and the fuse amperage required for each circuit. If

O

X

a fuse blows, determine the cause and repair any faults or failures. 3.

Do not not ins inser ertt a hig highe herr amper amperag age e fuse fuse int into o a low lower er amperage slot. Serious damage to the electrical components or fire can result.

HAOC670L

Figure 140

CAUTION AVOID INJURY Before replacing a fuse, be sure to turn starter switch to "O" (OFF) position.

Fuse Boxes There are two fuse boxes (Figure ( Figure 141) 141) on the left side of the heater box. The fuses prevent electrical devices from overloading or shorting. A decal attached inside the fuse box's cover indicates the function and amperage of each fuse. Change a fuse if the element separates. If the element of a new fuse separates, check the circuit and repair the circuit. FG000110

CAUTION AVOID INJURY Always replace fuses with the same type and capacity fuse that was removed. Otherwise, electrical damage could result.

Figure 141

Inspection, Maintenance and Adjustment  4-76

DX220A-2/DX220LCA-2

 

Fuse Identification

Fuse Box (1)

Fuse Box (2)

FG000542

Figure 142 Fuse Box One

Fuse Box Two

No. 1

Name Gauge Panel

Capacity 10A

No. 1

Name Horn

Capacity 10A

2

Breaker

10A

2

Auxiliary Mode

10A

3

High Speed

10A

3

Throttle Controller

10A

4

Wiper, Washer

10A

4

Pilot Cutoff

10A

5

12V Power

10A

5

Aircon Panel

10A

6

Spare

10A

6

Fan

10A

7

Stereo, Engine Stop Motor

10A

7

Memory Backup

10A

8

Starter Switch, Hour Meter

15A

8

Room Lamp

10A

9

Aircon, Heater

30A

9

Cabin Lamp

10A

10

Joystick, Electric Pedal

10A

10

Working Lamp

15A

11

TMS

10A

11

Pilot Buzzer

10A

12

Preheat

10A

12

Illumination

10A

13

Spare

10A

13

Spare

15A

14

Engine Delay Timer

15A

14

Wiper Motor

15A

Inspection, Maintenance and Adjustment  Adjustment  4-77

DX220A-2/DX220LCA-2

 

ENGINE COOLING SYSTEM General Keeping an engine's cooling system in peak operating condition, can have many benefits to keeping a machine in good operating condition. A properly functioning cooling system will; improve fuel efficiency, reduce engine wear, and extend component life. Always use distilled water in the radiator. Contaminants in tap water neutralize the corrosion inhibitor components. If tap water must be used, Refer to "Table of Standards for Allowed Tap Tap   Water" on page 4-80. 4-80. Water that has been treated with a water softener also contains salt that will cause corrosion of components. Water from creeks and stagnant pools usually contain dirt, minerals and/or organic material that are deposited in the cooling system and impair cooling efficiency. As such, the use of distilled water is recommended. Engine coolant shall be mixed with antifreeze solution and water in ratio of 50 : 50. Coolant shall be checked every 500 hours of operation for ensuring adequate concentration of antifreeze solution and additives. Engine overheating is often caused by bent or clogged radiator fins. The spaces between the fins can be cleaned by use of air or water under pressure. When straightening bent fins, use care not to damage the tubes or break the bonding joint between the fins and the tubes.

 WARNING AVOID DEATH OR SERIOUS INJURY Pressure at air nozzle must not exceed 2 kg/cm 2 (28 psi). Always wear goggles when using compressed air. Do not pour cold water into radiator when engine is hot and water level is below the top of the tubes. Such action could result in damage to engine cylinder heads. Heavy-duty diesel engines require a balanced mixture of water and antifreeze. Drain and replace the mixture 1 year or 2,000 hours of operation, whichever comes first. T This his will eliminate buildup of harmful chemicals. Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant's freezing point and

by raising its boiling point. Do not use more than 50% antifreeze in the mixture unless additional antifreeze protection is required. Never use more than 60% antifreeze under any condition.

Inspection, Maintenance and Adjustment  4-78

 

Types of Antifreeze Ethylene Glycol - DOOSAN Genuine Antifreeze Solution (for all seasons) Ethylene glycol is a very hazardous material to human beings, animals and environment. Drain of coolant must be disposed of by an authorized waste material treatment service provider. The color does not provide a standard. Unauthorized coolant may have the same color. Please check the label on the container. Use genuine product.

IMPORTANT Do not mix solutions from different manufacturers. Otherwise, the performance may be deteriorated. It is recommended to use the standard product from DOOSAN. In extreme temperatures, the performance of the coolant must be checked frequently and the coolant change cycle adjusted as necessary. Engine parts that are made of aluminum are quickly worn out by nitrite, and therefore you should make sure to use nitrite-free coolant.

DX220A-2/DX220LCA-2

Inspection, Maintenance and Adjustment  Adjustment  4-79

DX220A-2/DX220LCA-2

 

Antifreeze Concentration Tables Ethylene Glycol - DOOSAN Genuine Antifreeze Solution (for all seasons) (2,000 Hour/1 Year) Ambient Temperature

Cooling Water

Antifreeze

-20°C (-4°F)

67%

33%

-25°C (-13°F)

60%

40%

-30°C (-22°F) -40°C (-40°F)

56% 50%

44% 50%

NOTE:

The concentration shall be kept at 50% and in worst case at 30% minimum for the least corrosion resistance.

NOTE:

Replacement cycle of the DOOSAN Genuine Product is 2,000 hours or one year.

Table of Standards for Allowed Tap Water Requirement Item

Inorganic chloride

Sulfates

Total Hardness

Total Solids

Acidity

Value

< 40 ppm

< 50 ppm

< 9.5° d.H

< 340 ppm

5.5 - 9.0

PPM (Parts Per Million) - Unit of concentration of minor materials. •

1 ppm = 1 mg/1 kg, 1 mL/1 L

° d.H - Unit of concentration of minor materials. •

1° d.H = 17 ppm

 CAUTION AVOID INJURY The standard of tap water is for referece only, and may not be regarded as a standard. If quality of the water is not trustable, stop using tap water whenever possible and use distilled water.

Inspection, Maintenance and Adjustment  4-80

DX220A-2/DX220LCA-2

 

HANDLING OF ACCUMULATOR  WARNING AVOID DEATH OR SERIOUS INJURY Even though the engine is stopped, the hydraulic accumulators for the pilot system are still charged. Do not disconnect any pilot system hoses until accumulator pressure has been released from the circuit. To release pressure, turn the starter switch to "I" (ON) position and operate all hydraulic control levers and forward/reverse travel levers. Even though the engine is shutdown hydraulic actuated components may move while releasing pilot pressure. Keep all personnel away from excavator while performing this operation. •

Move Move sa safe fety ty lever lever to "L "LOC OCK" K" po posi sitio tion n after after st stop oppi ping ng engine.

•

DO NOT NOT mis misha hand ndle le a acc ccum umul ulat ator or(s (s). ). The They y are are very very dangerous because they contain high-pressure

•

nitrogen gas. DO NOT NOT pu punch nch a hole hole or app apply ly heat heat or fi fire re to an accumulator.

•

DO NO NOT T wel weld d on on acc accum umul ulat ator or,, or or ttry ry at atta tach chin ing g anything to it.

•

When When repl replac acin ing g an accum accumul ulat ator or,, cont contac actt a DOOS DOOSAN AN distributor or sales agency so the gas can be properly released.

•

Wear Wear sa safe fety ty gog goggl gles es and and prot protec ecti tive ve glo glove ves s when when working on an accumulator. Hydraulic oil under pressure can penetrate the skin and cause serious injuries.

Release pilot procedure;

accumulator

pressure

using

the

following

1.

Park Park mac machi hine ne on on firm firm and and llev evel el grou ground nd.. Lowe Lowerr th the e fron frontt attachment to the ground and stop engine.

2.

Move Move safe safety ty leve leverr to to "RE "RELE LEAS ASED ED"" p pos osit itio ion. n.

3.

Turn Turn sta start rter er swit switch ch to "I "I"" ((ON ON)) pos posit itio ion. n.

4.

Fu Full lly y stro stroke ke wor work k and and tr trav avel el lev lever ers s in all all dir direc ecti tion ons. s.

5.

Mo Move ve saf safet ety y le leve verr to "LOC "LOCK" K" po posi siti tion on..

6.

Tu Turn rn key key to to "O" "O" (OFF (OFF)) posi positi tion on and and rem remov ove e from from s sta tarte rterr

DS1703974

Figure 143

switch. 7.

Remo Remove ve ac accu cumu mula lato torr b by y unsc unscre rewi wing ng it slow slowly ly..

Inspection, Maintenance and Adjustment  Adjustment  4-81

DX220A-2/DX220LCA-2

 

TRACK TENSION  WARNING AVOID DEATH OR SERIOUS INJURY Measurement of track tension requires two people. Always follow these instructions: •

One One per perso son n mus mustt be be in in the the op oper erat ator or's 's se seat at ru runn nnin ing g the the controls to keep one side frame in the air, while the other person makes dimensional checks.

•

Take Take all all nec neces essa sary ry prec precau auti tion ons s to make make s sur ure e the the machine does not move or shift position during service.

•

War Warm u up p tth he en engi gin ne tto o pre preve ven nt s sta tall lls. s.

•

Posi Positio tion n exc excav avat ator or in an area area that that pr prov ovid ides es le leve vel, l, uniform ground support and/or use support blocks when necessary.

Track shoe link pins and bushings wear with normal usage, reducing track tension. Periodic adjustment is necessary to compensate for wear and it may also be required by working conditions. 1.

Track Track ten tensi sion on is is chec checke ked d by jjac acki king ng u up p one one side side o off the the excavator. See Figure 144. 144. Place blocking under frame while taking measurement. Turn the track backward 1 - 2 turns.

90 - 1 110 10

EX1300534

Figure 144 2.

Meas Measur urin ing g the the di dist stan ance ce (A (A,, Figure 145) 145) between the bottom of the side frame and the top of the lowest crawler shoe. Recommended tension for operation over most types of terrain is 290 - 310 mm (11.40 - 12.20 in). NOTE:

This measurement can be inaccurate if there is too much mud or dirt or other material in the track assembly. Clean off the tracks before checking clearance.

A

3.

The inc incre reas ased ed clea cleara ranc nce e recom recommen mende ded d for mud muddy dy,, sandy sandy or snowy ground gr ound conditions is between 310 - 340 mm

FG000162

Figure 145

(12.20 - 13.40 in).

Inspection, Maintenance and Adjustment  4-82

DX220A-2/DX220LCA-2

 

 WARNING AVOID DEATH OR SERIOUS INJURY The track adjusting mechanism is under very high-pressure. NEVER release pressure too suddenly. The track tension grease valve should never be backed off more than one (1) complete turn from the fully tightened down position. Bleed off pressure slowly and keep your body away from the valve at all times. If there is problem in the valve thread, the valve might be ejected at high-speed and cause death or serious injury. 4.

5.

Track Track ten tensi sion on ad adju justm stmen ents ts are are ma made de throu through gh tthe he grea grease se fitting (1, Figure 146) 146) in the middle of each side frame. Adding grease increases the length of an adjustment cylinder (2, Figure 146). 146). The longer the adjustment cylinder, the greater the pressure on the tension spring pushing the track idler wheel outward.

2

3

If tther here e is is not not enoug enough h slac slack k or cle cleara arance nce in the tracks tracks and the adjustment is too tight, the idler wheel and adjusting cylinder can be retracted by bleeding off grease through hole in valve (3, Figure 146) 146) by slowly turning handle screw (4, Figure 146) 146) clockwise 1 ~ 2 times. When grease starts to leak out, stop turning it. NOTE:

After track tension is adjusted by turning handle screw clockwise, be sure to turn handle screw (4, Figure 146 ) counter clockwise 1 ~ 2 times. If not turning handle screw counter clockwise, grease must leak.

4

Figure 146

1

DS1703734

Inspection, Maintenance and Adjustment  Adjustment  4-83

DX220A-2/DX220LCA-2

 

VENTING AND PRIMING HYDRAULIC SYSTEM Main System Pump NOTE:

Running the engine with insufficient hydraulic oil in the pump may cause damage to the pump. Be sure to perform the venting procedure.

1.

Run the engine engine at llow ow iidle dle unt untilil the the h hydr ydraul aulic ic oil oil tank tank and all hydraulic actuators are filled with oil.

2.

Stop the engine.

3.

Remov move the vent plug (Figure 147) 147) and check if hydraulic oil comes out of its port. •

4.

Tool: 36 mm (

)

Tighten th the pl plug ((Figure Figure 147 147)) once hydraulic oil starts coming out of the port.

Hydraulic Cylinders

IMPORTANT If cylinders are operated in high idle after the hydraulic system has been drained or the cylinder has been rebuilt, damage to piston packing and seals can occur. Always vent air from cylinders at low idle and at a slow speed. 1.

Run engine engine a att low low idle idle.. Exten Extend d and and retrac retractt each each cyli cylinde nderr to within 100 mm (4 in) of fully stroking it 4 - 5 times.

2. 3.

Operat Operate e fully fully extend extend and retract retract eac each h cyli cylinder nder 3 - 4 time times. s. Repe Repeat at proc proced edur ure e until until c cyl ylin inde ders rs exte extend nd and and ret retra ract ct smoothly.

DS1703975

Figure 147

Inspection, Maintenance and Adjustment  4-84

 

Swing Motor 1.

Run the engine engine at llow ow idl idle e for for appro approxim ximatel ately y ffive ive minutes minutes..

2.

With With th the e engin engine e runni running, ng, sli slight ghtly ly move move the joysti joystick ck left left and right. Never swing the machine fully.

3.

Afte Afterr the sli sligh ghtt mov moves es of of the joy joyst stic ick, k, swi swing ng th the e uppe upperr structure to the left and right by 20° each.

4.

Check Check that that these these ope operat ration ions s are are n norm ormal al before before you operate operate the machine.

Travel Motor 1.

Run the engine engine at llow ow idl idle e for for appro approxim ximatel ately y ffive ive minutes minutes..

2.

With With th the e engin engine e ru runni nning, ng, sli slight ghtly ly move move the travel travel lever lever b back ack and forth. Never drive the travel motors fully.

3.

Afte Afterr the the sl slig ight ht m mov oves es of of the le leve ver, r, dri drive ve the the m mac achi hine ne forward and backward by 1 m (3.3 ft) or less each.

4.

Check Check that that these these ope operat ration ions s are are n norm ormal al before before you operate operate the machine.

General Venting 1.

Afte Afterr venti venting ng air air from from all com compo pone nents nts,, shut shut the the engin engine e down and check the hydraulic oil level. Fill hydraulic oil tank to "H" mark on sight gauge.

2.

Start Start engi engine ne and and oper operate ate all contro controls ls a agai gain, n, run run engin engine e fo forr five minutes to ensure all systems have been vent and purged of air. Move engine speed to "LOW IDLE", and check hydraulic oil level again. Add oil as necessary.

3.

Check Check for for oil oil lleak eaks s and and cl clean ean all fill fill and and ve venti nting ng loca locatio tions. ns.

DX220A-2/DX220LCA-2

DX220A-2/DX220LCA-2

Inspection, Maintenance and Adjustment  Adjustment  4-85

 

LONG TERM STORAGE When a machine is taken out of service and stored for a time exceeding 30 days, steps must be taken to protect the machine. Leaving equipment outdoors exposed to the elements will shorten its life. An enclosure will protect the machine from rapid temperature changes and lessen the amount of condensation that forms in hydraulic components, engine, fuel tank, etc. If it is not possible to put the machine in an enclosure, cover it with a tarpaulin. Check that the storage site is not subject to flooding or other natural disasters. After the machine has been positioned for storage and the engine stopped, perform the following operations:

Before Storage Keep the excavator in the position shown in Figure 92 to prevent rust of the hydraulic piston rods. •

In Insp spec ectt for for da dama mage ged, d, loos loose e or or mis missi sing ng pa part rts. s.

•

Repa Repain intt n nec eces essa sary ry area area to prev preven entt o oxi xida dati tion on..

•

Wash Wash an and d clea clean n al alll pa part rts so off ma mach chin ine. e.

•

Stor Store e the the mach machin ine e ind indoo oor, r, sta stabl ble e pla place ce.. If If st stor ored ed outs outsid ide, e, cover with a waterproof tarpaulin.

•

Perf Perfor orm m lu lubri brica cati tion on proc proced edur ures es on all all gre grease ase poin points ts..

•

Appl Apply y a coat coatin ing g of of ligh lightt oil oil to the ex expo pose sed d pla plate ted d m met etal al surfaces (such as hydraulic cylinder rods, etc.) and to all the control linkage and control cylinders. (Control valve spools, etc.)

•

Remo Remove ve the batt batter ery y fro from m tthe he exca excava vato torr tto o be be fful ully ly charg charged ed and stored.

•

Insp In spec ectt the the cool coolan antt rec recov over ery y tan tank k and and radi radiat ator or to make make sure the antifreeze level in the system is correct. Make sure that antifreeze concentration is enough for the lowest temperature anticipated during storage.

•

Seal Seal all all ext exter erna nall ope openi ning ngs s (i. (i.e. e. engi engine ne exha exhaus ustt out outle let, t, crankcase and hydraulic breather, fuel vent line, etc.) with tape wide enough to cover the opening, regardless of size. NOTE:

When sealing with tape, be sure to extend tape approximately one inch (25 mm) beyond opening to insure a good seal.

EX1300542

Figure 148

Inspection, Maintenance and Adjustment  4-86

 

During Storage •

Once Once a m mon onth th,, sta start rt the the eng engin ine e a and nd fo foll llow ow the the ""Hy Hydra draul ulic ic Oil Warm-up" procedures listed in this manual. NOTE:

Remove all seals from the machine (i.e. crankcase and hydraulic breathers, engine air intake, fuel tank vent lines, etc.).

Operate two hydraulic for traveling, and digging or three functions times for lubrication afterswing "Hydraulic Oil Warm-up".Coat all the moving parts and surfaces of the components with a new oil film after operating. At the same time, charge the battery. Rotate track to prevent track seizing". •

Ever Every y 90 90 d day ays, s, us use e a hy hydr drom omet eter er to me meas asur ure e the the protection of the coolant. Refer to the antifreeze/coolant protection chart to determine protection of the cooling system. Add coolant as required.

After Storage •

When Whenthe op oper erati ating ng th the e wor work k rods. e equ quip ipme ment, nt, remo remove ve all all g gre reas ase e from hydraulic cylinder

•

Add Add gre greas ase e and and oil oil a att a all ll lubr lubric icat atio ion n poi point nts. s.

•

Adj djus ustt fan fan an and d alt alter erna nato torr bel beltt ten tensi sion on..

•

Connect the charged batte terry.

•

Chec Check k con condi diti tion on of all all hos hoses es an and d con conne nect ctio ions ns..

•

Chec Check k th the e lev level els s of engi engine ne o oil il,, fu fuel el,, cool coolan antt and and h hyd ydra rauli ulic c circuit oil. If there is water in the oil, change all the oil.

•

Change all filters.

•

When When star starti ting ng th the e engi engine ne af after ter lo long ng-te -term rm stora storage ge,, fol follo low w the "Hydraulic Oil Warm-up" procedures listed in this manual.

DX220A-2/DX220LCA-2

Inspection, Maintenance and Adjustment  Adjustment  4-87

DX220A-2/DX220LCA-2

 

MAINTENANCE IN SPECIAL CONDITIONS NOTE:

See "Operation Under Unusual Conditions" on page   3-44   for for other recommendations. Conditions

Operating in mud, water or rain.

Maintenance Required Perform a walk around inspection to check for any loose fittings, obvious damage to the machine or any fluid leakage. After completing operations, clean mud, rocks or debris from the machine. Inspect for damage, cracked welds or loosened parts. Perform all daily lubrication and service. If the operations were in salt water or other corrosive materials, make sure to flush the affected equipment with fresh water.

Operating in an extremely dusty or hot environment.

Clean the air intake filters on a more frequent basis. Clean the radiator and oil cooler fins to remove embedded dirt and dust. Clean the fuel system intake strainer and fuel filter more frequently. Inspect and clean as required the starter and alternator.

Operating in rocky terrain.

Check the undercarriage and track assemblies for damage or excessive wear. Inspect for loose or damaged fittings or bolts. Relax track tension. On a more frequent basis, inspect the front end attachments for damage or excessive wear. Install a top guard and front guard as required for protection against falling rock.

Operating in extreme cold.

Use the proper fuel for the temperature conditions. Using a hydrometer, check the antifreeze to make sure that it is providing the proper cold weather freeze protection. Verify the condition of the batteries. In extremely cold weather remove the batteries at night and store them in a warmer area. Remove mud buildup as soon as possible to prevent it from freezing to the undercarriage and causing damage.

Inspection, Maintenance and Adjustment  4-88

DX220A-2/DX220LCA-2

 

5Transportation Check federal, state and local laws and regulations regarding weight, width, and lengthroads of a load before making preparations for transporting on public or highways. The hauling vehicle, trailer, and load must comply with all applicable laws and regulations. Check the intended route for road width, overhead clearances, weight restrictions, and traffic control regulations. Special approval or permits may be required. If the actual height exceed the limitation on the trailer, the operator must submit special permission to the government. Consult to the national or regional Road authorities. Or, to avoid height limit, one may disassemble front linkage or guardrail during transportation.

 WARNING AVOID DEATH OR SERIOUS INJURY Whenever removal or reassemble guardrail, always use external ladder to access. And NEVER climbing up machine without guardrail and external ladder.  Consult to the Doosan dealer.

IMPORTANT Do not reuse counterweight torque bolt. Once fastened and used under the harsh condition such as counterweight, the bolt may exceeded its yield point. Use new bolt to counterweight reassemble every time.

Transportation  Transportation  5-1

DX220A-2/DX220LCA-2

 

LOADING AND UNLOADING Warning for Counterweight and Front Attachment Removal

WARNING AVOID DEATH OR SERIOUS INJURY DO NOT remove machine counterweight, front attachment or any other part. This could cause tipping or roll-over resulting in death or serious injury. Never remove counterweight or front attachment unless the upper structure is in-line with the lower structure. Never rotate the upper structure once the counterweight or front attachment has been removed.

EX1401352

Figure 1

Counterweight O ACC

WARNING

I

AVOID DEATH OR SERIOUS INJURY Death or serious injury can occur from a counterweight falling during removal or installation. Do not allow personnel under or around the counterweight during removal or installation.

LOCK OFF

WARNING

or serious injury.

O    N    

DO NOT OPERATE when performing inspection or maintenance maintenance 190-00695A

Use certified cables and shackles of adequate load rating. Improper lifting can allow the load to shift and cause death

OFF O    N    

OFF

ON DS1703735

Figure 2

Transportation  5-2

DX220A-2/DX220LCA-2

 

Removal 1.

Par ark k on on ffir irm m and and lev eve el gro groun und. d.

2.

Lowe Lowerr fron frontt a att ttac achm hment ent (buc (bucke ket) t) to gr grou ound nd..

3.

Stop engine.

4.

Move Move safe safety ty leve leverr to to "UN "UNLO LOCK CK"" p pos osit itio ion. n.

5.

Turn Turn sta start rter er swit switch ch to "I "I"" ((ON ON)) pos posit itio ion. n.

1

5

 WARNING AVOID DEATH OR SERIOUS INJURY If engine must be running while performing maintenance, use extreme care. Always have one person in the cabin at all times Never leave the cabin with the engine e ngine running. 6.

3

2

Fully Fully str stroke oke work work leve levers rs (joy (joysti sticks cks)) in all dir direct ection ions s to relieve any pressure from accumulators.

7.

Mo Move ve saf safet ety y le leve verr to "LOC "LOCK" K" po posi siti tion on..

8.

Turn Turn key key to "O" (OFF) (OFF) posi positio tion n an and d remov remove e from from s star tarter ter switch switch..

9.

Atta Attach ch main mainte tena nance nce warn warnin ing g ttag ag on contr control ols. s.

10. Turn Turn battery battery disc disconn onnect ect switc switch h to "OFF" "OFF" posi positio tion. n. 11.

Make sure all electr electrical ical lines and other other items items a are re disconn disconnected ected..

12.

Using Using a sui suitabl table e lifting lifting d devic evice e capable capable of hand handling ling a heav heavy y load, partially support counterweight from lifting holes (5, Figure 3), 3), counterweight (1) before loosening four bolts (2). Stop lifting with assist crane as soon as lifting slings are taut.

13 13..

Remo Remove ve four four bol bolts ts (2 (2,, Figure 3) 3) and washers (3) from counterweight (1, Figure 3). 3). •

Tool: 46 mm (

•

Weight

)

–

Standard dard:: 3 3,,800 kg kg ((8, 8,3 378 IIb b)

–

Optional : 4, 4,100 kg (9 (9,039 Ib Ib)

NOTE: 14. 14.

4

Heat bolts, if necessary, to free them.

When hen bo bollts (2, (2, Figure 3 3)) and washers (3) have been removed, lift counterweight (1) a very short distance above support frame (4) and stop. Check slings and make sure counterweight is being supported evenly.

EX1402071

Figure 3

Transportation  Transportation  5-3

DX220A-2/DX220LCA-2

 

Installation 1.

1

Using Using s suita uitable ble liftin lifting g devic device e capab capable le of of handl handling ing the weight weight of the counterweight, support counterweight from lifting holes (5, Figure 4). 4). Raise counterweight (1) into position  just above support frame (4) leaving counterweight suspended. Verify that counterweight is level and even. NOTE:

5

Leave counterweight (1, Figure 4   ) suspended 3 mm mounting (0.125") above (4) until all four boltssupport (2) frame are started in counterweight mounting holes.

2.

Slide washers (3, Figure 4 4)) onto bolts (2). Apply Loctite #242 to mounting bolt threads.

3.

Install fo four b bo olts (2 (2, Figure 4) 4) with washers (3) into counterweight until washers contact support frame. Fully lower counterweight onto support frame and finish tightening bolts. •

Tool: 46 mm (

•

Torq Torque ue:: 1 1,4 ,471 71 N.m (150 (150 kg kg.m .m,, 1,0 1,085 85 ft lb lb))

4

3

)

4.

Remove Remove liftin lifting g de devic vice e from from cou counte nterwe rweigh ightt lilifti fting ng h holes oles.. ((5, 5,

5.

Figure 4) 4) Make Make sure sure all all ele elect ctric rical al lines lines a and nd other other iitem tems s are conn connect ected ed..

6.

Tu Turn rn bat batte tery ry dis disco conn nnec ectt swit switch ch to to "O "ON" N" posi positi tion on..

 WARNING AVOID DEATH OR SERIOUS INJURY When transporting the machine, know the width, height, length, and weight. When loading or unloading the machine, make sure to run the engine at the lowest speed setting and travel at the slowest speed possible. Make sure that ramp being used can handle the weight of the machine. If required, add blocking under the ramp for additional support. Make sure that ramp surface is free of grease, debris, or mud that could cause the machine to slip or slide. Make sure that trailer is parked on firm and level ground before attempting to load/unload the excavator. If it is necessary to turn the machine while it is on the trailer, make sure to do this at the slowest engine and travel

2

EX1402071

Figure 4

speeds possible. Make sure to secure the excavator onto the trailer as required by local transportation laws and regulations.

Transportation  5-4

DX220A-2/DX220LCA-2

 

1.

Make Make s sure ure that that trail trailer er is is park parked ed on firm firm and level level ground. ground. See Figure 5. 5.

2.

Make Make sure sure th that at ram ramps ps that that are are bein being g us used ed are are des desig igned ned to handle the weight of the excavator. If required, add blocking under the ramp to provide additional support.

3.

90 - 110

The ramp ramp ang angle le mus mustt be lles ess s than than a 15° 15° an angl gle. e. R Ram amps ps steeper than this can cause traction or stability problems when loading or unloading. 15 EX1300746

Figure 5 4.

Set the travel travel spe speed ed sel select ector or swit switch ch to to "O" "O" (OFF) (OFF) pos positi ition. on. See Figure 6. 6.

O I

DS1703979

Figure 6 5.

Tu Turn rn "OFF" "OFF" auto auto idle idle sele select ctor or butt button on (1, (1, Figure 7). 7). The indicator symbol will disappear.

6.

Mo Move ve en engi gine ne sp spee eed d to to "LO "LOW W IDL IDLE" E"..

DS1703699

Figure 7 7.

If the machin machine e iis s equi equippe pped d with with work equipm equipment, ent, positi position on the work equipment toward the front of the excavator, and travel forward to load it. 90 - 110

15 EX1300746

Figure 8

Transportation  Transportation  5-5

DX220A-2/DX220LCA-2

 

8.

Th The e unit unit doe does s no nott requ requir ire e di disa sass ssem embl bly y for for norm normal al over-the-road transportation. If the boom and arm need to be removed, the counterweight will place more weight on the rear of the machine. Make sure to back the excavator onto the trailer so the counterweight end (heavy ( heavy end) of the excavator is positioned on the ramp first. See Figure 9 9..

15

EX1300747

Figure 9 9.

Exten Extend d buck bucket et and and ar arm m cyli cylind nder ers s to maxi maximu mum m leng length th a and nd then lower the boom slowly.

EX1300748

Figure 10 10. Move Move sa safety fety lev lever er tto o "L "LOCK OCK"" po posit sition ion..

Unlock

EX1300566

Lock

Figure 11 11. Stop Stop engine engine by by turnin turning g key to to "O" ((OFF OFF)) positi position on ((Figure Figure   12). 12). 12. 12.

Remov Remove e ke key y fro from m star starte terr swit switch ch..

O ACC

I

EX1402155

Figure 12

Transportation  5-6

DX220A-2/DX220LCA-2

 

13. Turn Turn battery battery disc disconne onnect ct switc switch h to "OFF" "OFF" posi positio tion n (Figure (Figure   13). 13). 14. 14.

Lock Lock all all doo doors rs and cove covers rs..

OFF

ON

OFF

15. Adjust Adjust d dire irecti ction on of rotati rotating ng beaco beacon n and TMS TMS antenn antenna. a.

OFF O    N    

O    N    

EX1500481

Figure 13 16. Make Make sure tto o secu secure re the excava excavator tor onto onto the trai trailer ler befor before e transporting. Place blocking (1, Figure 14 14)) in front of and behind each track. Tie front and rear (2, Figure 15 15)) and tie down point (3, Figure 15) 15) on the lower frame with wire cable as required by local transportation regulations. 17.

Refer to "Specifi "Specification cation"" section section of thi this s ma manual nual for o overall verall machine height and width dimensions. Make sure to position the excavator as shown. If not transported in this position, the height measurements may be different.

1

 

1

2

EX1300749

Figure 14

2

2 2

2 3

3 3

3

EX1300750

Figure 15

Transportation  Transportation  5-7

DX220A-2/DX220LCA-2

 

LIFTING MACHINE

1

 

1

WARNING AVOID DEATH OR SERIOUS INJURY Never lift the machine with a person in the cabin or on the machine. Never enter the area under or around a raised machine. Improper lifting can allow load to shift and cause death or serious injury or property damage. When lifting, move the safety lever to "LOCK" position to prevent the machine from moving unexpectedly. Use only properly rated cables and slings. Never go in the area under or around the machine when it is raised. Always use the posture given in the procedure below and use the proper lifting equipment to lift the machine. 1.

Refer Refer to "Spe "Specif cifica icatio tion" n" secti section on of this manual manual for wei weight ght and dimensional information.

2.

Lowe Lowerr th the e work work equ equip ipmen mentt to the the grou ground nd a as s sh show own n in tthe he diagram on the right.

3.

Move Move saf safet ety y le leve verr to ""LO LOCK CK"" posi positi tion on.. Stop Stop eng engin ine. e.

4.

Ensu Ensure re the there re is is no nothi thing ng aro aroun und d the the op opera erator tor's 's compartment, close the cabin door and front glass securely.

5.

Bind Bind w wire ire ropes ropes betw between een the 1st and 2nd track track roll rollers ers from from the front and between the 1st and 2nd track rollers from the t he rear.

6.

Use Use sprea spreade derr bars bars b bet etwe ween en the the wire wire rrop ope e and the the mach machin ine e to prevent damage to the rope or machine. Set the lifting angle (1, Figure 16) 16) of the wire rope to 30 - 40°.

7.

Afte Afterr the the ma mach chine ine come comes s off off the g gro roun und, d, chec check k the the ho hook ok condition and the lifting posture, and then lift slowly.

EX1300751

Figure 16

Transportation  5-8

DX220A-2/DX220LCA-2

 

6Specification STANDARD SPECIFICATION Specification

Component Bucket Capacity

SAE

Operating Weight

Engine

Metric

English

0.92 m3

1.20 yd3

21.3 metric tons

23.4 tons

Model

DB58TIS

Type

Water Cooled - 6 Cylinders

Rated Output (Gross)

113 kW @ 1,800 rpm

156 HP, 154 PS @ 1,800 rpm

Rated Output (Net)

109 kW @ 1,800 rpm

150 HP, 148 PS @ 1,800 rpm

Maximum Torque

66 kg.m @ 1,400 rpm

477 ft lb @ 1,400 rpm

400 liters

106 U.S. gal.

Fuel Tank Capacity Type

Axial Piston 350 kg/cm2

5,000 psi

2 x 207 liters/min

2 x 54.7 U.S. gpm

Tank Level

141 liters

37.2 U.S. gal.

Full

195 liters

51.5 U.S. gal.

System

270 liters

71.3 U.S. gal.

Bucket

14 metric tons

15.4 tons

Arm

10 metric tons

Discharging Pressure Hydraulic Pump

Maximum Discharge Quantity Hydraulic Oil Capacity Digging Capability Swing Speed

Performance

Travel Speed

Traction Force

High-speed

5.5 km/h

3.4 MPH

Low-speed

3.0 km/h

1.9 MPH

High-speed

11.7 metric tons

12.8 tons

Low-speed

22.2 metric tons

24.5 tons

Gradeability Ground Pressure Ground Clearance

11.2 tons 11.0 rpm

35° (70% slope) 0.45 kg/cm2

6.4 psi

450 mm

17.7 in

Ground Clearance

450 mm

17.7 in

Track Shoe Width

600 mm

23.6 in

Upper Roller Qty.

2 per side

Bottom Roller Qty.

8 per side

Base Option : Boom (5.7 m), Arm (2.9 m), Counterweight (3.8 ton), LC Track

Specification  Specification  6-1

DX220A-2/DX220LCA-2

 

OVERALL DIMENSIONS G

A

H

B

I

M

L

F

F'

E

N O

J K

C D

DS1703978

Figure 1

Dimension A B C D E F (Boom) F (Hose) F' (Hand Rail) G H I J K L M N O

Shipping Length Tail Swing Radius Tumbler Distance Track Length Counterweight Clearance Shipping Height Shipping Height Shipping Height Shipping Width House Width Cabin Width Shoe Width Undercarriage Width Height Over Cabin Cabin Height Above House Track Height Car Body Clearance

5.7 m (18' 8") Boom 2.9 m (9' 6") Arm 2.4 m (7' 10") Arm 9,505 mm (31' 2") 9,545 mm (31' 4") 2,840 mm (9' 4") 3,650 mm (12' 0") 3,270 mm (10' 9") 4,445 mm (14' 7") 4,065 mm (13' 4") 1,066 mm (3' 6") 2,860 mm (9' 5") 2,960 mm (9' 9") 3,005 mm (9' 10") 3,125 mm (10' 3") 2,990 mm (9' 10") 2,990 mm (9' 10") 2,800 mm (9' 2") 2,710 mm (8' 11") 1,010 mm (3' 4") 600 mm (2' 0") 2,990 mm (9' 10") 2,800 mm (9' 2") 2,955 mm (9' 8") 840 mm (2' 9") 883 mm (2' 11") 450.5 mm (1' 6")

Specification  6-2

DX220A-2/DX220LCA-2

 

DISASSEMBLED PARTS, DIMENSION AND WEIGHT Components Boom

A

B

FG019640

Figure 2 Description

5.7 m (18' 8") STD

Length (A) Length (B)

5,790 (19' 0") mm (ft in)

Width Weight

1,331 (4' 4") 628 (2' 1")

kg

1,553

lb

3,424

Specification  Specification  6-3

DX220A-2/DX220LCA-2

 

Arm

A

B

FG019861

Figure 3 Description

2.9 m (9' 6")

2.4 m (7' 10")

3,865 (12' 8")

3,367 (11' 1")

908 (3' 0")

908 (3' 0")

344 (1' 2")

344 (1' 2")

kg

751

667

lb

1,656

1,470

Length (A) Length (B)

mm (ft in)

Width Weight

Specification  6-4

DX220A-2/DX220LCA-2

 

Counterweight

C

A

B

EX1401711

Figure 4 Description

Counterweight

Length (A)

2,711 (8' 11") mm (ft in)

Length (B)

565 (1' 10")

Length (C)

1,047 (3' 5")

Weight

kg

3,800

lb

8,378

GROUND PRESSURE Description

Shoe Width mm

Boom Length mm (ft-in)

Arm Length mm (ft-in)

Bucket Capacity (SAE) m3 (yd3)

Counterweight kg (Ib)

21,300

600 LC Track 800 600 STD Track 800

Operating Weight kg (Ib)

5,700 (18' 8")

2,900 (9' 6")

0.92 (1.20)

3,800 (8,378)

Ground Pressure kg/cm2 (psi) 0.45 (6.40)

(46,958) 22,000 (48,502)

0.35 (4.98)

20,800 (45,856)

0.49 (6.97)

21,400 (47,179)

0.38 (5.40)

Specification  Specification  6-5

DX220A-2/DX220LCA-2

 

DIGGING FORCE Description

Unit

5.7 m (18' 8") STD Boom 2.9 m (9' 6") STD Arm

2.4 m (7' 10") Arm

mm Bucket Radius SAE Breakout Force ISO

SAE Tearout Force ISO Rotation Angle - Bucket

(in) kN

124

1,454 (4' 9") 124

kg

12,600

12,640

lb

27,870

27,866

kN

140.3

140.2

kg

14,000

14,309

lb

31,552

31,546

kN

97.1

112.7

kg

9,500

11,000

lb

21,828

25,313

kN

100

116.5

kg

9,900

11,500

lb

22,484

26,213

deg

177

177

Specification  6-6

 

DX220A-2/DX220LCA-2

Specification  Specification  6-7

DX220A-2/DX220LCA-2

 

WORKING RANGE M

F G D

E d

G.L

0

L H

J C

2,500 mm

K I

B A

EX1401493

Figure 5

Specification  6-8

DX220A-2/DX220LCA-2

 

Boom Type DIM.

5.7 m (18' 8")

Arm Type

2.9 m (9' 6")

2.4 m (7' 10")

Bucket Type (SAE)

0.92 m3 (1.2 yd3)

1.05 m3 (1.37 yd3)

A

Max. Digging Reach

9,875 mm (32' 5")

9,390 mm (30' 10")

B

Max. Digging Reach (Ground)

9,700 mm (31' 10")

9,210 mm (30' 3")

C

Max. Digging Depth

6,595 mm (21' 8")

6,095 mm (20' 0")

D

Max. Loading Height

6,840 mm (22' 5")

6,690 mm (21' 11")

E

Min. Loading Height

2,500 mm (8' 2")

2,995 mm (9' 10")

F

Max. Digging Height

9,625 mm (31' 7")

9,495 mm (31' 2")

G

Max. Bucket Pin Height

8,280 mm (27' 2")

8,130 mm (26' 8")

H

Max. Vertical Wall Depth

5,735 mm (18' 10")

5,410 mm (17' 9")

I

Max. Radius Vertical

6,180 mm (20' 3")

5,910 mm (19' 5")

J

Max. Depth to 2,500 mm Line

6,410 mm (21' 0")

5,860 mm (19' 3")

K

Min. Radius 2,500 mm Line

2,860 mm (9' 5")

2,790 mm (9' 2")

L

Min. Digging Reach

117 mm (0' 5")

975 mm (3' 2")

M

Min. Swing Radius

3,555 mm (11' 8")

3,575 mm (11' 9")

d

Bucket Angle

177°

177°

Specification  Specification  6-9

DX220A-2/DX220LCA-2

 

EXCAVATOR RATED LIFT CAPACITY TABLES IMPORTANT Always keep the Operation and Maintenance Manual in the operator station:  Whenever you are handling or lifting objects, ensure the Operation and Maintenance Manual is available in the station and refer to the lifting chart.  See the Specification Handbook for specifications not listed below.

WARNING AVOID DEATH OR SERIOUS INJURY Keep bystanders away from the boom cylinder. While operating, boom, arm or bucket hydraulic hoses could burst causing high-pressure oil to spray or sudden lowering of the load or front structure. This could cause death or serious injury. When changing the hydraulic hoses, record the part numbers of the hoses to factory log book. Figure 6

 WARNING AVOID DEATH OR SERIOUS INJURY All rated lift capacities are based on the machine and the load both remaining level at all times. DO NOT EXCEED THE RATED LIFT CAPACITY. Lifting loads greater than those shown in the rated capacity tables can cause tipping, equipment failure and/or structural failure of the machine. Operate the excavator on firm and level ground and surfaces that can support the weight of the excavator and the loads that will be lifted. Avoid operating the excavator, if these conditions exist: • •

Soft or uneven ground. Unlevel terrain.

• • •

Side loads. Modi Modifi fica cati tions ons or poor poor main mainte tena nanc nce e of th the e exca excava vato tor. r. Fa Fail ilur ure e to to lif liftt squ squar arel ely yo ove verr the the en end d or or ove overr the the side side of the the machine.

When a load is in the air, the operator must: •

Avoi Avoid d use use of unev uneven en slin slings gs th that at can can cau cause se side side lo load ads s whe when n traveling with a load or swinging the load.

Specification  6-10

DX220A-2/DX220LCA-2

 

•

Avoi Avoid d lif lifti ting ng lo load ads s that that can can bec becom ome e unb unbal alan ance ced d ifif the the ho hook ok line is twisted and starts to rotate. If the surface area of the load is large enough, wind gusts can create crea te side loads.

•

Keep Keep th the ea arm rm end end po poin intt d dire irect ctly ly ov over er the the loa load. d. Use Use tag tag line lines s on opposite sides of the load to help stabilize the load and prevent side loads caused by wind gusts.

The following rated loads are in compliance with ISO 10567 and applicable ISO standards for hydraulic excavators performing lifting operations on firm supporting surfaces. An asterisk (*) next to the load rating indicates rated load does not exceed 87% of hydraulic capacity. All other ratings do not exceed 75% of tipping capacity. Do not attempt to lift or hold any load that exceeds rated load capacity at the specified distances (from the machine's rotation centerline and height - see "Lifting Radius" and "Lifting Point Height" in the reference drawing, Figure 7 7). ).

Lifting Radius Centerline of Rotation

Lifting Point

Lifting Point Height

Ground Line (Machine Supporting Surface)

FG018603

Figure 7 The weight of slings and any auxiliary lifting device (and/or the weight difference of any attachment heavier than standard configuration) must be deducted from the rated lift capacity to determine net lifting load. The lift point must be on the end of the arm, as shown in Figure 7. 7.

IMPORTANT Select the Digging Mode switch on the Instrument Panel before using the excavator for lifting work. Engine and hydraulic oil should both be fully warmed up to operating temperature before operating.

Specification  Specification  6-11

DX220A-2/DX220LCA-2

 

A

B

Track Trac k Wi Widt dth h Boom Arm Bucket Counterweight

: 2. 2.99 99 m (9 (9'' 10 10") ") LC Tr Trac ack k : 5.7 m (18' 8") : 2.4 m (7' 10") : Without Bucket : 3,800 kg (8,378 Ib)

Shoe

: 600 mm (24")

Dozer

: Without Dozer : Rating Over Front : Rating Over Side or 360 degree

Unit

Figure 8

: 1,000 kg (1,000 lb)

DS1703736

METRIC

1,000 kg

A (m)  B (m)

3

4.5

6

7.5

MAX. REACH

 

A (m)

7.5 6

* 5.30

4.92

* 5.55

5.48

5.61

* 5.12

3.93

6.82

4.5

* 6.79

* 6.79

* 5.70

4.76

5.07

3.30

* 4.99

3.27

7.54

3

* 8.37

6.89

* 6.37

4.52

4.98

3.22

4.56

2.95

7.92

1.5

* 9.61

6.42

6.82

4.30

4.87

3.12

4.42

2.84

8.00

0

* 10.01

6.22

6.66

4.15

4.80

3.06

4.55

2.91

7.80

-1.5

* 9.70

* 9.70

* 9.64

6.20

6.62

4.12

5.03

3.20

7.27

-3

* 11.37

* 11.37

* 8.47

6.33

* 6.20

4.21

* 5.59

3.92

6.36

* 5.68

* 5.68

* 5.02

* 5.02

4.83

-4.5

FEET

1,000 Ib

A (ft)

10

15

20

25

MAX. REACH

 

 B (ft)

A (ft)

25 20

* 11.69

10.85

* 12.24

12.09

18.39

* 11.28

8.67

22.38

15 10

* 14.98 * 18.44

* 14.98 15.19

* 12.57 * 14.05

10.50 9.97

11.17 10.98

7.28 7.11

* 11.01 10.05

7.20 6.50

24.75 26.00

5

* 21.20

14.16

15.04

9.47

10.74

6.89

9.74

6.25

26.26

0

* 22.07

13.71

14.68

9.16

10.59

6.74

10.03

6.40

25.57

-5

* 21.39

* 21.39

* 21.25

13.68

14.59

9.08

11.09

7.06

23.85

-10

* 25.06

* 25.06

* 18.68

13.94

* 13.66

9.29

* 12.32

8.65

20.86

* 12.53

* 12.53

* 11.07

* 11.07

15.84

-15

1.

Lo Load ad po poin intt is is the the en end d of of the the arm. arm.

2.

Capaci Capacities ties m mark arked ed with with an aster asterisk isk (*) (*) are are lim limite ited d by hydrau hydraulic lic c capac apaciti ities. es.

3.

Lift capaci capacities ties shown do not not exceed exceed 75% 75% of minimum minimum tipp tipping ing loads or 87% of hydraulic hydraulic capacities. capacities.

4.

Th The e lea least st stab stable le posi positi tion on is over over th the es sid ide. e.

5.

Lift capac capacitie ities s appl apply y only to to the machin machine e as original originally ly man manufac ufacture tured d and normall normally y equipped equipped by the the manufact manufacturer. urer.

6.

Lift Lift cap capac acit itie ies s are are in com compl plia ianc nce e with with IISO SO 105 10567 67..

Specification  6-12

DX220A-2/DX220LCA-2

 

A

B

Track Trac k Wi Widt dth h Boom Arm Bucket Counterweight

: 3. 3.19 19 m (1 (10' 0' 6" 6")) LC Tr Trac ack k : 5.7 m (18' 8") : 2.4 m (7' 10") : Without Bucket : 3,800 kg (8,378 Ib)

Shoe

: 800 mm (32")

Dozer

: Without Dozer : Rating Over Front : Rating Over Side or 360 degree

Unit

Figure 9

: 1,000 kg (1,000 lb)

DS1703737

METRIC

1,000 kg

A (m)  B (m)

3

4.5

6

7.5

MAX. REACH

 

A (m)

7.5 6

* 5.30

5.06

* 5.55

* 5.55

5.61

* 5.12

4.05

6.82

4.5

* 6.79

* 6.79

* 5.70

4.91

5.24

3.41

* 4.99

3.37

7.54

3

* 8.37

7.10

* 6.37

4.67

5.15

3.33

4.72

3.05

7.92

1.5

* 9.61

6.63

* 7.01

4.44

5.04

3.23

4.57

2.94

8.00

0

* 10.01

6.43

6.89

4.29

4.97

3.17

4.71

3.01

7.80

-1.5

* 9.70

* 9.70

* 9.64

6.41

6.85

4.26

5.21

3.31

7.27

-3

* 11.37

* 11.37

* 8.47

6.53

* 6.20

4.36

* 5.59

4.06

6.36

* 5.68

* 5.68

* 5.02

* 5.02

4.83

-4.5

FEET

1,000 Ib

A (ft)

10

15

20

25

MAX. REACH

 

 B (ft)

A (ft)

25 20

* 11.69

11.16

* 12.24

* 12.24

18.39

* 11.28

8.93

22.38

15 10

* 14.98 * 18.44

* 14.98 15.65

* 12.57 * 14.05

10.82 10.28

11.55 11.36

7.52 7.34

* 11.01 10.40

7.44 6.72

24.75 26.00

5

* 21.20

14.61

* 15.45

9.78

11.11

7.12

10.08

6.47

26.26

0

* 22.07

14.17

15.19

9.47

10.96

6.98

10.38

6.63

25.57

-5

* 21.39

* 21.39

* 21.25

14.13

15.10

9.39

11.48

7.30

23.85

-10

* 25.06

* 25.06

* 18.68

14.40

* 13.66

9.60

* 12.32

8.94

20.86

* 12.53

* 12.53

* 11.07

* 11.07

15.84

-15

1.

Lo Load ad po poin intt is is the the en end d of of the the arm. arm.

2.

Capaci Capacities ties m mark arked ed with with an aster asterisk isk (*) (*) are are lim limite ited d by hydrau hydraulic lic c capac apaciti ities. es.

3.

Lift capaci capacities ties shown do not not exceed exceed 75% 75% of minimum minimum tipp tipping ing loads or 87% of hydraulic hydraulic capacities. capacities.

4.

Th The e lea least st stab stable le posi positi tion on is over over th the es sid ide. e.

5.

Lift capac capacitie ities s appl apply y only to to the machin machine e as original originally ly man manufac ufacture tured d and normall normally y equipped equipped by the the manufact manufacturer. urer.

6.

Lift Lift cap capac acit itie ies s are are in com compl plia ianc nce e with with IISO SO 105 10567 67..

Specification  Specification  6-13

DX220A-2/DX220LCA-2

 

A

B

Track Trac k Wi Widt dth h Boom Arm Bucket Counterweight

: 2. 2.99 99 m (9 (9'' 10 10") ") LC Tr Trac ack k : 5.7 m (18' 8") : 2.4 m (7' 10") : Without Bucket : 4,100 kg (9,039 Ib)

Shoe

: 600 mm (24")

Dozer

: Without Dozer : Rating Over Front : Rating Over Side or 360 degree

Unit

Figure 10

: 1,000 kg (1,000 lb)

DS1703759

METRIC

1,000 kg

A (m)  B (m)

3

4.5

6

7.5

MAX. REACH

 

A (m)

7.5 6

* 5.30

5.10

* 5.55

* 5.55

5.61

* 5.12

4.08

6.82

4.5

* 6.79

* 6.79

* 5.70

4.94

5.24

3.44

* 4.99

3.40

7.54

3

* 8.37

7.15

* 6.37

4.70

5.15

3.36

4.72

3.07

7.92

1.5

* 9.61

6.69

* 7.01

4.48

5.04

3.26

4.58

2.96

8.00

0

* 10.01

6.48

6.89

4.33

4.97

3.20

4.71

3.04

7.80

-1.5

* 9.70

* 9.70

* 9.64

6.47

6.85

4.30

5.21

3.34

7.27

-3

* 11.37

* 11.37

* 8.47

6.59

* 6.20

4.39

* 5.59

4.09

6.36

* 5.68

* 5.68

* 5.02

* 5.02

4.83

-4.5

FEET

1,000 Ib

A (ft)

10

15

20

25

MAX. REACH

 

 B (ft)

A (ft)

25 20

* 11.69

11.25

* 12.24

* 12.24

18.39

* 11.28

9.00

22.38

15 10

* 14.98 * 18.44

* 14.98 15.77

* 12.57 * 14.05

10.90 10.37

11.55 11.36

7.58 7.41

* 11.01 10.40

7.50 6.78

24.75 26.00

5

* 21.20

14.74

* 15.45

9.87

11.12

7.19

10.09

6.53

26.26

0

* 22.07

14.29

15.19

9.55

10.96

7.04

10.39

6.69

25.57

-5

* 21.39

* 21.39

* 21.25

14.26

15.11

9.47

11.48

7.37

23.85

-10

* 25.06

* 25.06

* 18.68

14.53

* 13.66

9.69

* 12.32

9.02

20.86

* 12.53

* 12.53

* 11.07

* 11.07

15.84

-15

1.

Lo Load ad po poin intt is is the the en end d of of the the arm. arm.

2.

Capaci Capacities ties m mark arked ed with with an aster asterisk isk (*) (*) are are lim limite ited d by hydrau hydraulic lic c capac apaciti ities. es.

3.

Lift capaci capacities ties shown do not not exceed exceed 75% 75% of minimum minimum tipp tipping ing loads or 87% of hydraulic hydraulic capacities. capacities.

4.

Th The e lea least st stab stable le posi positi tion on is over over th the es sid ide. e.

5.

Lift capac capacitie ities s appl apply y only to to the machin machine e as original originally ly man manufac ufacture tured d and normall normally y equipped equipped by the the manufact manufacturer. urer.

6.

Lift Lift cap capac acit itie ies s are are in com compl plia ianc nce e with with IISO SO 105 10567 67..

Specification  6-14

DX220A-2/DX220LCA-2

 

A

B

Track Trac k Wi Widt dth h Boom Arm Bucket Counterweight

: 3. 3.19 19 m (1 (10' 0' 6" 6")) LC Tr Trac ack k : 5.7 m (18' 8") : 2.4 m (7' 10") : Without Bucket : 4,100 kg (9,039 Ib)

Shoe

: 800 mm (32")

Dozer

: Without Dozer : Rating Over Front : Rating Over Side or 360 degree

Unit

Figure 11

: 1,000 kg (1,000 lb)

DS1703760

METRIC

1,000 kg

A (m)  B (m)

3

4.5

6

7.5

MAX. REACH

 

A (m)

7.5 6

* 5.30

5.24

* 5.55

* 5.55

5.61

* 5.12

4.21

6.82

4.5

* 6.79

* 6.79

* 5.70

5.09

* 5.26

3.55

* 4.99

3.51

7.54

3

* 8.37

7.36

* 6.37

4.85

5.32

3.47

4.88

3.18

7.92

1.5

* 9.61

6.89

* 7.01

4.62

5.21

3.37

4.73

3.06

8.00

0

* 10.01

6.69

7.12

4.47

5.14

3.30

4.87

3.14

7.80

-1.5

* 9.70

* 9.70

* 9.64

6.68

7.08

4.44

5.39

3.45

7.27

-3

* 11.37

* 11.37

* 8.47

6.80

* 6.20

4.54

* 5.59

4.22

6.36

* 5.68

* 5.68

* 5.02

* 5.02

4.83

-4.5

FEET

1,000 Ib

A (ft)

10

15

20

25

MAX. REACH

 

 B (ft)

A (ft)

25 20

* 11.69

11.56

* 12.24

* 12.24

18.39

* 11.28

9.27

22.38

15 10

* 14.98 * 18.44

* 14.98 16.23

* 12.57 * 14.05

11.21 10.68

* 11.59 11.73

7.82 7.65

* 11.01 10.75

7.74 7.00

24.75 26.00

5

* 21.20

15.20

* 15.45

10.18

11.49

7.42

10.43

6.75

26.26

0

* 22.07

14.75

15.70

9.87

11.33

7.28

10.74

6.92

25.57

-5

* 21.39

* 21.39

* 21.25

14.72

15.61

9.79

11.87

7.62

23.85

-10

* 25.06

* 25.06

* 18.68

14.99

* 13.66

10.00

* 12.32

9.31

20.86

* 12.53

* 12.53

* 11.07

* 11.07

15.84

-15

1.

Lo Load ad po poin intt is is the the en end d of of the the arm. arm.

2.

Capaci Capacities ties m mark arked ed with with an aster asterisk isk (*) (*) are are lim limite ited d by hydrau hydraulic lic c capac apaciti ities. es.

3.

Lift capaci capacities ties shown do not not exceed exceed 75% 75% of minimum minimum tipp tipping ing loads or 87% of hydraulic hydraulic capacities. capacities.

4.

Th The e lea least st stab stable le posi positi tion on is over over th the es sid ide. e.

5.

Lift capac capacitie ities s appl apply y only to to the machin machine e as original originally ly man manufac ufacture tured d and normall normally y equipped equipped by the the manufact manufacturer. urer.

6.

Lift Lift cap capac acit itie ies s are are in com compl plia ianc nce e with with IISO SO 105 10567 67..

Specification  Specification  6-15

DX220A-2/DX220LCA-2

 

A

B

Track Trac k Wi Widt dth h Boom Arm Bucket Counterweight

: 2. 2.99 99 m (9 (9'' 10 10") ") LC Tr Trac ack k : 5.7 m (18' 8") : 2.9 m (9' 6") : Without Bucket : 3,800 kg (8,378 Ib)

Shoe

: 600 mm (24")

Dozer

: Without Dozer : Rating Over Front : Rating Over Side or 360 degree

Unit

Figure 12

: 1,000 kg (1,000 lb)

DS1703761

METRIC

1,000 kg

A (m)

1.5

3

4.5

6

7.5

MAX. REACH

 

 B (m)

A (m)

7.5

* 4.66

* 4.66

* 4.05

* 4.05

6.20

6

* 4.81

* 4.81

* 3.76

3.53

7.31

4.5

* 5.27

4.81

* 4.85

3.33

* 3.70

2.97

7.99

3

* 7.72

7.00

* 5.99

4.54

4.98

3.22

* 3.80

2.69

8.35

1.5

* 9.15

6.45

* 6.71

4.28

4.85

3.09

* 4.05

2.59

8.42

0

* 5.70

* 5.70

* 9.83

6.15

6.61

4.10

4.74

3.00

4.15

2.63

8.23

* 9.82

* 9.82

* 9.74

6.08

6.53

4.03

4.72

2.98

4.52

2.86

7.74

* 10.59 * 10.59 * 12.38

12.09

* 8.88

6.16

* 6.58

4.07

* 5.38

3.41

6.88

* 9.38

* 9.38

* 6.84

6.41

* 5.20

4.83

5.51

-1.5

* 6.22

-3

* 6.22

-4.5

FEET

1,000 Ib

A (ft)

5

10

15

20

25

MAX. REACH

 

 B (ft)

A (ft)

25

* 10.26 * 10.26

* 8.92

* 8.92

20.33

20

* 10.61 * 10.61

* 8.29

7.78

2 23 3.97

7.34 7.09

* 8.16 * 8.37

6.55 5.94

26.21 27.39

15 10

* 17.02

* 11.61 15.43 * 13.20

5

* 20.17

14.22 * 14.79

9.44

10.68

6.82

* 8.92

5.71

27.64

0

* 12.56 * 12.56 * 21.68

13.57

14.57

9.04

10.46

6.61

9.15

5.81

26.99

-5

* 13.71 * 13.71 * 21.66 * 21.66 * 21.47

13.40

14.39

8.88

10.40

6.56

9.97

6.31

25.38

-10

* 23.34 * 23.34 * 27.29

13.57 * 14.51

8.98

* 11.85

7.52

22.59

* 11.46

10.64

18.07

-15

26.64 * 19.58

* 20.68 * 20.68 * 15.09

10.61 * 10.70 10.02 10.99

14.13

1.

Lo Load ad po poin intt is is the the en end d of of the the arm. arm.

2.

Capaci Capacities ties m mark arked ed with with an aster asterisk isk (*) (*) are are lim limite ited d by hydrau hydraulic lic c capac apaciti ities. es.

3.

Lift capaci capacities ties shown do not not exceed exceed 75% 75% of minimum minimum tipp tipping ing loads or 87% of hydraulic hydraulic capacities. capacities.

4.

Th The e lea least st stab stable le posi positi tion on is over over th the es sid ide. e.

5.

Lift capac capacitie ities s appl apply y only to to the machin machine e as original originally ly man manufac ufacture tured d and normall normally y equipped equipped by the the manufact manufacturer. urer.

6.

Lift Lift cap capac acit itie ies s are are in com compl plia ianc nce e with with IISO SO 105 10567 67..

Specification  6-16

DX220A-2/DX220LCA-2

 

A

B

Track Trac k Wi Widt dth h Boom Arm Bucket Counterweight

: 3. 3.19 19 m (1 (10' 0' 6" 6")) LC Tr Trac ack k : 5.7 m (18' 8") : 2.9 m (9' 6") : Without Bucket : 3,800 kg (8,378 Ib)

Shoe

: 800 mm (32")

Dozer

: Without Dozer : Rating Over Front : Rating Over Side or 360 degree

Unit

Figure 13

: 1,000 kg (1,000 lb)

DS1703762

METRIC

1,000 kg

A (m)

1.5

3

4.5

6

7.5

MAX. REACH

 

 B (m)

A (m)

7.5

* 4.66

* 4.66

* 4.05

* 4.05

6.20

6

* 4.81

* 4.81

* 3.76

3.64

7.31

4.5

* 5.27

4.95

* 4.85

3.44

* 3.70

3.07

7.99

3

* 7.72

7.21

* 5.99

4.69

* 5.15

3.33

* 3.80

2.79

8.35

1.5

* 9.15

6.66

* 6.71

4.42

5.01

3.20

* 4.05

2.68

8.42

0

* 5.70

* 5.70

* 9.83

6.36

6.84

4.24

4.91

3.11

4.30

2.73

8.23

* 9.82

* 9.82

* 9.74

6.29

6.76

4.17

4.89

3.08

4.69

2.96

7.74

* 10.59 * 10.59 * 12.38 * 12.38

* 8.88

6.36

* 6.58

4.22

* 5.38

3.53

6.88

* 6.84

6.62

* 5.20

4.99

5.51

-1.5

* 6.22

-3

* 6.22

-4.5

* 9.38

* 9.38

FEET

1,000 Ib

A (ft)

5

10

15

20

25

MAX. REACH

 

 B (ft)

A (ft)

25

* 10.26 * 10.26

* 8.92

* 8.92

20.33

20

* 10.61 * 10.61

* 8.29

8.02

2 23 3.97

7.58 7.33

* 8.16 * 8.37

6.77 6.15

26.21 27.39

15 10

* 17.02

* 11.61 15.89 * 13.20

10.92 * 10.70 10.33 * 11.35

5

* 20.17

14.67 * 14.79

9.75

11.05

7.05

* 8.92

5.91

27.64

0

* 12.56 * 12.56 * 21.68

14.02

15.08

9.35

10.83

6.85

9.48

6.02

26.99

-5

* 13.71 * 13.71 * 21.66 * 21.66 * 21.47

13.86

14.90

9.19

10.78

6.80

10.33

6.54

25.38

-10

* 23.34 * 23.34 * 27.29 * 27.29 * 19.58

14.03 * 14.51

9.29

* 11.85

7.78

22.59

-15

* 20.68 * 20.68 * 15.09

* 11.46

10.99

18.07

14.59

1.

Lo Load ad po poin intt is is the the en end d of of the the arm. arm.

2.

Capaci Capacities ties m mark arked ed with with an aster asterisk isk (*) (*) are are lim limite ited d by hydrau hydraulic lic c capac apaciti ities. es.

3.

Lift capaci capacities ties shown do not not exceed exceed 75% 75% of minimum minimum tipp tipping ing loads or 87% of hydraulic hydraulic capacities. capacities.

4.

Th The e lea least st stab stable le posi positi tion on is over over th the es sid ide. e.

5.

Lift capac capacitie ities s appl apply y only to to the machin machine e as original originally ly man manufac ufacture tured d and normall normally y equipped equipped by the the manufact manufacturer. urer.

6.

Lift Lift cap capac acit itie ies s are are in com compl plia ianc nce e with with IISO SO 105 10567 67..

Specification  Specification  6-17

DX220A-2/DX220LCA-2

 

A

B

Track Trac k Wi Widt dth h Boom Arm Bucket Counterweight

: 2. 2.99 99 m (9 (9'' 10 10") ") LC Tr Trac ack k : 5.7 m (18' 8") : 2.9 m (9' 6") : Without Bucket : 4,100 kg (9,039 Ib)

Shoe

: 600 mm (24")

Dozer

: Without Dozer : Rating Over Front : Rating Over Side or 360 degree

Unit

Figure 14

: 1,000 kg (1,000 lb)

DS1703763

METRIC

1,000 kg

A (m)

1.5

3

4.5

6

7.5

MAX. REACH

 

 B (m)

A (m)

7.5

* 4.66

* 4.66

* 4.05

* 4.05

6.20

6

* 4.81

* 4.81

* 3.76

3.67

7.31

4.5

* 5.27

4.99

* 4.85

3.47

* 3.70

3.10

7.99

3

* 7.72

7.26

* 5.99

4.73

* 5.15

3.35

* 3.80

2.81

8.35

1.5

* 9.15

6.71

* 6.71

4.46

5.02

3.23

* 4.05

2.71

8.42

0

* 5.70

* 5.70

* 9.83

6.42

6.84

4.28

4.91

3.13

4.30

2.76

8.23

* 9.82

* 9.82

* 9.74

6.34

6.76

4.21

4.89

3.11

4.69

2.99

7.74

* 10.59 * 10.59 * 12.38 * 12.38

* 8.88

6.42

* 6.58

4.25

* 5.38

3.56

6.88

* 6.84

6.67

* 5.20

5.03

5.51

-1.5

* 6.22

-3

* 6.22

-4.5

* 9.38

* 9.38

FEET

1,000 Ib

A (ft)

5

10

15

20

25

MAX. REACH

 

 B (ft)

A (ft)

25

* 10.26 * 10.26

* 8.92

* 8.92

20.33

20

* 10.61 * 10.61

* 8.29

8.09

2 23 3.97

7.64 7.39

* 8.16 * 8.37

6.83 6.20

26.21 27.39

15 10

* 17.02

* 11.61 16.01 * 13.20

11.01 * 10.70 10.42 * 11.35

5

* 20.17

14.80 * 14.79

9.84

11.06

7.12

* 8.92

5.97

27.64

0

* 12.56 * 12.56 * 21.68

14.15

15.08

9.43

10.83

6.91

9.48

6.08

26.99

-5

* 13.71 * 13.71 * 21.66 * 21.66 * 21.47

13.98

14.90

9.27

10.78

6.86

10.34

6.60

25.38

-10

* 23.34 * 23.34 * 27.29 * 27.29 * 19.58

14.15 * 14.51

9.38

* 11.85

7.85

22.59

-15

* 20.68 * 20.68 * 15.09

* 11.46

11.09

18.07

14.71

1.

Lo Load ad po poin intt is is the the en end d of of the the arm. arm.

2.

Capaci Capacities ties m mark arked ed with with an aster asterisk isk (*) (*) are are lim limite ited d by hydrau hydraulic lic c capac apaciti ities. es.

3.

Lift capaci capacities ties shown do not not exceed exceed 75% 75% of minimum minimum tipp tipping ing loads or 87% of hydraulic hydraulic capacities. capacities.

4.

Th The e lea least st stab stable le posi positi tion on is over over th the es sid ide. e.

5.

Lift capac capacitie ities s appl apply y only to to the machin machine e as original originally ly man manufac ufacture tured d and normall normally y equipped equipped by the the manufact manufacturer. urer.

6.

Lift Lift cap capac acit itie ies s are are in com compl plia ianc nce e with with IISO SO 105 10567 67..

Specification  6-18

DX220A-2/DX220LCA-2

 

A

B

Track Trac k Wi Widt dth h Boom Arm Bucket Counterweight

: 3. 3.19 19 m (1 (10' 0' 6" 6")) LC Tr Trac ack k : 5.7 m (18' 8") : 2.9 m (9' 6") : Without Bucket : 4,100 kg (9,039 Ib)

Shoe

: 800 mm (32")

Dozer

: Without Dozer : Rating Over Front : Rating Over Side or 360 degree

Unit

Figure 15

: 1,000 kg (1,000 lb)

DS1703764

METRIC

1,000 kg

A (m)

1.5

3

4.5

6

7.5

MAX. REACH

 

 B (m)

A (m)

7.5

* 4.66

* 4.66

* 4.05

* 4.05

6.20

6

* 4.81

* 4.81

* 3.76

* 3.76

7.31

4.5

* 5.27

5.13

* 4.85

3.57

* 3.70

3.20

7.99

3

* 7.72

7.47

* 5.99

4.87

* 5.15

3.46

* 3.80

2.91

8.35

1.5

* 9.15

6.92

* 6.71

4.60

5.19

3.34

* 4.05

2.80

8.42

0

* 5.70

* 5.70

* 9.83

6.63

7.07

4.42

5.08

3.24

4.45

2.85

8.23

* 9.82

* 9.82

* 9.74

6.55

6.99

4.35

5.06

3.22

4.85

3.10

7.74

* 10.59 * 10.59 * 12.38 * 12.38

* 8.88

6.63

* 6.58

4.40

* 5.38

3.68

6.88

* 6.84

* 6.84

* 5.20

5.19

5.51

-1.5

* 6.22

-3

* 6.22

-4.5

* 9.38

* 9.38

FEET

1,000 Ib

A (ft)

5

10

15

20

25

MAX. REACH

 

 B (ft)

A (ft)

25

* 10.26 * 10.26

* 8.92

* 8.92

20.33

20

* 10.61 * 10.61

* 8.29

* 8.29

23.97

15 10

* 17.02

* 11.61 16.47 * 13.20

11.32 * 10.70 10.73 * 11.35

7.88 7.63

* 8.16 * 8.37

7.05 6.41

26.21 27.39

5

* 20.17

15.26 * 14.79

10.15

11.43

7.35

* 8.92

6.17

27.64

0

* 12.56 * 12.56 * 21.68

14.61

15.59

9.75

11.21

7.15

9.81

6.29

26.99

-5

* 13.71 * 13.71 * 21.66 * 21.66 * 21.47

14.44

15.41

9.59

11.15

7.10

10.69

6.83

25.38

-10

* 23.34 * 23.34 * 27.29 * 27.29 * 19.58

14.61 * 14.51

9.69

* 11.85

8.11

22.59

* 11.46

11.44

18.07

-15

* 20.68 * 20.68 * 15.09 * 15.09

1.

Lo Load ad po poin intt is is the the en end d of of the the arm. arm.

2.

Capaci Capacities ties m mark arked ed with with an aster asterisk isk (*) (*) are are lim limite ited d by hydrau hydraulic lic c capac apaciti ities. es.

3.

Lift capaci capacities ties shown do not not exceed exceed 75% 75% of minimum minimum tipp tipping ing loads or 87% of hydraulic hydraulic capacities. capacities.

4.

Th The e lea least st stab stable le posi positi tion on is over over th the es sid ide. e.

5.

Lift capac capacitie ities s appl apply y only to to the machin machine e as original originally ly man manufac ufacture tured d and normall normally y equipped equipped by the the manufact manufacturer. urer.

6.

Lift Lift cap capac acit itie ies s are are in com compl plia ianc nce e with with IISO SO 105 10567 67..

Specification  Specification  6-19

DX220A-2/DX220LCA-2

 

A

B

Track Trac k Wi Widt dth h Boom Arm Bucket Counterweight

: 2. 2.80 80 m (9 (9'' 2" 2")) ST STD D Tr Trac ack k : 5.7 m (18' 8") : 2.4 m (7' 10") : Without Bucket : 3,800 kg (8,378 Ib)

Shoe

: 600 mm (24")

Dozer

: Without Dozer : Rating Over Front : Rating Over Side or 360 degree

Unit

Figure 16

: 1,000 kg (1,000 lb)

DS1703765

METRIC

1,000 kg

A (m)  B (m)

3

4.5

6

7.5

MAX. REACH

 

A (m)

7.5 6

* 5.30

4.44

* 5.55

4.94

5.61

* 5.12

3.53

6.82

4.5

* 6.79

6.7

* 5.70

4.28

4.38

2.96

4.33

2.93

7.54

3

* 8.37

6.13

6.06

4.05

4.29

2.88

3.93

2.63

7.92

1.5

8.99

5.67

5.82

3.82

4.19

2.78

3.80

2.52

8.00

0

8.76

5.48

5.66

3.68

4.12

2.72

3.91

2.58

7.80

-1.5

* 9.70

* 9.70

8.75

5.46

5.62

3.65

4.31

2.84

7.27

-3

* 11.37

10.74

* 8.47

5.58

5.73

3.74

5.30

3.49

6.36

* 5.68

* 5.68

* 5.02

* 5.02

4.83

-4.5

FEET

1,000 Ib

A (ft)

10

15

20

25

MAX. REACH

 

 B (ft)

A (ft)

25 20

* 11.69

9.78

* 12.24

10.9

18.39

* 11.28

7.79

22.38

15 10

* 14.98 * 18.44

14.77 13.51

* 12.57 13.36

9.44 8.92

9.65 9.47

6.52 6.35

9.55 8.66

6.45 5.79

24.75 26.00

5

19.82

12.51

12.82

8.43

9.23

6.13

8.38

5.56

26.26

0

19.32

12.08

12.48

8.12

9.08

5.99

8.61

5.69

25.57

-5

* 21.39

* 21.39

19.28

12.04

12.40

8.04

9.51

6.27

23.85

-10

* 25.06

23.67

* 18.68

12.30

12.63

8.25

11.69

7.70

20.86

* 12.53

* 12.53

* 11.07

* 11.07

15.84

-15

1.

Lo Load ad po poin intt is is the the en end d of of the the arm. arm.

2.

Capaci Capacities ties m mark arked ed with with an aster asterisk isk (*) (*) are are lim limite ited d by hydrau hydraulic lic c capac apaciti ities. es.

3.

Lift capaci capacities ties shown do not not exceed exceed 75% 75% of minimum minimum tipp tipping ing loads or 87% of hydraulic hydraulic capacities. capacities.

4.

Th The e lea least st stab stable le posi positi tion on is over over th the es sid ide. e.

5. 6.

Lift capac capacitie ities s appl apply y only to to the machin machine e as original originally ly man manufac ufacture tured d and normall normally y equipped equipped by the the manufact manufacturer. urer. Lift Lift cap capac acit itie ies s are are in com compl plia ianc nce e with with IISO SO 105 10567 67..

Specification  6-20

DX220A-2/DX220LCA-2

 

A

B

Track Trac k Wi Widt dth h Boom Arm Bucket Counterweight

: 3. 3.0 0 m (9 (9'' 10 10") ") ST STD D Tr Trac ack k : 5.7 m (18' 8") : 2.4 m (7' 10") : Without Bucket : 3,800 kg (8,378 Ib)

Shoe

: 800 mm (32")

Dozer

: Without Dozer : Rating Over Front : Rating Over Side or 360 degree

Unit

Figure 17

: 1,000 kg (1,000 lb)

DS1703766

METRIC

1,000 kg

A (m)  B (m)

3

4.5

6

7.5

MAX. REACH

 

A (m)

7.5 6

* 5.30

4.54

* 5.55

5.06

5.61

* 5.12

3.62

6.82

4.5

* 6.79

* 6.79

* 5.70

4.39

4.50

3.04

4.45

3.00

7.54

3

* 8.37

6.28

6.23

4.15

4.42

2.96

4.04

2.70

7.92

1.5

9.24

5.82

5.98

3.93

4.31

2.86

3.91

2.60

8.00

0

9.01

5.63

5.83

3.79

4.24

2.80

4.02

2.66

7.80

-1.5

* 9.70

* 9.70

9.00

5.61

5.79

3.75

4.44

2.93

7.27

-3

* 11.37

11.01

* 8.47

5.73

5.89

3.85

5.45

3.59

6.36

* 5.68

* 5.68

* 5.02

* 5.02

4.83

-4.5

FEET

1,000 Ib

A (ft)

10

15

20

25

MAX. REACH

 

 B (ft)

A (ft)

25 20

* 11.69

10.01

* 12.24

11.15

18.39

* 11.28

7.98

22.38

15 10

* 14.98 * 18.44

* 14.98 13.84

* 12.57 13.73

9.67 9.15

9.92 9.73

6.69 6.52

9.82 8.91

6.62 5.96

24.75 26.00

5

20.37

12.84

13.19

8.66

9.50

6.30

8.63

5.72

26.26

0

19.87

12.40

12.85

8.35

9.35

6.16

8.87

5.86

25.57

-5

* 21.39

* 21.39

19.83

12.37

12.76

8.27

9.79

6.45

23.85

-10

* 25.06

24.27

* 18.68

12.63

12.99

8.48

12.02

7.91

20.86

* 12.53

* 12.53

* 11.07

* 11.07

15.84

-15

1.

Lo Load ad po poin intt is is the the en end d of of the the arm. arm.

2.

Capaci Capacities ties m mark arked ed with with an aster asterisk isk (*) (*) are are lim limite ited d by hydrau hydraulic lic c capac apaciti ities. es.

3.

Lift capaci capacities ties shown do not not exceed exceed 75% 75% of minimum minimum tipp tipping ing loads or 87% of hydraulic hydraulic capacities. capacities.

4.

Th The e lea least st stab stable le posi positi tion on is over over th the es sid ide. e.

5. 6.

Lift capac capacitie ities s appl apply y only to to the machin machine e as original originally ly man manufac ufacture tured d and normall normally y equipped equipped by the the manufact manufacturer. urer. Lift Lift cap capac acit itie ies s are are in com compl plia ianc nce e with with IISO SO 105 10567 67..

Specification  Specification  6-21

DX220A-2/DX220LCA-2

 

A

B

Track Trac k Wi Widt dth h Boom Arm Bucket Counterweight

: 2. 2.80 80 m (9 (9'' 2" 2")) ST STD D Tr Trac ack k : 5.7 m (18' 8") : 2.4 m (7' 10") : Without Bucket : 4,100 kg (9,039 Ib)

Shoe

: 600 mm (24")

Dozer

: Without Dozer : Rating Over Front : Rating Over Side or 360 degree

Unit

Figure 18

: 1,000 kg (1,000 lb)

DS1703767

METRIC

1,000 kg

A (m)  B (m)

3

4.5

6

7.5

MAX. REACH

 

A (m)

7.5 6

* 5.30

4.61

* 5.55

5.13

5.61

* 5.12

3.68

6.82

4.5

* 6.79

* 6.79

* 5.70

4.46

4.54

3.09

4.49

3.06

7.54

3

* 8.37

6.38

6.27

4.22

4.45

3.01

4.08

2.75

7.92

1.5

9.31

5.92

6.03

4.00

4.35

2.91

3.95

2.65

8.00

0

9.09

5.73

5.87

3.86

4.28

2.85

4.06

2.71

7.80

-1.5

* 9.70

* 9.70

9.07

5.71

5.84

3.82

4.48

2.98

7.27

-3

* 11.37

11.19

* 8.47

5.83

5.94

3.92

5.50

3.65

6.36

* 5.68

* 5.68

* 5.02

* 5.02

4.83

-4.5

FEET

1,000 Ib

A (ft)

10

15

20

25

MAX. REACH

 

 B (ft)

A (ft)

25 20

* 11.69

10.16

* 12.24

11.31

18.39

* 11.28

8.11

22.38

15 10

* 14.98 * 18.44

* 14.98 14.06

* 12.57 13.83

9.82 9.30

10.00 9.81

6.81 6.64

9.90 8.99

6.74 6.07

24.75 26.00

5

20.53

13.06

13.29

8.81

9.58

6.42

8.70

5.83

26.26

0

20.03

12.63

12.95

8.50

9.43

6.28

8.94

5.97

25.57

-5

* 21.39

* 21.39

19.99

12.59

12.87

8.42

9.87

6.57

23.85

-10

* 25.06

24.67

* 18.68

12.85

13.10

8.63

12.12

8.05

20.86

* 12.53

* 12.53

* 11.07

* 11.07

15.84

-15

1.

Lo Load ad po poin intt is is the the en end d of of the the arm. arm.

2.

Capaci Capacities ties m mark arked ed with with an aster asterisk isk (*) (*) are are lim limite ited d by hydrau hydraulic lic c capac apaciti ities. es.

3.

Lift capaci capacities ties shown do not not exceed exceed 75% 75% of minimum minimum tipp tipping ing loads or 87% of hydraulic hydraulic capacities. capacities.

4.

Th The e lea least st stab stable le posi positi tion on is over over th the es sid ide. e.

5. 6.

Lift capac capacitie ities s appl apply y only to to the machin machine e as original originally ly man manufac ufacture tured d and normall normally y equipped equipped by the the manufact manufacturer. urer. Lift Lift cap capac acit itie ies s are are in com compl plia ianc nce e with with IISO SO 105 10567 67..

Specification  6-22

DX220A-2/DX220LCA-2

 

A

B

Track Trac k Wi Widt dth h Boom Arm Bucket Counterweight

: 3. 3.0 0 m (9 (9'' 10 10") ") ST STD D Tr Trac ack k : 5.7 m (18' 8") : 2.4 m (7' 10") : Without Bucket : 4,100 kg (9,039 Ib)

Shoe

: 800 mm (32")

Dozer

: Without Dozer : Rating Over Front : Rating Over Side or 360 degree

Unit

Figure 19

: 1,000 kg (1,000 lb)

DS1703768

METRIC

1,000 kg

A (m)  B (m)

3

4.5

6

7.5

MAX. REACH

 

A (m)

7.5 6

* 5.30

4.71

* 5.55

5.24

5.61

* 5.12

3.77

6.82

4.5

* 6.79

* 6.79

* 5.70

4.56

4.66

3.17

4.61

3.13

7.54

3

* 8.37

6.53

* 6.37

4.32

4.57

3.09

4.19

2.82

7.92

1.5

9.56

6.07

6.19

4.10

4.47

2.99

4.06

2.72

8.00

0

9.34

5.88

6.04

3.96

4.40

2.93

4.17

2.78

7.80

-1.5

* 9.70

* 9.70

9.32

5.86

6.00

3.92

4.60

3.06

7.27

-3

* 11.37

* 11.37

* 8.47

5.98

6.11

4.02

* 5.59

3.75

6.36

* 5.68

* 5.68

* 5.02

* 5.02

4.83

-4.5

FEET

1,000 Ib

A (ft)

10

15

20

25

MAX. REACH

 

 B (ft)

A (ft)

25 20

* 11.69

10.39

* 12.24

11.56

18.39

* 11.28

8.31

22.38

15 10

* 14.98 * 18.44

* 14.98 14.39

* 12.57 * 14.05

10.05 9.53

10.27 10.08

6.98 6.81

10.16 9.24

6.91 6.23

24.75 26.00

5

21.08

13.39

13.65

9.04

9.85

6.59

8.95

5.99

26.26

0

20.58

12.96

13.31

8.73

9.70

6.45

9.20

6.13

25.57

-5

* 21.39

* 21.39

20.54

12.92

13.23

8.65

10.15

6.75

23.85

-10

* 25.06

* 25.06

* 18.68

13.18

13.46

8.86

* 12.32

8.26

20.86

* 12.53

* 12.53

* 11.07

* 11.07

15.84

-15

1.

Lo Load ad po poin intt is is the the en end d of of the the arm. arm.

2.

Capaci Capacities ties m mark arked ed with with an aster asterisk isk (*) (*) are are lim limite ited d by hydrau hydraulic lic c capac apaciti ities. es.

3.

Lift capaci capacities ties shown do not not exceed exceed 75% 75% of minimum minimum tipp tipping ing loads or 87% of hydraulic hydraulic capacities. capacities.

4.

Th The e lea least st stab stable le posi positi tion on is over over th the es sid ide. e.

5. 6.

Lift capac capacitie ities s appl apply y only to to the machin machine e as original originally ly man manufac ufacture tured d and normall normally y equipped equipped by the the manufact manufacturer. urer. Lift Lift cap capac acit itie ies s are are in com compl plia ianc nce e with with IISO SO 105 10567 67..

Specification  Specification  6-23

DX220A-2/DX220LCA-2

 

A

B

Track Trac k Wi Widt dth h Boom Arm Bucket Counterweight

: 2. 2.8 8 m (9 (9'' 2" 2")) ST STD D Tr Trac ack k : 5.7 m (18' 8") : 2.9 m (9' 6") : Without Bucket : 3,800 kg (8,378 Ib)

Shoe

: 600 mm (24")

Dozer

: Without Dozer : Rating Over Front : Rating Over Side or 360 degree

Unit

Figure 20

: 1,000 kg (1,000 lb)

DS1703769

METRIC

1,000 kg

A (m)

1.5

3

4.5

6

7.5

MAX. REACH

 

 B (m)

A (m)

7.5

* 4.66

4.51

* 4.05

* 4.05

6.20

6

* 4.81

4.51

* 3.76

3.17

7.31

4.5

* 5.27

4.33

4.41

2.98

* 3.70

2.66

7.99

3 1.5 0

6.23

* 5.99

4.07

4.29

2.87

3.60

2.40

8.35

9.03

5.70

5.81

3.81

4.16

2.75

3.48

2.30

8.42

* 5.70

* 5.70

8.70

5.41

5.61

3.63

4.06

2.66

3.56

2.33

8.23

* 9.82

* 9.82

8.62

5.34

5.53

3.56

4.04

2.63

3.87

2.53

7.74

* 10.59 * 10.59 * 12.38

10.42

8.70

5.41

5.58

3.60

4.62

3.02

6.88

* 9.38

* 9.38

* 6.84

5.66

* 5.20

4.29

5.51

-1.5

* 6.22

-3

* 7.72

* 6.22

-4.5

FEET

1,000 Ib

A (ft)

5

10

15

20

25

MAX. REACH

 

 B (ft)

A (ft)

25

* 10.26

9.93

* 8.92

* 8.92

20.33

20

* 10.61

9.93

* 8.29

6.98

23.97

15 10

* 17.02

* 11.61 13.74 * 13.20

9.54 8.96

9.73 9.46

6.58 6.33

* 8.16 7.95

5.85 5.28

26.21 27.39

5

19.91

12.56

12.81

8.40

9.17

6.06

7.68

5.06

27.64

0

* 12.56 * 12.56

19.18

11.93

12.37

8.00

8.95

5.86

7.85

5.14

26.99

-5

* 13.71 * 13.71 * 21.66 * 21.66

18.99

11.77

12.20

7.84

8.90

5.81

8.54

5.59

25.38

-10

* 23.34 * 23.34 * 27.29

19.19

11.94

12.31

7.94

10.19

6.67

22.59

* 20.68 * 20.68 * 15.09

12.48

* 11.46

9.46

18.07

-15

22.97

1.

Lo Load ad po poin intt is is the the en end d of of the the arm. arm.

2.

Capaci Capacities ties m mark arked ed with with an aster asterisk isk (*) (*) are are lim limite ited d by hydrau hydraulic lic c capac apaciti ities. es.

3.

Lift capaci capacities ties shown do not not exceed exceed 75% 75% of minimum minimum tipp tipping ing loads or 87% of hydraulic hydraulic capacities. capacities.

4.

Th The e lea least st stab stable le posi positi tion on is over over th the es sid ide. e.

5. 6.

Lift capac capacitie ities s appl apply y only to to the machin machine e as original originally ly man manufac ufacture tured d and normall normally y equipped equipped by the the manufact manufacturer. urer. Lift Lift cap capac acit itie ies s are are in com compl plia ianc nce e with with IISO SO 105 10567 67..

Specification  6-24

DX220A-2/DX220LCA-2

 

A

B

Track Trac k Wi Widt dth h Boom Arm Bucket Counterweight

: 3. 3.0 0 m (9 (9'' 10 10") ") ST STD D Tr Trac ack k : 5.7 m (18' 8") : 2.9 m (9' 6") : Without Bucket : 3,800 kg (8,378 Ib)

Shoe

: 800 mm (32")

Dozer

: Without Dozer : Rating Over Front : Rating Over Side or 360 degree

Unit

Figure 21

: 1,000 kg (1,000 lb)

DS1703770

METRIC

1,000 kg

A (m)

1.5

3

4.5

6

7.5

MAX. REACH

 

 B (m)

A (m)

7.5

* 4.66

4.61

* 4.05

* 4.05

6.20

6

* 4.81

4.61

* 3.76

3.25

7.31

4.5

* 5.27

4.43

4.53

3.06

* 3.70

2.73

7.99

3

* 7.72

6.38

* 5.99

4.17

4.41

2.95

3.71

2.46

8.35

1.5

* 9.15

5 5..85

5.97

3.91

4.28

2.83

3.59

2.36

8.42

0

* 5.70

* 5.70

8.95

5.56

5.78

3.73

4.18

2.73

3.67

2.40

8.23

* 9.82

* 9.82

8.86

5.49

5.70

3.66

4.16

2.71

3.99

2.61

7.74

* 10.59 * 10.59 * 12.38

10.69

* 8.88

5.56

5.75

3.71

4.76

3.11

6.88

* 9.38

* 9.38

* 6.84

5.81

* 5.20

4.40

5.51

-1.5

* 6.22

-3

* 6.22

-4.5

FEET

1,000 Ib

A (ft)

5

10

15

20

25

MAX. REACH

 

 B (ft)

A (ft)

25

* 10.26

1 10 0.16

* 8.92

* 8.92

20.33

20

* 10.61

1 10 0.16

* 8.29

7.16

2 23 3.97

15 10

* 17.02

* 11.61 14.07 * 13.20

9.77 9.19

10.00 9.73

6.75 6.51

* 8.16 8.18

6 6..01 5.43

26.21 27.39

5

* 20.17

12.89

13.17

8.62

9.44

6.23

7.92

5.21

27.64

0

* 12.56 * 12.56

19.73

12.26

12.73

8.23

9.22

6.03

8.09

5.30

26.99

-5

* 13.71 * 13.71 * 21.66 * 21.66

19.54

12.10

12.56

8.07

9.17

5.98

8.80

5.75

25.38

-10

* 23.34 * 23.34 * 27.29

23.57 * 19.58

12.26

12.67

8.17

10.49

6.86

22.59

* 20.68 * 20.68 * 15.09

12.81

* 11.46

9.71

18.07

-15

1.

Lo Load ad po poin intt is is the the en end d of of the the arm. arm.

2.

Capaci Capacities ties m mark arked ed with with an aster asterisk isk (*) (*) are are lim limite ited d by hydrau hydraulic lic c capac apaciti ities. es.

3.

Lift capaci capacities ties shown do not not exceed exceed 75% 75% of minimum minimum tipp tipping ing loads or 87% of hydraulic hydraulic capacities. capacities.

4.

Th The e lea least st stab stable le posi positi tion on is over over th the es sid ide. e.

5. 6.

Lift capac capacitie ities s appl apply y only to to the machin machine e as original originally ly man manufac ufacture tured d and normall normally y equipped equipped by the the manufact manufacturer. urer. Lift Lift cap capac acit itie ies s are are in com compl plia ianc nce e with with IISO SO 105 10567 67..

Specification  Specification  6-25

DX220A-2/DX220LCA-2

 

A

B

Track Trac k Wi Widt dth h Boom Arm Bucket Counterweight

: 2. 2.8 8 m (9 (9'' 2" 2")) ST STD D Tr Trac ack k : 5.7 m (18' 8") : 2.9 m (9' 6") : Without Bucket : 4,100 kg (9,039 Ib)

Shoe

: 600 mm (24")

Dozer

: Without Dozer : Rating Over Front : Rating Over Side or 360 degree

Unit

Figure 22

: 1,000 kg (1,000 lb)

DS1703771

METRIC

1,000 kg

A (m)

1.5

3

4.5

6

7.5

MAX. REACH

 

 B (m)

A (m)

7.5

* 4.66

* 4.66

* 4.05

* 4.05

6.20

6

* 4.81

4.68

* 3.76

3.30

7.31

4.5

* 5.27

4.50

4.57

3.11

* 3.70

2.78

7.99

3

* 7.72

6.48

* 5.99

4.24

4.45

3.00

3.74

2.51

8.35

1.5

* 9.15

5 5..95

6.02

3.98

4.32

2.88

3.62

2.41

8.42

0

* 5.70

* 5.70

9.02

5.66

5.82

3.80

4.22

2.79

3.70

2.45

8.23

* 9.82

* 9.82

8.94

5.59

5.74

3.73

4.19

2.76

4.03

2.66

7.74

* 10.59 * 10.59 * 12.38

10.88

* 8.88

5.66

5.80

3.78

4.80

3.17

6.88

* 9.38

* 9.38

* 6.84

5.91

* 5.20

4.48

5.51

-1.5

* 6.22

-3

* 6.22

-4.5

FEET

1,000 Ib

A (ft)

5

10

15

20

25

MAX. REACH

 

 B (ft)

A (ft)

25

* 10.26 * 10.26

* 8.92

* 8.92

20.33

20

* 10.61

1 10 0.31

* 8.29

7.28

2 23 3.97

15 10

* 17.02

* 11.61 14.29 * 13.20

9.92 9.34

10.07 9.81

6.87 6.62

* 8.16 8.25

6 6..12 5.54

26.21 27.39

5

* 20.17

13.11

13.27

8.77

9.52

6.35

7.98

5.31

27.64

0

* 12.56 * 12.56

19.89

12.48

12.84

8.38

9.30

6.14

8.16

5.40

26.99

-5

* 13.71 * 13.71 * 21.66 * 21.66

19.70

12.32

12.66

8.22

9.25

6.10

8.88

5.86

25.38

-10

* 23.34 * 23.34 * 27.29

23.98 * 19.58

12.49

12.78

8.32

10.58

6.99

22.59

* 20.68 * 20.68 * 15.09

13.03

* 11.46

9.88

18.07

-15

1.

Lo Load ad po poin intt is is the the en end d of of the the arm. arm.

2.

Capaci Capacities ties m mark arked ed with with an aster asterisk isk (*) (*) are are lim limite ited d by hydrau hydraulic lic c capac apaciti ities. es.

3.

Lift capaci capacities ties shown do not not exceed exceed 75% 75% of minimum minimum tipp tipping ing loads or 87% of hydraulic hydraulic capacities. capacities.

4.

Th The e lea least st stab stable le posi positi tion on is over over th the es sid ide. e.

5. 6.

Lift capac capacitie ities s appl apply y only to to the machin machine e as original originally ly man manufac ufacture tured d and normall normally y equipped equipped by the the manufact manufacturer. urer. Lift Lift cap capac acit itie ies s are are in com compl plia ianc nce e with with IISO SO 105 10567 67..

Specification  6-26

DX220A-2/DX220LCA-2

 

A

B

Track Trac k Wi Widt dth h Boom Arm Bucket Counterweight

: 3. 3.0 0 m (9 (9'' 10 10") ") ST STD D Tr Trac ack k : 5.7 m (18' 8") : 2.9 m (9' 6") : Without Bucket : 4,100 kg (9,039 Ib)

Shoe

: 800 mm (32")

Dozer

: Without Dozer : Rating Over Front : Rating Over Side or 360 degree

Unit

Figure 23

: 1,000 kg (1,000 lb)

DS1703772

METRIC

1,000 kg

A (m)

1.5

3

4.5

6

7.5

MAX. REACH

 

 B (m)

A (m)

7.5

* 4.66

* 4.66

* 4.05

* 4.05

6.20

6

* 4.81

4.78

* 3.76

3.38

7.31

4.5

* 5.27

4.60

4.69

3.19

* 3.70

2.85

7.99

3

* 7.72

6.63

* 5.99

4.34

4.57

3.08

* 3.80

2.58

8.35

1.5

* 9.15

6 6..10

6.18

4.08

4.44

2.96

3.73

2.48

8.42

0

* 5.70

* 5.70

9.27

5.81

5.99

3.90

4.34

2.87

3.81

2.52

8.23

* 9.82

* 9.82

9.19

5.74

5.91

3.83

4.32

2.84

4.14

2.74

7.74

* 10.59 * 10.59 * 12.38

11.15

* 8.88

5.81

5.96

3.88

4.94

3.26

6.88

* 9.38

* 9.38

* 6.84

6.06

* 5.20

4.59

5.51

-1.5

* 6.22

-3

* 6.22

-4.5

FEET

1,000 Ib

A (ft)

10

15

20

25

MAX. REACH

 

 B (ft)

A (ft)

25

* 10.26 * 10.26

* 8.92

* 8.92

20.33

20

* 10.61

1 10 0.54

* 8.29

7.46

2 23 3.97

15 10

* 17.02

* 11.61 14.62 * 13.20

10.15 9.57

10.34 10.08

7.04 6.79

* 8.16 * 8.37

6.28 5.69

26.21 27.39

5

* 20.17

13.44

13.64

9.00

9.79

6.52

8.22

5.46

27.64

0

* 12.56 * 12.56

20.44

12.81

13.20

8.61

9.57

6.32

8.40

5.55

26.99

-5

* 13.71 * 13.71 * 21.66 * 21.66

20.26

12.65

13.03

8.45

9.52

6.27

9.13

6.03

25.38

-10

* 23.34 * 23.34 * 27.29

24.58 * 19.58

12.82

13.14

8.55

10.88

7.18

22.59

* 20.68 * 20.68 * 15.09

13.36

* 11.46

10.13

18.07

-15

1.

5

Lo Load ad po poin intt is is the the en end d of of the the arm. arm.

2.

Capaci Capacities ties m mark arked ed with with an aster asterisk isk ( ) are are lim limite ited d by hydrau hydraulic lic c capac apaciti ities. es.

3.

Lift capaci capacities ties shown do not not exceed exceed 75% 75% of minimum minimum tipp tipping ing loads or 87% of hydraulic hydraulic capacities. capacities.

4.

Th The e lea least st stab stable le posi positi tion on is over over th the es sid ide. e.

5. 6.

Lift capac capacitie ities s appl apply y only to to the machin machine e as original originally ly man manufac ufacture tured d and normall normally y equipped equipped by the the manufact manufacturer. urer. Lift Lift cap capac acit itie ies s are are in com compl plia ianc nce e with with IISO SO 105 10567 67..

Specification  Specification  6-27

DX220A-2/DX220LCA-2

 

APPROXIMATE WEIGHT OF WORKLOAD MATERIALS IMPORTANT Weights are approximations of estimated average volume and mass. Exposure to rain, snow or groundwater; settling or compaction because of overhead weight and chemical or industrial processing or changes because of thermal or chemical transformations could all increase value of weights listed in table. Density 1,200 kg/m3  (2,000 lb/yd3), or less

Density 1,500 kg/m3  (2,500 lb/yd3), or less

Density 1,800 kg/m3  (3,000 lb/yd3), or less

Density 2,100 kg/m3  (3,500 lb/yd3), or less

Charcoal

401 kg/m3 (695 lb/yd3)

-

-

-

Coke, blast furnace size

433 kg/m3 (729 lb/yd3)

-

-

-

Coke, foundry size

449 kg/m3 (756 lb/yd3)

-

-

-

Coal, bituminous slack, piled

801 kg/m3 (1,350 lb/yd3)

-

-

-

Coal, bituminous r. of m., piled

881 kg/m3 (1,485 lb/yd3)

-

-

-

Coal, anthracite

897 kg/m3 (1,512 lb/yd3)

-

-

-

Clay, DRY, in broken lumps

1,009 kg/m3 (1,701 lb/yd3)

-

-

-

 Material

3

Clay, DAMP, natural bed

-

-

1,746 kg/m (2,943 lb/yd3)

-

Cement, portland, DRY granular

-

-

1,506 kg/m3 (2,583 lb/yd3)

-

Cement, portland, DRY clinkers

-

1,362 kg/m3 (2,295 lb/yd3)

-

-

Dolomite, crushed

-

-

1,522 kg/m3 (2,565 lb/yd3)

-

Earth, loamy, DRY, loose

-

-

-

1,202 kg/m3

(2,025 lb/yd3) Earth, DRY, packed

Earth, WET, muddy Gypsum, calcined, (heated, powder)

-

1,522 kg/m3 (2,565 lb/yd3)

-

-

-

1,762 kg/m3 (2,970 lb/yd3)

961 kg/m3 (1,620 lb/yd3)

-

-

Specification  6-28

-

-

DX220A-2/DX220LCA-2

 

 Material

Gypsum, crushed to 3 inch size

Density 1,200 kg/m3  (2,000 lb/yd3), or less

Density 1,500 kg/m3  (2,500 lb/yd3), or less

Density 1,800 kg/m3  (3,000 lb/yd3), or less

Density 2,100 kg/m3  (3,500 lb/yd3), or less

-

-

1,522 kg/m3 (2,565 lb/yd3)

1,810 kg/m3 (3,051 lb/yd3) 1,922 kg/m3 (3,240 lb/yd3)

Gravel, DRY, packed fragments

-

-

-

Gravel, WET, packed fragments

-

-

-

Limestone, graded above 2

-

1,282 kg/m3 (2,160 lb/yd3)

-

-

Limestone, graded 1-1/2 or 2

-

1,362 kg/m3 (2,295 lb/yd3)

-

-

Limestone, crushed

-

-

1,522 kg/m3 (2,565 lb/yd3)

-

Limestone, fine

-

-

1,602 kg/m3 (2,705 lb/yd3)

-

Phosphate, rock

-

-

-

1,282 kg/m3 3

(2,160 lb/yd ) 3

929 kg/m (1,566 lb/yd3)

-

-

-

Snow, light density

529 kg/m3 (891 lb/yd3)

-

-

-

Sand, DRY, loose

-

-

1,522 kg/m3 (2,565 lb/yd3)

-

Sand, WET, packed

-

-

-

1,922 kg/m3 (3,240 lb/yd3)

Shale, broken

-

1,362 kg/m3 (2,295 lb/yd3)

-

-

-

-

-

Salt

Sulfur, broken

529 kg/m3 3

(891 lb/yd )

DX220A-2/DX220LCA-2

 

Specification  Specification  6-29

Specification  6-30

DX220A-2/DX220LCA-2

 

1Index Numerics 1,000 Hour / 6 Month Service 4-47 10 Hour / Daily Service  4-17 12,000 Hour / 6 Year Service 4-62 2,000 Hour / Yearly Service 4-56 250 Hour / Monthly Service 4-31 4,000 Hour / Biennial Service 4-61 50 Hour / Weekly Service  4-28 500 Hour / 3 Month Service 4-37

A

Booster Cable 3-9 Breaker Button 2-14 Breaker Operating Precautions 3-38 Breaker Symbol 2-23 Bucket 4-72 O-ring 4-73 Teeth and Side Cutters 4-24 Tooth 4-72 Bucket Replacement and Reversal 3-34 Burn Prevention 1-49

Accumulator 1-55 Additional Water Separator 4-33 Adjust Valve Clearance Air Intake System 4-25 4-60 Outer Element of Air Cleaner 4-42 Replace Outer Air Cleaner Element 4-56 Air-Conditioning Inner Filter 4-53 Alternator and Starter 4-60 Antifreeze Concentration Tables 4-80 Antivibration Shock Mounts 4-60 Arm and Bucket Joint Pins 4-28 Asbestos Information 1-69 Attachment 1-40 Attachments 3-34 Auto Idle Button 2-15 Auto Idle Mode 3-22 Auto Idle Symbol 2-22

C

Auxiliary Mode Switch 2-11 Avoid Mixing Lubricants 4-2

Cleaning  1-31, 1-47 System Warm-up  3-12 Cold Weather Hydraulic Cold Weather Starting 3-8 Component Locations 2-2 Compressed Air 1-55 Coolant and Water for Dilution 4-10 Coolant Temperature Warning Light Symbol 2-20 Cooling System Clean Radiator, Oil Cooler and Air Conditioner Condenser Coil 4-41 Engine 4-78

B Batteries 4-36 Battery 1-58, 4-74 Box Door 2-40 Electrolyte Level 4-75 Terminals 4-75 Battery Disconnection 1-10

Cabin Light 2-31 Cabin Storage Compartments 2-38 Cabin Work Light Switch 2-13 Ceiling Cover 2-37 Change Main Fuel Filter 4-45 Change of Water Separator & Pre Fuel Filter (Fuel Prefilter) 4-44 Charge Warning Symbol 2-20 Check Additional Water Separator  4-20 Check and Confirmation After Stopping Engine 3-14 Check Drained Oil and Used Filter 4-1 Check Water Separator & Pre Fuel Filter (Fuel Prefilter) and Drain Water as Required 4-21 Checks After Inspection and Maintenance Works 4 4-3 3 Checks Before Starting Engine 3-4 Circuit Breaker (60A) 2-31

Battery Explosion 1-10 Battery Hazard Prevention 1-58 Before Engine Starting 1-28 Before Storage 3-49 Bolt and Nut Inspection  4-64 Boom and Arm Joint Pins  4-31 Boost Starting or Charging Engine Batteries 1-33

Engine Coolant Temperature Warning Light 2-20 Oil Cooler Dust Net 4-23 Radiator Coolant 4-57 Refill Cooling System 4-23 Correction of Machine Problems 1-19 Counterweight 5-2 Cracks and Faulty Welds 4-25

Index   Index

DX220A-2/DX220LCA-2

7-1

 

Crush Hazard 1-11 Crushing and Cutting 1-19 Cup Holder 2-39 Cycle Time Tests 4-60

D Deep Digging 1-60 Description of Lubrication and Service Chart 4-13 Digging Under an Overhang 1-60 Disassembling Precautions 1-47 Display Monitor 2-15 Display Warning Symbols 2-19 Disposal of Hazardous Materials 1-70 Do not Drop Things Inside Machine 4-2 Door Side Latch 2-38 Door Window Holder 2-39 DOOSAN Genuine Lubricants 4-1 DOOSAN Genuine Replacement Parts 4-1 Drop-off or Edge 1-61 Dusty Work Site 4-2

E ECO Mode Symbol 2-22 Electric Welding Attention 1-14 Electrical System 4-74 Electrical System and Electrical Shock 1-25 Emergency Exit 1-12 Emergency Exit from Operator's Station 1-25 Engine Adjust Valve Clearance 4-60 Check and Adjust Engine 4-53 Coolant Temperature Gauge 2-18 Coolant Temperature Warning Light 2-20 Cover 2-40 Fan Belt 4-35, 4-36 Head Bolt Torques 4-60 Oil and Filter 4-38 Oil Level 4-17 Shutdown 3-13 Speed Control Dial 2-11 Start 3-6 Start and Stop 3-2 Engine Oil Pressure Warning Symbol  2-20 Engine Preheat Symbol 2-22 Engine Stop 1-41 Entanglement in Rotating Parts 1-9 Entering/Leaving/Climbing the Machine 4-7

F Fall Hazard 1-12 Falling Object 1-13 Fan Belt 4-30 Fire and Explosion Prevention 1-21, 1-48 Fire Extinguisher and First-aid Kit (Emergency Medical Kit) 1-24 Flying Debris or Objects 1-11 Flying or Falling Objects 1-18 Fresh and Clean Lubricants 4-1 Front End Attachments 4-36 Fuel Change Fuel Cap Filter 4-54 Filter 4-45 Gauge 2-18 Level 4-19 System 4-45 Tank Drain Valve 4-29 Fuel Shortage Warning Symbol 2-21 Fuel Strainer 4-1 Fuse Boxes  2-32, 4-76 Fuses 4-76 Fusible Link 2-32 Identification 4-77

G Gauges Engine Coolant Temperature Gauge 2-18 Fuel Gauge 2-18 General 1-16 General Hazard 1-8 General Venting 4-85

H Handling Excavator  3-1 Handling a ofNew Accumulator  4-81 Hanger 2-39 Head Bolt Torques 4-60 Headlight Switch 2-13 Heater and Air Conditioner 2-24 Additional Operating Instruction 2-29 Control Panel 2-11, 2-25 Filter 4-39, 4-52 Location of Controls and Vents 2-24 Memory Function of Used Mode 2-29

Environment and Circumstances 1-60 Equipment Lowering with Engine Stopped 1-40 Escaping from Mud 3-31 Excavator Rated Lift Capacity Tables 6-10

System 4-63 High-pressure Lines, Tubes and Hoses 1-57 High-voltage Cables 1-62 Horn Button 2-14

Exhaust Ventilation 1-68

Hose Clamps 4-36 Hot Coolant and Oils- Burn Prevention 1-20 Hot Pressurized Fluid 1-9

Index 

DX220A-2/DX220LCA-2

7-2

 

Hot Surface 1-12 Hydraulic Attachments (Optional) 3-37 Hydraulic Breaker 1-13 Hydraulic Hose Installation 4-3 Hydraulic Oil Check (Optional) 1-15 Hydraulic System General Venting 4-85 Hydraulic Breaker Hydraulic Hoses and Tubing 3-37 Oil and Filter 3-41 Selection 3-37 Hydraulic Cylinders 4-84 Hydraulic Oil Exchange 4-58 Hydraulic Oil Return Filter 4-36, 4-48 Hydraulic Oil Tank 4-18 Leaks in the Hydraulic System 4-19 Main System Pump 4-84 Oil Exchange 4-58 Swing Motor 4-85 Warm-up 3-11 Hydraulic System - Air Bleeding  4-3

Long Term Storage 3-49, 4-86 Loose or Soft Ground 1-61 Lubrication and Service Chart 4-12

M Machine Condition 1-28 Machine Setup Position for Maintenance 4-5 Magnetic Clutch 4-63 Maintenance Handling Access 4-7 Maintenance in Special Conditions 4-88 Maintenance Information 4-1 Maintenance Intervals 4-15 Miscellaneous Access Doors 2-40 Mode Selection 3-21 Mounting/Dismounting 1-30

N Nuts and Bolts 4-36

O Obey State and Local Over-the-Road Regulations

1-26 IIndicator Lights

L

Oil Cooler Dust Net 4-23 Oil Level of Travel Reducer 4-46 Operating Controls 2-1 Instructions 3-21 Precautions 3-25 Operation 3-1 Operation at High Altitudes 1-68 Operation During Electrical Storms 1-68, Operation In Extreme Cold 3-44 Extreme Heat 3-45 High Altitudes 3-48 Rainy or Humid Conditions  3-47

LCD Control Button 2-19 LCD Information Area 2-19 Leaks in the Fuel System 4-20 Leaks in the Hydraulic System 4-19 Levers Adjusting Reclining 2-33, 2-35 Adjusting the Seat Forward 2-33, Adjusting the Seat's Angle 2-34 Safety Lever 2-16 Lift/Tie down 1-13 Lifting and Digging 1-37

Salt Water Areas 3-48 Operation In Dusty and Sandy Areas 1-66 Operation In Extreme Cold 1-64 Operation in Extreme Conditions 1-64 Operation in Extreme Heat 1-65 Operation in Rainy or Humid Conditions 1-67 Operation in Saltwater Areas 1-67 Operation of All Switches 4-25 Operation on Slopes 1-38 Operation Under Unusual Conditions 3-44 Operational Controls and Panels 2-8

Coolant Temperature Warning Light 2-20 Information and Location for Safety Decals 1-6 Inspection, Maintenance and Adjustment 4-1 Installation 5-4 Instrument Panel 2-17 ISO Control Pattern 1-12

K Keep Bystanders Away 1-9 Know Your Machine 1-16

2-34

3-48

Lifting Machine 5-8 Lifting Objects 3-42 Lights Cabin 2-31

Operational Hour Meter Reading 4-1 Operator Station 1-31 Operator's Area 2-6 Operator's Compartment Light 2-31

Loading and Unloading 1-26 Lock Inspection Covers 1-54 Locking the Inspection Covers 4-2

Other Signal Words 1-3 Outer Air Cleaner Element 4-56 Outer Element of Air Cleaner 4-42

Index   Index

DX220A-2/DX220LCA-2

7-3

 

Overall Dimensions 6-2

P Panels Air Conditioner Control Panel 2-11 Heater and Air Conditioner 2-24 Heater and Air Conditioner Control Panel 2-25 Instrument Panel 2-17 Parking Excavator 3-32 Parking Machine 1-41 Personal Protective Equipment (PPE) 1-19 Photo Sensor 2-12 Pilot Cutoff Switch 2-31, 4-26 Pilot Filter 4-36, 4-49 Pins and Bushings 4-36 Poor Visibility 1-61 Power Mode 3-21 Power Mode Button 2-15 Power Mode Symbol 2-22 Power Socket 2-12 Preservation/Storing Machine 1-42 Pressurized Fluids 1-17 Pressurized Fluid 1-47  1-11 Proper ToolsGas andand Clothing Proper Work Tools and Attachments 1-17 Protecting Cabin from Flying Objects (Optional) 1-25

R Radiator Coolant 4-57 Refill Cooling System 4-23 Removal 5-3 Replacement 3-34 Reversal (If Applicable) 3-36 Rotating Fan 1-10 Rubber and Plastics 1-51 Rubber That Contains Fluorides 1-50

S Safe Operation is Operator's Responsibility 1-16 Safety 1-1 Safety Decals 1-4 Safety Decals With Text 1-4 Safety Decals Without Text (No-Text)  1-5 Safety Lever 2-16, 3-15 Safety Precautions 4-4 Seat 2-33

3-14 Parking Excavator 3-32 Stopping Engine 3-13 Side Door 2-40 Silica Dust Information 1-69 Sound 1-70 Specification 6-1 Standard Specification 6-1 Starting Engine 1-34 Starting Engine Using a Booster Battery 3-9 Start-up Cold Weather Hydraulic System Warm-up 3-12 Cold Weather Starting 3-8 Engine Start 3-6 Hydraulic System Warm-up 3-11 Inspection Before Starting Engine 3-2 Operational Checks Before Starting Engine  3-5 Starting Engine Using a Booster Battery 3-9 Stereo 2-30 Structural Damage 4-60 Suction Strainer 4-58 Supports and Blocking for Work Equipment 1-56 Swing Bearing 4-29 Gear and Pinion 4-37 Motor 4-85 Reduction Device 4-22, 4-46, 4-47, 4-51 Swinging or Traveling 1-35 Switches Automatic Travel Speed Control 3-16 Auxiliary Mode 2-11 Cabin Work Light Switch 2-13 Engine Speed Control 3-21 Engine Speed Control Dial 2-11 Headlight Switch 2-13 Horn Button 2-14 Pilot Cutoff Switch 2-31 Power Socket 2-12 Starter Switch 2-10 Travel Speed Selector Switch  2-12 Symbols Air Cleaner Clogged Warning Symbol 2-21 Hydraulic Oil Overheat Warning Symbol 2-21

T Table of Recommended Lubricants 4-8 Tie down 1-14

Seat Adjustment Adjusting Reclining 2-33, 2-35 Adjusting the Seat Forward 2-33, 2-34 Adjusting the Seat's Angle 2-34 Seat Adjustment (Suspension Seat - Optional) 2-34 Seat Belt 1-32, 2-36, 4-25 Shutdown Check and Confirmation After Stopping Engine

Towing 1-39 Towing Procedure 3-33 Track Assemblies 4-30 Track on One Side Stuck 3-31 Track Tension 4-82 Track Tension Adjustments 1-56 Tracks on Both Sides Stuck  3-31

Index 

DX220A-2/DX220LCA-2

7-4

 

Transportation 5-1 Transporting Machine 1-27 Travel 3-16 Control Lever Operation 3-17 Instructions 3-18 Reduction Device 4-46, 4-50 Speed Selector Switch 2-12 Travel High Speed Symbol  2-23

Removal 1-53, 5-2 Warning Tag 1-46 Warning Tag - "Do Not Operate" 1-9 Water In Fuel Warning Symbol 2-21 Water Separator 4-21 Weight of Workload Materials 6-28 Welding Instructions 4-2 Welding Repairs 1-52

Vibration 1-71

Window Washer Liquid 4-24 Windows Door Window Holder 2-39 Windshield Washer Fluid 4-1 Wiper Control Switch 2-13 Work Lever 1-15 Work Levers (Joysticks) (ISO Pattern)  3-24 Work Mode and Breaker Operation 3-23 Work Mode Select Button 2-14 Work Site 1-29 Work Site Areas Requiring Extra Caution  1-60 Work Site Rules 1-33 Working in Contaminated Environment 1-63 Working in Water 1-63, 3-31 Working on Machine 1-54 Working Range 6-8

W

Y

U Ultra Low Sulfur Diesel Fuell (Optional) 1-14 Underground Operation 1-63 Unloading and Loading 5-2 Use of Lighting 1-47

V Ventilation for Enclosed Area 1-68 Venting and Priming Hydraulic System 4-84 General Venting 4-85 Hydraulic Cylinders 4-84 Main System Pump 4-84 Swing Motor 4-85

Walk around Checks 3-2 Warning for Counterweight and Front Attachment

Your Machine Serial Numbers 0-4

DX220A-2/DX220LCA-2

Index   Index 7-5