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1. After the new machine has operated for 250 hours, replace the fuel filter and the secondary fuel filter. Check the engine valve clearance to ensure proper operation and prevent potential damage.
2. Daily maintenance tasks include checking, cleaning, or replacing the air filter to maintain airflow efficiency. Clean the inside of the cooling system to remove debris and prevent overheating. Inspect and tighten the track plate bolts, check and adjust the track tension for stability, and verify the intake heater is functioning. Replace worn-out teeth, adjust the bucket clearance, check the front window washer fluid level, and inspect and adjust the air conditioning system. Keep the cab floor clean and replace the breaker filter if needed.
When cleaning the cooling system, always wait until the engine is fully cooled before opening the water inlet cover to release pressure. Never perform this task while the engine is running, as the high-speed fan can cause serious injury. Always park the machine on a flat surface during maintenance. Replace the coolant and corrosion inhibitor according to the recommended ratio specified in Table 4.
Coolant Type | Cleaning & Replacement Cycle | Anti-Corrosion Replacement Cycle
AF-ACL (Super Antifreeze) | Every 2 years or 4000 hours | Every 1000 hours or when changing coolant
AF-PTL (Long-Acting Antifreeze) | Every 1 year or 2000 hours | -
AF-PT (Winter Type) | Every 6 months (added only in autumn) | -
Table 4: Antifreeze to Water Mixing Ratio
Ambient Temperature (°C) | Capacity (L) | PC200 | PC220 | Water PC200 | Water PC220
-5 | 5.1 | 6.7 | 8.0 | 9.1 | 10.2 | 11.10
-10 | 5.4 | 7.0 | 8.4 | 9.6 | 10.7 | 11.65
-15 | 17.1 | 15.5 | 14.2 | 13.1 | 12.0 | 11.10
-20 | 17.9 | 16.3 | 14.9 | 13.7 | 12.6 | 11.65
3. Before starting the engine, check the coolant level and add water if necessary. Ensure the engine oil level is adequate and top it up. Check the fuel tank and fill it if needed. Verify the hydraulic oil level and add more if required. Inspect the air filter for blockages, check the wiring, test the horn, and ensure the bucket is properly lubricated. Check for water and sediment in the water separator.
4. Every 100 hours of maintenance includes checking and lubricating key components such as the boom cylinder head pin, boom pin, arm cylinder rod end, and other critical joints. Also, check the oil level in the swing mechanism box and drain any water or sediment from the fuel tank.
5. Every 250 hours of maintenance involves checking the final gearbox oil level and adding gear oil if necessary. Check the battery electrolyte, replace the engine oil and filter, lubricate the slewing ring, and adjust the tension of the fan and air conditioner belts.
6. Every 500 hours of maintenance includes all previous tasks and adds replacing the fuel filter, checking and greasing the rotary pinion, cleaning the radiator and oil cooler fins, replacing the hydraulic oil filter element, and cleaning the air filter inside the air conditioning system.
7. Every 1000 hours of maintenance includes all prior tasks, plus replacing the oil in the swing mechanism box, checking the damper housing oil level, inspecting the turbocharger, checking the generator belt tension, and replacing the anti-corrosion filter.
8. Every 2000 hours of maintenance includes all previous checks and adds cleaning the hydraulic tank filter, inspecting the turbocharger, testing the generator and starter motor, adjusting the engine valve clearance, and checking the shock absorber.
9. For maintenance above 4000 hours, increase inspection frequency for the pump and consider replacing the hydraulic oil every 5000 hours to ensure optimal performance.
10. For long-term storage, place the working device on the ground to prevent piston rod rust. Wash and dry the machine, store it indoors in a dry location. If outdoor storage is unavoidable, park on a well-drained concrete surface. Fill the fuel tank, lubricate all parts, replace hydraulic and engine oil, apply grease to exposed metal surfaces, and disconnect the battery. Add antifreeze to the cooling system based on the minimum ambient temperature. Start the engine monthly to lubricate moving parts and charge the battery. Run the air conditioning and cooling system for 5–10 minutes to keep components in good condition.