Develon DX800LC-7 Crawler Excavator Operation and Maintenance Manual (950106-02241GE) (1000 and Up)
Big DX800 like this usually lives in rough spots—quarries, big demo jobs, deep trench work—running long days in dust, mud, and cold starts. This operation and maintenance manual keeps you on a steady rhythm: what to check at startup, what to inspect weekly, what to service before the busy season so the machine doesn’t quit when trucks are lined up. Picture a night shift: you trace a small hydraulic seep, check the book, and it walks you through how to verify the source, decide if you can run, and plan the repair instead of guessing.
Applications & Use Cases
- Set up a daily walk‑around so you trace leaks, inspect track tension, and check fluid levels before a minor issue turns into downtime.
- Plan 250/500‑hour services so you don’t skip filters, miss grease points, or forget to bleed air after fuel work.
- Use it to isolate odd behaviors—slow boom, noisy swing—so you can test likely causes in order instead of throwing parts at it.
- Train new operators on how to start, warm up, and shut down properly, so they don’t abuse the hydraulics or misroute hoses during quick fixes.
- Before peak season, run through the periodic checklists to verify cooling, align attachments, and make sure the machine stays predictable under heavy load.
FAQ
Q: Is this a PDF I can search on a laptop or tablet?
A: Yes, it’s typically a searchable PDF, so you can jump to what you need by keyword instead of flipping through pages.
Q: Can I print just the sections I use in the field?
A: You usually can; most folks print the maintenance schedules and lube charts, stick them in a binder, and keep the full file on a computer.
Safety Note
Always relieve hydraulic pressure and properly support any raised attachment before you get your hands near lines, pins, or linkage.
Develon DX800LC-7 Crawler Excavator Index:
- DX800LC-7
- Revision
- Table of Contents
- Foreword
- Intended Use
- Engine and Emission Control System Maintenance
- Machine Capacity
- Attachments
- California Proposition 65
- Product Identification Number (PIN)
- Component Serial Numbers
- Engine Identification
- Machine Serial Numbers
- Safety Messages
- EC Declaration of Conformity
- UK DECLARATION OF CONFORMITY
- Regulation (EU) 2017/654 Annex XV
- Engine Operation and Maintenance
- Malfunctions & Inducement
- DEVELON Fleet Management System General Information and Privacy Notice
- Safety
- Safety Decals
- Safety Decals – Information and Location
- General
- Operator’s Responsibility – Safe Operation
- Know Your Machine
- Proper Work Tools and Attachments
- Pressurized Fluids
- Flying or Falling Objects
- Personal Protective Equipment (PPE)
- Correction of Machine Problems
- Crushing and Cutting
- Hot Coolant and Oils – Burn Prevention
- Fire and Explosion Prevention
- Fire Extinguisher and First-aid Kit (Emergency Medical Kit)
- Electrical System and Electrical Shock
- Roll-over Protective Structure (ROPS)
- Regulation 8.35(2) of the Mines Safety and Inspection Regulations (1995)
- Transportation
- Obey State and Local Over-the-Road Regulations
- Loading and Unloading
- Transporting Machine
- Operation
- Before Engine Starting
- Work Site
- Mounting/Dismounting
- Cleaning
- Operator Station
- Seat Belt
- Visibility Information
- Boost Starting or Charging Engine Batteries
- Starting Engine
- Swinging or Traveling
- Lifting and Digging
- Operation on Slopes
- Towing
- Attachment
- Equipment Lowering with Engine Stopped
- Engine Stop
- Parking Machine
- Long Term Storage
- Before Storage
- During Storage
- After Storage
- Maintenance
- Warning Tag
- Cleaning
- Proper Tools and Clothing
- Disassembling Precautions
- Use of Lighting
- Fire and Explosion Prevention
- Burn Prevention
- Rubber That Contains Fluorides
- Rubber and Plastics
- Welding Repairs
- Warning for Counterweight and Front Attachment Removal
- Lock Inspection Covers
- Working on Machine
- Accumulator
- Compressed Air
- Track Tension Adjustments
- Supports and Blocking for Work Equipment
- High-pressure Lines, Tubes and Hoses
- Battery
- Environment and Circumstances
- Work Site Areas Requiring Extra Caution
- High-voltage Cables
- Underground Operation
- Working in Water
- Working in Contaminated Environment
- Operation in Extreme Conditions
- Exhaust Ventilation
- Asbestos Information
- Silica Dust Information
- Disposal of Hazardous Materials
- Sound
- Vibration Information
- Operating Controls
- Component Locations
- Operator’s Area
- Operational Controls and Panels
- 1. Starter Switch
- 1-1. Start/Stop Button
- 2. Smart Key
- 3. Air Conditioning and Heating Control Panel
- 4. 12V Power Socket
- 5. 24V Power Socket
- 6. USB Charger
- 7. Bluetooth Control Panel
- 8. Wiper Control Panel
- 9. Engine Speed Control Dial
- 10. After Treatment System Switch
- 11. Light Switch
- 12. Travel Speed Selector Switch
- 13. Lower Wiper Switch (If Equipped)
- 14. Overload Warning Switch (If Equipped)
- 15. Buzzer Alarm Stop Switch (If Equipped)
- 16. Swing Priority Switch
- 17. Cabin Work Light Switch (If Equipped)
- 18. Intelligent Floating Boom Switch (If Equipped)
- 19. Warning Light Switch (If Equipped)
- 20. Reverse Fan Switch
- 21. Air Compressor Switch (If Equipped)
- 22. Auto Grease System Switch (If Equipped)
- 23. Emergency Start Mode Switch
- 24. Auxiliary Mode Switch
- 25. Quick Coupler Switch (If Equipped)
- 26. Photo Sensor
- 27. Display Monitor
- 28. Around View Monitoring (AVM) Monitor (If Equipped)
- 29. Hour Meter
- 30. Micro Phone (If Equipped)
- 31. Safety Lever
- 32. Horn Button
- 33. Breaker/Booster Button
- 34. Rotating Button (If Equipped)
- 35. Shear Button (If Equipped)
- Display Monitor
- Functional Check
- Setting a Password
- 1. Fuel Gauge
- 2. DEF (AdBlue®) Level Gauge
- 3. Engine Coolant Temperature Gauge
- 4. Hydraulic Oil Temperature Gauge
- 5. Tachometer
- 6. Audio Display
- 7. Main Warning Lamp
- 8. Digital Clock
- 9. Favorites Button
- 10. Main Information Selector Button
- 11. Main Information Indicator
- 12. Power Mode Selector Button
- 13. Power Mode Indicator
- 14. Operating Mode/Flow Setting Selector Button
- 15. Auto Idle Selector Button
- 16. Menu Selector Button
- 17. Back Button
- 18. Camera Mode Selector / ESC Button
- 19. Jog Switch
- 20. Mode Symbol Display
- 21. Indicator Display
- 22. Display Warning Symbols
- Warning Pop-Up Messages
- User Menu
- User Menu – Access and Escape Methods
- Around View Monitoring (AVM) System (If equipped)
- Operating Conditions and Instructions
- Screen Components and View Modes
- Displaying Outlines of the Vehicle Area
- Proximity Alarm System (If equipped)
- Sensor Locations
- Sensor Operating Conditions and Settings
- Sensor Alarm Setting
- Operating Range and Display
- Heater and Air Conditioner Control Panel
- Location of Controls and Vents
- Control Panel
- Memory Function
- Additional Operating Instructions
- Miscellaneous Electrical Devices
- Cabin Light
- Safety Lever
- Circuit Breaker (50A, 80A)
- Junction Box
- DAB (Digital Audio Broadcasting) Audio
- Seat Adjustment
- 1. Forward/Backward Adjustment
- 2. Adjusting Height of Seat and Depth of Cushion
- 3. Reclining Position Adjustment
- 4. Headrest
- 5. Lumbar Support Adjustment
- 6. Seat Heater Switch
- 6-1. Heating/Ventilation Switch (If Equipped)
- 7. Left and Right Control Stand Adjustment
- 8. Left and Right Control Stand Height Adjustment
- 9. Adjusting Height/Angle of Armrest
- Seat Belt
- Seat Belt Locking and Unlocking
- Engine Emergency Stop Switch
- Emergency Exit Glass Breaking Tool
- Miscellaneous Convenience Devices
- Ceiling Cover
- Front Windows
- Door Side Latch
- Cabin Storage Compartments
- Sun Visor
- Sunglasses Case
- Cup Holder
- Storage Box
- Miscellaneous Access Covers and Doors
- Side Door
- Storage Box Door
- Battery Room Door
- Engine Cover
- Air Gun and Compressor (If Equipped)
- Air Gun
- How to Use Air Compressor
- How to Connect Air Gun
- Operation
- To Operate a New Excavator
- Starting and Stopping Engine
- Inspection Before Starting Engine
- Operational Checks Before Starting Engine
- Engine Start
- Diesel Heater (If Equipped)
- Hydraulic System Warm-up
- Hydraulic System Warm-up – Cold Weather
- Stopping Engine
- Checks and Maintenance After Stopping Engine
- Wait to Disconnect Indicator
- DEF (AdBlue®) Level Lamp
- Safety Lever
- Travel
- Automatic Travel Speed Control
- Travel Control Lever Operation
- General Travel Instructions
- Straight Travel Pedal (If Equipped)
- Operating Instructions
- Engine Speed Control
- Emission Control System
- After Treatment System
- Delayed Engine Shutdown (DES)
- Mode Selection
- Change Machine Control Pattern By Selector Valve (If Equipped)
- Work Levers (Joysticks) (ISO Pattern)
- Work Levers (Joysticks) (BHL Pattern)
- Intelligent Floating Boom Control (If Equipped)
- Smart Power Control (SPC)
- Operating Precautions
- Working in Water
- Escaping From Mud
- Parking Excavator
- Towing Procedure
- Attachments
- Bucket – Replace and Reverse
- Breaker Operation
- Shear Operation
- One-Way/Two-Way Valve Operation
- Rotating Operation
- Quick Coupler Operation
- Lifting Objects
- Lifting Objects with Quick Coupler
- Operation Under Abnormal Conditions
- Equipment Lowering with Engine Stopped
- Removable Counterweight (If Equipped)
- Auto Grease System (If Equipped)
- Overview
- Location
- Lubricants
- Pump Display and Control Elements of Control Screen
- Pump Display Mode
- Pump Programming
- Maintenance
- Troubleshooting
- Inspection, Maintenance and Adjustment
- Maintenance Information
- Machine Setup Position for Maintenance
- Handling Oil, Fuel, DEF (AdBlue®), Coolant
- Oil
- Fuel
- DEF (AdBlue®)
- Grease
- Coolant and Water for Dilution
- Filters
- Electrical System Maintenance
- Recommend Fuel, Coolant, and Lubricant
- Lubrication
- Symbols for “Lubrication and Service Chart”
- Fluid Capacities
- Table of Recommended Lubricants
- Maintenance Intervals
- 10 Hour
- Boom, Arm and Front Attachment Pins – Lubricate
- Engine Oil Level – Check
- Hydraulic Oil Level – Check
- Fuel Level – Check
- DEF (AdBlue®) Tank Level- Check
- Fuel Prefilter and Water Separator – Check
- Additional Water Separator – Check
- Swing Reduction Gear Oil Level – Check
- Dust Net – Clean
- Coolant Level – Check
- Window Washer Liquid Level – Check
- Bucket Teeth and Side Cutters – Inspect
- Cooling Fan Blade – Inspect
- Air Intake System and Emission Control System – Check
- Seat Belt – Inspect
- AVM (Around View Monitoring system) – Check
- Mirrors – Check
- Structure – Inspect
- All Switches and Travel Alarm (If Equipped) – Check
- Safety Lever – Check
- Exterior Lights, Horn, Control Console Indicator, Gauge Panel – Check
- Overall of Engine Condition – Check
- All Controls and Linkages – Check
- 50 Hour
- Perform All Daily Service Checks
- Arm and Bucket Joint Pins – Lubricate
- Swing Bearing – Lubricate
- Fuel Tank Water and Sediment – Drain
- Air Compressor and Tank – Check
- Engine Fan Belt – Check
- Track Assemblies (Links, Shoes, Rollers, Idlers) – Inspect
- 250 Hour
- Perform All Daily and 50 Hour Service Checks
- Boom and Arm Joint Pins – Lubricate
- Engine Fan and Alternator Belts – Check
- Breaker Filter (If Equipped) – Replace
- Hydraulic Oil Return Filter – Replace
- Pilot Filter – Replace
- Drain Filter – Replace
- Pin and Bushings of the Front End Attachment – Inspect
- Battery Fluid – Check
- Bolts and Nuts – Inspect
- Fuel System Hose Clamps – Inspect
- 500 Hour
- Perform All Daily, 50 and 250 Hour Service Checks
- Track Spring – Check
- Swing Gear and Pinion – Lubricate
- Engine Oil and Filter – Replace
- Air Compressor Filter (If Equipped) – Clean
- Air-conditioning Outer Filter – Clean
- Air-conditioning Inner Filter – Clean
- Cooling System – Clean
- Air Cleaner Outer Filter – Clean
- Fuel Prefilter and Water Separator – Replace
- Additional Water Separator (If Equipped) – Clean
- Main Fuel Filter – Replace
- Final Drive Gear Oil – Check
- Check Belt
- Final Drive Gear Oil – Change
- Swing Reduction Gear Oil – Change
- 1,000 Hour
- Perform All Daily, 50, 250 and 500 Hour Service Checks
- Swing Reduction Gear – Lubricate
- Hydraulic Oil Tank Breather Filter – Replace
- Hydraulic Oil Return Filter – Replace
- Pilot Filter – Replace
- Drain Filter – Replace
- Final Drive Gear Oil – Change
- Swing Reduction Gear Oil – Change
- Air-conditioning Outer Filter – Replace
- Air-conditioning Inner Filter – Replace
- Fuel Cap Filter – Replace
- 2,000 Hour
- Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks
- Air Cleaner Outer and Inner Filter – Replace
- Coolant – Change
- Hydraulic Oil and Suction Filter – Replace
- Alternator and Starter** – Check
- Rubber Antivibration Shock Mounts – Check
- Perform and Record Results of Cycle Time Tests
- Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage
- Adjust Valve Clearance** – Check
- Head Bolt Torques – Check
- 4,000 Hour
- Major Parts – Periodic Replacement
- 5,000 Hour
- DEF (AdBlue®) Filter – Replace
- DPF – Clean
- 12,000 Hour
- Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 (CEN))
- Air-conditioning System
- Gauge Panel – Check
- Air Conditioner Hoses – Check
- Condenser – Check
- Magnetic Clutch – Check
- Bucket
- Bucket Tooth – Replace
- Bucket O-ring – Replace
- Electrical System
- Engine Cooling System
- General
- Antifreeze Concentration Tables
- Table of Standards for Allowed Tap Water
- Fuel Transfer Pump (If Equipped)
- Removable Counterweight System (If Equipped)
- Counterweight Joint Pins – Lubricate
- Handling of Accumulator
- Track Tension (If Equipped Type 1)
- Track Tension (If Equipped Type 2)
- Venting and Priming Hydraulic System
- Main Pump
- Cylinders
- Swing Motor
- Travel Motor
- General Venting
- Maintenance in Special Conditions
- Transportation
- Disassembly and Assembly Before and after Transportation
- Personnel and Equipment
- Disassembly and Reassembly
- Remove and Install Counterweight
- Track Frame Extension and Retraction
- Lifting the Machine Componets
- Upper Structure Swing Body
- Counterweight
- Arm with Bucket Cylinder
- Bucket
- Boom with Arm Cylinder
- Boom Cylinder
- Loading and Unloading
- Warning for Counterweight and Front Attachment Removal
- Specification
- Standard Specification
- Overall Dimensions
- Ground Pressure
- Digging Force
- Arm – Tearout Force
- Bucket – Breakout Force
- Working Range
- Excavator Rated Lift Capacity Tables
- Approximate Weight of Workload Materials
- Index
Develon
