Doosan DX140LC. Operation and Maintenance Manual (2007) - page 8
5.
Coat surface of packing (2, Figure 69) with fuel on new
cartridge (1).
6.
Tighten the cartridge by hand until the packing comes into
contact with the surface of the filter housing head.
7.
When it reach the surface, tighten the cartridge about 3/4
2
of a turn more.
8.
Coat surface of seal (3, Figure 69) with fuel, and tighten
the bowl with tool.
1
3
FG000428
Figure 69
Change Fuel Filter
WARNING!
Exchange filter after waiting for engine to cool. Be careful of
fire hazards. Do not smoke.
1.
Locate fuel filter inside engine compartment.
2.
Position a small container under fuel filter.
FG006315
Figure 70
3.
Unscrew fuel filter from head assembly. Discard fuel filter.
NOTE:
Dispose of drained fluids according to local
regulations.
4.
After cleaning filter head, install new fuel filter. Screw filter
on head until gasket contacts head, and turn filter 1/2 turn
more with a filter wrench.
NOTE:
Coat fuel filter gasket with fuel.
NOTE:
Fill fuel filter with clean fuel. This will help
reduce fuel system priming.
FG000478
Figure 71
OP000599
Inspection, Maintenance and Adjustment
4-43
Fuel System Priming
1
If air remains in the fuel inlet line to the engine, it may cause the
2
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.
Shut down engine.
FG000431
2.
Loosen plug (1, Figure 72) on the fuel prefilter head.
Figure 72
3.
Pump the hand operated primer pump (2, Figure 72) on the
fuel prefilter. Pump primer until fuel is present at plug hole
in fuel prefilter head.
4.
Tighten plug (1, Figure 72) in fuel prefilter head.
5.
Continue to pump primer pump until a strong resistance is
felt.
6.
Start engine and look for signs of leaks.
7.
Repeat procedure if necessary.
Inspection, Maintenance and Adjustment
OP000599
4-44
1,000 HOUR / 6 MONTH SERVICE
Perform All Daily, 50, 250 and 500 Hour
Service Checks
Grease Swing Reduction Device
1.
Position the machine on firm, level ground. Lower the front
attachment to the ground and shut down engine.
2.
Remove air vent plug (1, Figure 73) from swing reduction
device.
1
FG006316
Figure 73
3.
Press grease fitting and inject grease with the grease gun
on the marked point (2, Figure 74).
4.
Install air vent plug (1, Figure 73) in swing reduction
device.
2
FG009576
Figure 74
OP000599
Inspection, Maintenance and Adjustment
4-45
Replace Hydraulic Oil Return Filter
02/05 [MO] 11:30
NOTE:
Change hydraulic oil return filter after first 250 hours
of operation or rebuild, and every
1,000 hours
thereafter.
NOTE:
If return filter clogged warning light (Figure 75) on
E
F
instrument panel comes "ON" the return filter must be
serviced.
C
H
C
H
E/G SPEED 1700 RPM
FG000760
Figure 75
WARNING!
The hydraulic oil will be hot after normal machine
operation. Allow the system to cool before attempting to
3
service any of the hydraulic components.
The hydraulic tank is pressurized. Loosen the hydraulic
breather cap slightly to allow the pressurized air to vent.
1
2
After the pressure has been released, it is safe to remove
either the fill cap or service covers or drain water from the
FG009577
tank.
Figure 76
3
4
6
IMPORTANT
Make sure to clean any dirt or water from the top of the
7
hydraulic tank, especially around the fill port and filter
ports.
5
1.
Position the machine on firm, level ground. Lower the front
attachment to the ground and shut down engine.
8
2.
Loosen the breather cap (1, Figure 76) slightly to release
the internal pressure.
3.
Remove bolts
(2, Figure
76) and service cover
(3).
Remove spring (4), valve (5) O-ring (6), and bypass
strainer (7), and then filter (8).
4.
Remove filter and discard.
NOTE:
Used filter should always be disposed of
according to local regulations.
FG000761
5.
Install new filter and a new O-ring. Install bypass strainer,
Figure 77
valve and spring. Install service cover plate.
6.
Tighten the breather cap (1, Figure 76).
7.
Run engine for ten minutes at low idle to purge air from
circuit.
8.
Check level in hydraulic oil tank (See page 4-15). Add oil if
necessary.
Inspection, Maintenance and Adjustment
OP000599
4-46
Change Pilot Filter
02/05 [MO] 11:30
NOTE:
Change pilot filter after first 250 hours of operation or
rebuild, and every 1,000 hours thereafter.
NOTE:
If pilot filter clogged warning light (Figure 78) on
instrument panel comes "ON" the pilot filter must be
E
F
serviced.
C
H
C
H
E/G SPEED 1700 RPM
FG000763
Figure 78
WARNING!
The hydraulic oil will be hot after normal machine
operation.
Allow the system to cool down before changing pilot filter.
1.
Position the machine on firm, level ground. Lower the front
attachment to the ground and shut down engine.
FG006317
2.
Loosen the breather cap (1, Figure 76) slightly to release
Figure 79
the internal pressure.
3.
Locate pilot system filter assembly. See Figure 79.
4.
Unscrew canister (5, Figure 80) and remove O-ring (3) and
filter cartridge (4).
1
NOTE:
The canister will be filled with oil. Use caution
2
when removing this assembly.
3
5.
Insert a new filter cartridge and O-ring. Apply a small
amount of oil around the entire O-ring and install the
4
canister assembly onto the filter head (1, Figure 80).
NOTE:
Used filter should always be disposed of
according to local regulations.
5
FG000323
6.
After changing pilot filter, vent air from pump and check
Figure 80
level of hydraulic oil tank.
OP000599
Inspection, Maintenance and Adjustment
4-47
Change Oil in Travel Reduction Device
(One on Each Side of Unit)
3
WARNING!
1
2
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,
FG009568
etc., loosen the plug slightly to allow pressurized air to
escape.
Figure 81
NOTE:
Drain oil after first 250 hours of operation or rebuild,
and every 1,000 hours thereafter.
1.
Make sure that the machine is on firm, level ground.
2.
Rotate the track until ports (1 thru 3, Figure 81) are in their
proper positions as shown.
3.
Place a container under drain plug (2, Figure 81) and
remove plugs (1 thru 3) to drain the travel reduction gear
oil.
NOTE:
Dispose of drained fluids according to local
regulations.
4.
Install drain plug (2, Figure 81). Refill the travel reduction
gear case with fluid through fill port (3) until the fluid level is
at port (1). Install level plug (1) and fill plug (3).
NOTE:
See “Fluid Capacities” on page 4-8. for
capacity.
5.
Repeat this procedure on the other travel reduction device.
Inspection, Maintenance and Adjustment
OP000599
4-48
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 should be cleaned out.
NOTE:
In the event that the unit is being operated in a dusty
environment, the cleaning and replacement should
be performed more frequently. If filter is damaged,
replace damaged filter with a new one.
WARNING!
All service and inspection of air-conditioning system
should be performed with the starter switch in the "O"
(OFF) position.
NOTE:
All right and left call outs are based on the operator
being seated in the operator's seat facing the front.
1.
Open the door in the left of the machine.
Doosan
FG009578
Figure 82
2.
Open the cover by unscrewing the knob (1, Figure 83) in
the rear of the cabin.
1
FG000441
Figure 83
OP000599
Inspection, Maintenance and Adjustment
4-49
3.
Remove filter (Figure 84) and replace with new one.
4.
Reassemble in reverse order.
FG000342
Figure 84
Check Air Conditioner Refrigerant
WARNING!
Mixing of tobacco smoke and freon is deadly.
Do not smoke while servicing or recharging
air-conditioning system.
1.
Run engine at about 1800 rpm. Operate for a minimum of
FG009579
ten minutes to stabilize the system.
Figure 85
2.
Press the "HI" fan speed switch to set maximum air flow.
3.
Put the temperature control switch in maximum cooling
position.
4.
Press the "Internal Air Circulation" switch.
5.
Compare the flow of bubbles in the sight glass of receiver
dryer with the drawings in the following table.
CAUTION!
Overfilling refrigerant may cause dangerous
high-pressure and poor cooling action; and low
refrigerant level may cause compressor damage.
Always maintain refrigerant at normal level.
Inspection, Maintenance and Adjustment
OP000599
4-50
Amount of
Appearance of the Sight Glass
Solutions
Refrigerant
Almost clear.
Normal
Any bubbles disappear.
Charge or withdraw the system with
the correct amount of HFC-134a
High
No bubbles are seen.
refrigerant.
Low
A flow of bubbles is visible.
Check and Adjust Engine **
Contact your nearest DOOSAN dealer.
Engine dealer for checking and adjusting the following items:
•
Engine Compression Pressure.
•
Injection Pressure.
•
Injection Timing.
OP000599
Inspection, Maintenance and Adjustment
4-51
2,000 HOUR / YEARLY SERVICE
Perform All Daily, 50, 250, 500 and 1,000
Hour Service Checks
Change Swing Reduction Device Oil
1
NOTE:
Change swing reduction device oil after first
250
2
hours of operation or rebuild and every 2,000 hours
thereafter.
WARNING!
The gear oil is very hot after the machine has been
operating. Shut all systems down and allow them to cool.
FG009555
Figure 86
1.
Set a container under excavator.
2.
Remove cap (3, Figure 87) and install hose (4) to drain the
swing reduction device oil.
NOTE:
Dispose of drained fluids according to local
3
regulations.
3.
After draining oil, remove hose and install cap.
FG009556
Figure 87
4.
Remove breather/fill cap (2, Figure 86) and add oil to "H"
mark on dipstick (1).
FG000419
Figure 88
Inspection, Maintenance and Adjustment
OP000599
4-52
Replace Outer and Inner Air Cleaner
Elements
WARNING!
Doosan
3
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
FG009580
2,000 hours of service.
Figure 89
NOTE:
Replace inner element whenever a new outer
element is installed.
If there is clogged filter signal on the gauge panel, use the
2
following procedure.
1.
Open the access door at the rear of the cabin.
2.
Remove the evacuator valve (1, Figure 90) and air cleaner
cover (2).
4
NOTE:
Inspect evacuator valve seal lips for wear or
1
damage. Replace valve if necessary. Install
FG000425
evacuator valve with lips parallel to the cover.
Figure 90
3.
Remove outer filter (4, Figure 90) from the air cleaner
housing.
4.
Clean the air cleaner cover and the inside of the air cleaner
housing.
5.
Remove inner filter (5, Figure 91).
6.
Clean out inside of air cleaner housing. Do not use
compressed air to blow out housing.
7.
Install new inner filter. Do not clean and reuse inner
element.
8.
Install new outer filter.
9.
Install air cleaner cover and evacuator valve.
5
NOTE:
Make sure that all gaskets and cover are
4
properly installed and seated.
FG000426
Figure 91
OP000599
Inspection, Maintenance and Adjustment
4-53
Change Radiator Coolant
WARNING!
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
ARO1760L
engine. Make sure to lock out and tag the controls notifying
Figure 92
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.
1.
Slowly open the radiator cap to allow any pressure to
escape.
2.
Place a container under the radiator and open the drain
valve (2, Figure 93).
NOTE:
Dispose of drained fluids according to local
regulations.
2
FG009581
Figure 93
3.
Open heater shutoff valves (3 and 4, Figure 94) to allow
coolant to drain from heater core.
4
3
FG006320
Figure 94
Inspection, Maintenance and Adjustment
OP000599
4-54
4.
Remove coolant drain plug (1, Figure 95) from engine.
5.
Install drain plug, and close drain valve after coolant has
completely drained from system.
6.
Fill cooling system with a flushing solution.
7.
Run engine at low idle until the coolant temperature gauge
1
reaches the "BLUE ZONE." Run engine for another ten
minutes.
8.
Allow engine to cool.
9.
Drain flushing fluid and fill system with water.
FG000322
Figure 95
10. Run engine again to allow water to completely circulate.
11. After allowing engine to cool, drain water and fill system
with proper antifreeze mixture for ambient temperature.
Refer to coolant concentration table. See “Antifreeze
Concentration Tables” on page 4-77.
12. Run engine without radiator cap installed, so that all air will
be purged from system. Fill radiator to fill neck.
13. Drain and fill radiator coolant recovery tank.
Hydraulic Oil Exchange and Suction
Strainer Cleaning
WARNING!
The hydraulic oil will be hot after normal machine
operation. Allow the system to cool before attempting to
service any of the hydraulic components.
ARO1760L
The hydraulic tank is pressurized. Loosen the breather cap
Figure 96
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, only when
DOOSAN Genuine Oil is used. If another brand of oil is
used, guaranteed change interval is 1,000 hours.
OP000599
Inspection, Maintenance and Adjustment
4-55
NOTE:
Based on the type of excavating being completed,
the working conditions (extremely hot or dusty) and
the extra front end attachments being used (hydraulic
breaker, etc.), the hydraulic fluid will need to be
changed more frequently.
1.
Position the machine on firm, level ground. Swing upper
structure perpendicular (90°) to tracks. Lower boom and
position bucket on ground as shown in Figure 97.
2.
Set safety lever on "LOCK" position.
3.
Shut down engine.
4.
Release pressurized air from hydraulic tank by rotating
breather cap (1, Figure 100).
FG000356
Figure 97
5.
Drain hydraulic oil from tank into a container capable of
holding 147.8 liters (39 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
FG009551
disposed of according to local regulations.
Figure 98
6.
Carefully remove bolts and cover (2, Figure 100) 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 100) and strainer (5), by pulling
on rod (4).
A
8.
Clean inside and outside of strainer. Replace strainer if it is
broken.
9.
Position strainer (5, Figure 100) on boss portion of suction
pipe (6).
NOTE:
Measurement "A" is 650 mm (25.59 in).
HAOC411L
Figure 99
Inspection, Maintenance and Adjustment
OP000599
4-56
10. Fill the hydraulic oil tank. Check level using sight gauge on
side of tank.
1
2
11. Place spring (3, Figure 100) on rod (4) and assemble cover
(2).
12. After replacing and cleaning the hydraulic oil, filter and
strainer, vent the system. See “Venting and Priming
3
Hydraulic System” on page 4-84.
IMPORTANT
4
When the hydraulic breaker is being used, due to the
higher heat generated by this unit, use replacement
intervals recommended under the “Hydraulic Oil and
5
Filter Service Intervals” on page 3-38.
13. Check level of hydraulic oil tank. (See page 4-15)
6
ARO1720L
Figure 100
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
OP000599
Inspection, Maintenance and Adjustment
4-57
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
Parts Name to be Exchanged Periodically
Time to Exchange
Engine
Fuel hose (Tank to fuel prefilter)
2 years or 4,000 hours
Fuel hose (Fuel prefilter to fuel cooler)
Fuel hose (Fuel cooler to ECU)
Fuel hose (Tank to CP pump)
Heater hose (Heater to engine)
Heater hose (Heater to radiator)
Air Conditioner hose
Hydraulic
Body
Pump suction hose
System
Pump discharge hoses
Pump side branch hoses
Swing motor hoses
Travel motor hoses
Work
Boom cylinder line hoses
Device
Arm cylinder line hoses
Bucket cylinder line hoses
Inspection, Maintenance and Adjustment
OP000599
4-58
12,000 HOUR / SIX 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 exceed six years. DOOSAN
recommends the following;
•
Hoses at the customer premises cannot be stored
more than 2 years before being discarded or installed
on a machine.
•
In-service lifetime of hoses fitted on a machine can
never exceed 6 years, but replace hoses described in
“Major Parts - Periodic Replacement” on page 4-58,
every
2 years. Always replace hoses having
exceeded the allowed in-service lifetime irrespective
of the external appearance/wear.
•
Always store hoses in a dark place at a maximum of
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.
OP000599
Inspection, Maintenance and Adjustment
4-59
AIR-CONDITIONING SYSTEM
NOTE:
See “Clean Air-Conditioning Outer Filter” on
page 4-38.
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!
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 4-40.
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 4-32.
Inspection, Maintenance and Adjustment
OP000599
4-60
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.
BOLT
TORQUE
BOLT
NO.
POINT TO BE INSPECTED
QTY.
HEAD
DIA. MM
kg•m
Nm
ft lb
SIZE
1
Joint bolt with engine
pump side
16
8
24
27
264
195
mounting bracket and
fan side
10
8
17
6.5
64
47
engine
2
Joint bolt and nut
pump side
20
2
30
46
451
333
between engine mount-
fan side
20
2
30
46
451
333
ing bracket and frame
3
Radiator mounting bolt
16
4
24
27
264
195
4
Tightening bolt for hydraulic oil tank
16
4
24
27
264
195
5
Tightening bolt for fuel tank
16
4
24
27
264
195
6
Tightening bolt for pump
10
12
17
6.5
64
47
7
Tightening bolt for control valve
16
4
24
27
264
195
8
Tightening bolt for swing reduction device
16
9
24
27
264
195
9
Tightening bolt for swing motor
12
10
10 (S)
11
108
80
10
Tightening bolt for battery
10
2
17
6.5
64
47
11
Joint bolt with cabin mounting rubber and
10
16
17
6.5
64
47
frame
Joint bolt with cabin mounting rubber and
16
4
24
21
205
152
cabin
12
Joint bolt with swing bearing and upper
20
36
30
55
539
398
frame
Joint bolt with swing bearing and bottom
20
36
30
55
539
398
frame
13
Tightening bolt for travel device
16
40
24
30
294
217
Tightening bolt for sprocket
16
30
24
30
294
217
14
Tightening bolt for upper roller
20
2
30
55
539
398
15
Tightening bolt for bottom roller
16
56
24
27
264
195
16
Tightening bolt for track guard
16
8
24
27
264
195
17
Bolt for track shoes
16
368
24
39
382
282
18
Tightening bolt for front pin
16
10
24
27
264
195
19
Breaker Filter (Optional)
1
30
27
264
195
20
Grease valve for track adjuster
PF 1/2
2
27
14
137
101
OP000599
Inspection, Maintenance and Adjustment
4-61
1.
Joint bolt with engine mounting bracket and engine
1) Pump side
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (264 Nm, 195 ft lb)
FG009582
Figure 101
2) Fan side
•
Tool: 17 mm (
)
•
Torque: 6.5 kg•m (64 Nm, 47 ft lb)
FG006423
Figure 102
2.
Joint bolt and nut between engine mounting bracket and
frame
1) Pump side
•
Tool: 30 mm (
)
•
Torque: 46 kg•m (451 Nm, 333 ft lb)
FG009583
Figure 103
2) Fan side
•
Tool: 30 mm (
)
•
Torque: 46 kg•m (451 Nm, 333 ft lb)
FG006424
Figure 104
Inspection, Maintenance and Adjustment
OP000599
4-62
3.
Radiator mounting bolt
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (264 Nm, 195 ft lb)
FG009584
Figure 105
4.
Tightening bolt for hydraulic oil tank
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (264 Nm, 195 ft lb)
FG009585
Figure 106
5.
Tightening bolt for fuel tank
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (264 Nm, 195 ft lb)
FG009586
Figure 107
6.
Tightening bolt for pump
•
Tool: 17 mm (
)
•
Torque: 6.5 kg•m (64 Nm, 47 ft lb)
FG009587
Figure 108
OP000599
Inspection, Maintenance and Adjustment
4-63
7.
Tightening bolt for control valve
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (264 Nm, 195 ft lb)
FG009588
Figure 109
8.
Tightening bolt for swing reduction device
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (264 Nm, 195 ft lb)
FG009589
Figure 110
9.
Tightening bolt for swing motor
•
Tool: 10 mm (
)
•
Torque: 11 kg•m (108 Nm, 80 ft lb)
FG009590
Figure 111
10. Tightening bolt for battery
•
Tool: 17 mm (
)
•
Torque: 6.5 kg•m (64 Nm, 47 ft lb)
FG009591
Figure 112
Inspection, Maintenance and Adjustment
OP000599
4-64
11. Joint bolt with cabin mounting rubber and frame
•
Tool: 17 mm (
)
•
Torque: 6.5 kg•m (64 Nm, 47 ft lb)
FG000454
Figure 113
Joint bolt with cabin mounting rubber and cabin
•
Tool: 24 mm (
)
•
Torque: 21 kg•m (205 Nm, 152 ft lb)
FG000455
Figure 114
12. Joint bolt with swing bearing and upper frame
•
Tool: 30 mm (
)
•
Torque: 55 kg•m (539 Nm, 398 ft lb)
FG000456
Figure 115
Joint bolt with swing bearing and bottom frame
•
Tool: 30 mm (
)
•
Torque: 55 kg•m (539 Nm, 398 ft lb)
FG000457
Figure 116
OP000599
Inspection, Maintenance and Adjustment
4-65
13. Tightening bolt for travel device
•
Tool: 24 mm (
)
•
Torque: 30 kg•m (294 Nm, 217 ft lb)
FG009592
Figure 117
Tightening bolt for sprocket
•
Tool: 24 mm (
)
•
Torque: 30 kg•m (294 Nm, 217 ft lb)
FG009593
Figure 118
14. Tightening bolt for upper roller
•
Tool: 30 mm (
)
•
Torque: 55 kg•m (539 Nm, 398 ft lb)
FG000460
Figure 119
15. Tightening bolt for bottom roller
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (264 Nm, 195 ft lb)
FG000461
Figure 120
Inspection, Maintenance and Adjustment
OP000599
4-66
16. Tightening bolt for track guard
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (264 Nm, 195 ft lb)
FG000462
Figure 121
17. Bolt for track shoes
•
Tool: 24 mm (
)
•
Torque: 39 kg•m (382 Nm, 282 ft lb)
FG000463
Figure 122
18. Fixing bolt for front pin
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (264 Nm, 195 ft lb)
FG009911
Figure 123
OP000599
Inspection, Maintenance and Adjustment
4-67
19. Fixing breaker filter (Optional)
•
Tool: 30 mm (
)
•
Torque: 27 kg•m (264 Nm, 195 ft lb)
FG009569
Figure 124
20. Grease valve for track adjuster
2
•
Tool: 27 mm (
)
•
Torque: 14 kg•m (137 Nm, 101 ft lb)
1
3
FG000163
Figure 125
Inspection, Maintenance and Adjustment
OP000599
4-68
BUCKET
Bucket Tooth Replacement
WARNING!
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 126
1.
On a routine basis, inspect bucket teeth to make sure 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 126.
2.
To replace a tooth (1, Figure 127), use a hammer and
punch to drive locking pin (2) and lock washer (3) out of
tooth adapter (4).
4
3.
Once worn tooth has been removed, use a putty knife to
3
scrape adapter as clean as possible.
2
4.
Slide new tooth into position and insert lock washer.
1
FG000346
Figure 127
5.
Insert locking pin into tooth and with a hammer, drive pin in
until lock washer seats in locking groove.
OP000599
Inspection, Maintenance and Adjustment
4-69
Bucket O-ring Replacement
WARNING!
Due to possibility of flying metal objects, always wear
safety helmet, protective gloves and eye protection when
changing pins.
1.
Inspect bucket O-rings on a routine basis. If worn or
damaged, replacement is necessary.
FG006750
Figure 128
2.
Roll old O-ring (1, Figure 129) onto boss (2) around bucket
pin (3). Remove bucket pin and move arm or bucket link
1
4
(4) out of way.
2
3
ARO1390L
Figure 129
3.
Remove old O-ring and temporarily install new O-ring (1,
Figure 130) onto bucket boss (2). Make sure that O-ring
1
4
groove on both bucket link (4) and boss have been
2
cleaned.
4.
Realign arm or link with bucket pin hole and insert bucket
pin (3, Figure 129).
ARO1391L
Figure 130
Inspection, Maintenance and Adjustment
OP000599
4-70
5.
Roll new O-ring (1, Figure 131) into O-ring groove.
1
ARO1392L
Figure 131
OP000599
Inspection, Maintenance and Adjustment
4-71
ELECTRICAL SYSTEM
NOTE:
Never disassemble electrical or electronic parts.
Consult with a DOOSAN distributor or sales agency
before servicing.
Battery
WARNING!
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, 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, shut down engine and turn
the starter switch to the "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 the 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
OP000599
4-72
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
FG000347
Check charging state through the charging indicator.
Figure 132
•
GREEN: Sufficiently charged.
•
BLACK: Insufficient charged.
•
TRANSPARENT: Replace battery.
Check the Battery Terminals
Be certain that the 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,
HAOU790L
replace the battery. The batteries should always be replaced in
Figure 133
pairs.
Using an old battery with a new one will shorten the life span of
the new battery.
Fuses
1.
The fuses in the fuse box are used to protect the various
O
X
electrical circuits and their components from being
damaged. See Figure 134. The fuses used are standard
automotive type fuses.
2.
The section on “Fuse Identification” on page 4-75, lists the
circuits and the fuse amperage required for each circuit. If
a fuse blows, determine the cause and repair any faults or
failures.
HAOC670L
3.
Do not insert a higher amperage fuse into a lower
Figure 134
amperage slot. Serious damage to the electrical
components or fire can result.
OP000599
Inspection, Maintenance and Adjustment
4-73
CAUTION!
Before replacing a fuse, be sure to turn starter switch to "O"
(OFF) position.
Fuse Boxes
There are two fuse boxes (Figure 135) on the left side of the
heater box. The fuses prevent electrical devices from
overloading or shorting.
A decal attached to the inside of the fuse box's cover indicates
the function and amperage of each fuse.
Spare fuses are mounted on the inside of fuse box's cover. (One
each of a 10A, 15A, 20A and 30A.)
Change a fuse if the element separates. If the element of a new
FG000110
fuse separates, check the circuit and repair the circuit.
Figure 135
CAUTION!
Always replace fuses with the same type and capacity fuse
that was removed. Otherwise, electrical damage could
result.
Inspection, Maintenance and Adjustment
OP000599
4-74
Fuse Identification
Fuse Box (1)
Fuse Box (2)
FG004974
Figure 136
Fuse Box One
Fuse Box Two
No.
No.
Name
Capacity
Name
Capacity
1
Warning Light (Optional)
10A
1
Horn
10A
2
2-pump (Optional)
10A
2
Quick Clamp (Optional)
10A
3
Cigar Lighter
10A
3
Travel Alarm (Optional)
10A
4
12V Power
10A
4
Auxiliary Mode
10A
5
Wiper, Washer
10A
5
Check Connector
10A
6
Lower Wiper (Optional)
10A
6
Pilot Cutoff
10A
7
Stereo
10A
7
Memory Backup
10A
Starter Switch, Hour
8
10A
8
Room Light
10A
Meter
9
Spare
30A
9
Cabin Light (Optional)
30A
10
Air Conditioner, Heater
20A
10
Work Light
20A
11
Shear, Breaker (Optional)
20A
11
Fuel Heater
20A
Instrument Panel, Pressure
12
Seat Heater (Optional)
15A
12
15A
Sensor
e-EPOS, Booster, Travel
13
15A
13
Headlight
15A
speed changer, Booster
14
ECU
15A
14
Fuel Pump (Optional), Wiper
15A
OP000599
Inspection, Maintenance and Adjustment
4-75
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, it should not exceed 300 ppm hardness, or
contain more than 100 ppm of either chloride or sulfate. 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 contains dirt, minerals and/or organic
material that are deposited in the cooling system and impair
cooling efficiency. Distilled water is the best.
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 bond between the fins and
the tubes.
WARNING!
Pressure at air nozzle must not exceed 30 PSI (2.1 kg/
cm2). Always wear goggles when using compressed air.
Do not pour cold water into radiator when engine is very
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 every year or
2,000 hours of operation, which ever comes first. This 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 freeze protection is required.
Never use more than 68% antifreeze under any condition.
Inspection, Maintenance and Adjustment
OP000599
4-76
Types of Antifreeze
There are two main classifications of antifreeze available on the
market today.
1.
Ethylene Glycol - Standard Life Antifreeze
2.
Propylene Glycol - Extended Life Antifreeze
Ethylene glycol (standard life antifreeze) has been on the market
for many years. Its chemical properties do not provide the
improved corrosion resistance that propylene glycol (extended
life antifreeze) does. Ethylene glycol is also very hazardous to
the environment, people and animals. DOOSAN recommends
that ethylene glycol be replaced with propylene glycol.
The newer propylene glycol antifreeze comes in many different
colors. Some of the colors are pink, red, orange and yellow.
There are even some that come in a blue-green color. The
blue-green color makes it very difficult to tell the difference of
what type of antifreeze is in a cooling system. The colors are
only a dye added to the clear antifreeze. Do not rely on color.
Keep careful machine records of what brand and type of
antifreeze is used in the unit. If you are unsure of what type of
antifreeze is in the system, drain and flush the system.
NOTE:
Do not mix ethylene glycol and propylene glycol
antifreeze together. If the two are mixed, the
protection level will be reduced to the level of the
ethylene glycol.
Antifreeze Concentration Tables
Ethylene Glycol - Standard Life Antifreeze
(1,000 Hour / 6 Months)
Ambient Temperature
Cooling Water
Antifreeze
-10°C (14°F)
80%
20%
-15°C (5°F)
73%
27%
-20°C (-4°F)
67%
33%
-25°C (-13°F)
60%
40%
-30°C (-22°F)
56%
44%
-40°C (-40°F)
50%
50%
Propylene Glycol - Extended Life Antifreeze
(2,000 Hour / Yearly)
Ambient Temperature
Cooling Water
Antifreeze
-10°C (14°F)
78%
22%
-15°C (5°F)
71%
29%
-20°C (-4°F)
65%
35%
-25°C (-13°F)
59%
41%
-30°C (-22°F)
55%
45%
-40°C (-40°F)
48%
52%
OP000599
Inspection, Maintenance and Adjustment
4-77
FUEL TRANSFER PUMP
(OPTIONAL)
WARNING!
Do not dry operate fuel pump for more than fifteen seconds.
•
Cooling and lubrication of pump is achieved by
fuel passing through pump. If pump is dry
operated, heat generated by moving parts will
cause damage to pump rotors, vanes and seals.
To prevent unnecessary wear and/or damage to
pump do not dry operate fuel pump for more than
fifteen seconds.
Do not operate pump for more than fifteen minutes at a
time.
•
Continuous usage of pump over recommended
time interval will cause overheating of motor and
will result in causing motor damage.
Do not use refueling pump for other types of fuel or fluids.
(Use only for diesel fuel.)
•
Do not use refueling pump for other types of fuel
which have a low flash point.
•
Do not use refueling pump for fuel contaminated
with water or high humidity. Moisture in pump
mechanism can cause rust and can create pump
failure.
Always operate pump using strainer installed on inlet hose.
This will prevent any foreign materials from being
introduced into pump. Always maintain pump and all of its
components in a clean condition.
•
If dirt or other foreign materials enter pump, it can
become lodged between the rotor and/or vanes
and generate heat which can cause pump
damage.
•
Do not remove strainer or use a strainer with
larger mesh to increase flow of fuel.
Be careful not to overfill or spill fuel.
Make sure direction of check valve is in line with flow
direction of fuel.
If any pump parts or components become lost, damaged or
inoperable, immediately replace it with a new ones.
Inspection, Maintenance and Adjustment
OP000599
4-78
IMPORTANT
If there are any sign of leakage while operating transfer
pump, inspect the following components to prevent any
fires or hazardous fuel spills.
•
Check all hoses leading to and from the transfer
pump.
•
Check all hose clamps.
•
Check transfer pump inlet port.
The transfer pump is used to transfer fuel from a refueling
source to the fuel tank. A check valve is installed in the inlet
hose to prevent fuel from flowing back from fuel tank to source.
A strainer is installed in inlet hose to prevent any foreign material
from being introduced into transfer pump or fuel tank.
A thermal limiter, built into the motor, will automatically shut off
power if motor is overheating to protect it from being damaged.
FUEL
1
4
3
2
5
FUEL TANK
IN
OUT
FG000161
Figure 137
Reference
Reference
Description
Description
Number
Number
1
Body
4
Strainer Cap
2
Check Valve
5
Inlet Hose
3
Strainer
OP000599
Inspection, Maintenance and Adjustment
4-79
1.
Remove strainer cap (4, Figure 137) from strainer (3) on
end of inlet hose (5).
NOTE:
Keep strainer cap (4, Figure 137) in a safe
location to reseal strainer (3) after refueling is
complete.
I
O
2.
Insert inlet hose (5, Figure 137) into refueling tank.
3.
Turn fuel pump switch (Figure 138) inside of battery box on
front side to "I" (ON) position.
NOTE:
Transfer pump rate of flow is approximately 35
FG003379
liters/minute (9.24 U.S. gpm). Use extra care
Figure 138
not to overfill fuel tank so that fuel does not over
flow.
4.
Once fuel transfer is completed, immediately turn switch to
"O" (OFF) position to stop pump.
5.
Lift inlet hose (5, Figure 137) from fueling source and turn
switch to "I" (ON) position for two - three seconds to drain
remaining fuel from hose to fuel tank.
6.
Install strainer cap (4, Figure 137) on inlet strainer (3) and
return hose (5) to storage position.
Inspection, Maintenance and Adjustment
OP000599
4-80
HANDLING OF ACCUMULATOR
WARNING!
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 the "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.
•
Set safety lever on "LOCK" position after
stopping engine.
•
DO NOT mishandle accumulator(s). They are very
dangerous because they contain high-pressure
nitrogen gas.
•
DO NOT punch a hole or apply heat or fire to an
accumulator.
•
DO NOT weld on accumulator, or try attaching
anything to it.
•
When replacing an accumulator, contact a
DOOSAN distributor or sales agency so the gas
can be properly released.
•
Wear safety goggles and protective gloves when
working on an accumulator. Hydraulic oil under
pressure can penetrate the skin and cause
serious injuries.
Release pilot accumulator pressure using the following
procedure;
1.
Position the machine on firm, level ground. Lower the front
attachment to the ground and shut down engine.
2.
Set safety lever on "RELEASED" position.
3.
Turn starter switch to the "I" (ON) position.
4.
Fully stroke work and travel levers in all directions.
5.
Set safety lever on "LOCK" position.
FG009594
6.
Turn key to "O" (OFF) position and remove from starter
Figure 139
switch.
7.
Remove accumulator by unscrewing it slowly.
OP000599
Inspection, Maintenance and Adjustment
4-81
TRACK TENSION
WARNING!
Safely measuring track tension requires two people. One
person must be in the operator's seat, running the controls
to keep one side frame in the air, while the other person
makes dimensional checks. Take all necessary precautions
to make sure the machine won't move or shift position
during service. Warm up the engine to prevent stalls, travel
the excavator to an area that provides level, uniform ground
support and/or use support blocks when necessary.
The track adjusting mechanism is under very
high-pressure. NEVER release pressure too suddenly. The
grease cylinder valve should never be backed off more than
one complete turn from the fully snugged down position.
Bleed off pressure slowly and keep your body away from
the valve at all times.
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 tension is checked by jacking up one side of the
excavator. See Figure 140. Place blocking under frame
while taking measurement.
90 ~ 110
FG000345
Figure 140
2.
Measuring the distance (A, Figure
141) 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 320 - 340 mm (12.60 - 13.39 in)
NOTE:
This measurement can be thrown off if there is
too much mud or dirt or other material in the
track assembly. Clean off the tracks before
A
checking clearance.
FG000162
Figure 141
Inspection, Maintenance and Adjustment
OP000599
4-82
3.
Too little sag in the crawler track (less than 320 mm
(12.60 in) clearance) can cause excessive component
wear. The recommended adjustment can also be too tight
causing accelerated stress and wear if ground conditions
are wet, marshy or muddy, or if the ground is hard and full
of rocks or gravel.
4.
The increased clearance recommended for muddy ground
conditions is between 340 - 370 mm (13.39 - 14.57 in). The
clearance should be approximately 370 mm (14.57 in) for
operation over gravel, rocky terrain, or over sand or snow.
WARNING!
The track adjusting mechanism is under very
high-pressure. NEVER release pressure too suddenly.
The grease cylinder valve should never be backed off
more than 1 complete turn from the fully snugged
down position. Bleed off pressure slowly and keep
your body away from the valve at all times. If there is
problem in the fitting thread, the valve or fitting might
be ejected at high speed to cause fatal wound.
5.
Track tension adjustments are made through the grease
fitting (1, Figure 142) in the middle of each side frame.
2
Adding grease increases the length of an adjustment
cylinder
(2). The longer the adjustment cylinder, the
greater the pressure on the tension spring pushing the
track idler wheel outward.
6.
If there is not enough slack or clearance in the tracks and
the adjustment is too tight, the idler wheel and adjusting
cylinder can be retracted by bleeding off grease through
1
3
hole in valve (3, Figure 142) by loosening valve slowly (3,
Figure 142).
FG000163
Figure 142
NOTE:
After track tension is adjusted by loosening
valve, be sure to tighten valve (3, Figure 142)
with 14 kg•m (137 Nm, 101 ft lb).
WARNING!
Do not loosen or remove the grease fitting (1, Figure
142) until the pressure is entirely bleed off by
loosening valve (3, Figure 142) slowly.
OP000599
Inspection, Maintenance and Adjustment
4-83
VENTING AND PRIMING
HYDRAULIC SYSTEM
Main System Pump
NOTE:
If pump is run without sufficient oil in the main
hydraulic pump, damage can occur. Always vent
pump of air after draining hydraulic system.
1.
With the engine stopped, remove vent plug (Figure 143) to
see if any oil is present.
2.
If oil is not present, fill pump with oil through port (Figure
143).
3.
Install vent plug (Figure 143) first.
FG009595
Figure 143
4.
Start engine and run it for several minutes at low idle
engine speed. This will pressurize the hydraulic oil tank
and system.
5.
Slowly loosen vent plug (Figure 143) several turns, until
hydraulic oil flows out of plug. This shows that air has been
released.
6.
Tighten the plug (Figure 143).
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 may occur. Always
vent air from cylinders at low idle and at a slow speed.
1.
Run engine at low idle. Extend and retract each cylinder to
within 100 mm (4 in) of fully stroking it 4 - 5 times.
2.
Operate fully extend and retract each cylinder 3- 4 times.
3.
Repeat procedure until cylinders extend and retract
smoothly.
Inspection, Maintenance and Adjustment
OP000599
4-84
Swing Motor
IMPORTANT
If the air is not vented from the system, it will cause damage
to the swing motor and bearings.
NOTE:
Perform this only when oil has been drained from
swing motor.
FG009596
1.
Shut down engine.
Figure 144
2.
Disconnect drain hose and fill swing motor case with
hydraulic oil.
3.
Connect the drain hose.
4.
Start engine and set throttle at "LOW IDLE" and swing
upper structure slowly two full revolutions to the left and
right.
Travel Motor
NOTE:
Perform this only when oil is drained from travel
motor
1.
Shut down engine
2.
Disconnect drain hose (Figure 145) and fill motor case with
hydraulic oil.
3.
Connect drain hose.
4.
Start engine and set engine speed control dial to "LOW
FG009597
IDLE." Run the engine for one minute and slowly drive
Figure 145
excavator forwards and backwards.
General Venting
1.
After venting air from all components, shut the engine
down and check the hydraulic oil level. Fill hydraulic oil
tank to "H" mark on sight gauge.
2.
Start engine and operate all controls again, run engine for
five minutes to ensure all systems have been vent and
purged of air. Set engine speed to "LOW IDLE," and check
hydraulic oil level again. Add oil as necessary.
3.
Check for oil leaks and clean all fill and venting locations.
OP000599
Inspection, Maintenance and Adjustment
4-85
LONG TERM STORAGE
Perform the following if storing the excavator for more than one
month.
Conditions
Maintenance Required
Cleaning
Pressure wash the 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 the exposed plated metal
surfaces, such as hydraulic cylinder rods, etc.
Apply a coating of light oil to all of the control linkages and
control cylinders (control valve spools, etc.).
Battery
Remove the battery from the excavator or remove the battery
leads from the battery to fully charge and store.
Cooling System
Inspect the coolant recovery tank to make sure that the
antifreeze level in the system is at the correct level.
Every 90 days, use a hydrometer to measure the protection
level of the coolant. Refer to the antifreeze/coolant protection
chart to determine the amount of protection the cooling system
requires. Add coolant as required.
Hydraulic System
Once a month, start the engine and follow the "Hydraulic Oil
Warm-up" procedures listed in this manual.
Inspection, Maintenance and Adjustment
OP000599
4-86
MAINTENANCE IN SPECIAL
CONDITIONS
NOTE:
See “Operation Under Unusual Conditions” on
page 3-44 for other recommendations.
Conditions
Maintenance Required
Operating in mud, water or rain.
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
Clean the air intake filters on a more frequent basis.
environment.
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.
OP000599
Inspection, Maintenance and Adjustment
4-87
Inspection, Maintenance and Adjustment
OP000599
4-88
OP000600
4Transportation
Obey all local, state or federal regulations for the
transportation of the excavator. If unsure of regulations
check with local authorities.
Check the intended route for road width, overhead
clearances, weight restrictions, and traffic control regulations.
Special approval or permits may be required.
LOADING AND UNLOADING
Warning for Counterweight and Front
Attachment Removal
DANGER!
DOOSAN warns any user, that the removal of the
counterweight from the machine, front attachment or any
other part, may affect the stability of the machine. This
could cause unexpected movement, resulting in death or
serious injuries. DOOSAN is not liable for any misuse.
Never remove the counterweight or front attachment unless
the upper structure is in-line with the lower structure.
FG000371
Never rotate the upper structure once the counterweight or
Figure 1
front attachment has been removed.
OP000600
Transportation
5-1
WARNING!
When transporting the machine, know the width, height,
length and weight.
Loading or unloading the machine can be a dangerous
operation. Make sure to run the engine at the lowest speed
setting, and travel at the slowest speed possible.
Make sure that the ramp being used can handle the weight
of the machine. If required, add blocking under the ramp for
additional support.
Make sure that the ramp surface is free of grease or mud
that could cause the machine to slip or slide.
Make sure that the trailer is parked on firm, level ground
before attempting to load/unload the excavator.
If it is required to turn the machine while it is on the trailer,
make sure to do this at the slowest engine and travel
speeds possible.
Make sure to secure the excavator onto the trailer as
required by local transportation laws.
Total Height
Total Width
Total Length
Weight
Remarks
2,773 mm
2,590 mm
7,680 mm
14.0 metric tons
4.6 m Boom
(9' 1")
(8' 6")
(25' 2")
(15.46 tons)
2.5 m Arm
600 G Shoe
1.
Make sure that the trailer is parked on firm, level
ground. See Figure 2.
2.
Make sure that the ramps that are being used are
designed to handle the weight of the excavator. If
90 ~ 110
required, add blocking under the ramp to provide
additional support.
3.
The ramp angle should be less than or not exceeding
a
15° angle. Ramps steeper than this may cause a
problem when loading or unloading.
15
FG000325
Figure 2
Transportation
OP000600
5-2
4.
Set the travel speed selector switch to "O" (OFF)
position. See Figure 3.
O
I
II
FG000023
Figure 3
5.
Turn "OFF" auto idle selector button (1, Figure 4). The
indicator light (2) will not be lit.
2
1
6.
Set engine speed to "LOW IDLE."
POWER
AUTO
1
2
3
4
ESC
5
6
7
8
FG000164
Figure 4
7.
If the machine is equipped with work equipment, set
the work equipment at the front, and travel forward to
load it.
90 ~ 110
15
FG000325
Figure 5
8.
The unit does not require disassembly for normal
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 that the counterweight
end of the excavator is positioned on the ramp first.
See Figure 6.
15
FG000326
Figure 6
OP000600
Transportation
5-3
9.
Extend bucket and arm cylinders to maximum length
and then lower the boom slowly.
FG000327
Figure 7
10. Set safety lever on "LOCK" position.
Unlock
lock
FG001091
Figure 8
11. Shut down engine by turning key to "O" (OFF) position
(Figure 9).
O I
12. Remove key from starter switch.
FG000175
Figure 9
13. Make sure to secure the excavator onto the trailer
before transporting. Place blocking
(1, Figure
10) in
front of and behind each track. Use chains or cable
tie-downs (2) as required by local transportation laws.
14. Refer to the Dimensions for Transportation table and
1
drawing for overall machine height and width
1
measurements. Make sure to position the excavator as
shown. If not transported in this position, the height
measurements may be different.
2
FG000334
Figure 10
Transportation
OP000600
5-4
LIFTING WITH SLING
WARNING!
Improper lifting can allow load to shift and cause injury or
damage.
1.
Refer to “Specification” on page 7-1 of this manual for
information on weight and dimensions.
2.
Use properly rated cables and slings for lifting.
3.
Position machine for a level lift.
4.
Lifting cables should have a long enough length to
prevent contact with the machine. Spreader bars may
be required.
Figure 11
NOTE:
If spreader bars are used, be sure that cables
are properly secured to them and that the angle
of the cables is factored into the lift strength.
OP000600
Transportation
5-5
Transportation
OP000600
5-6
OP000013
6Troubleshooting
Anytime that a malfunction occurs, take immediate corrective
action. Check for and investigate the cause of the
malfunction. A schedule maintenance program can prevent
malfunctions from occurring by doing preventative
maintenance. A systematic approach should be taken to
troubleshooting, since several overlapping malfunctions may
give the appearance of a problem that does not exist. If
cause for the malfunction cannot be determined, contact
your DOOSAN distributor. Never perform an adjustment of
or disassembly of, hydraulic components, electrical and
electronic components, without first consulting a DOOSAN
distributor.
ELECTRICAL SYSTEM
Problem
Cause
Remedy
Battery will not hold a
Low battery power.
Clean and retighten.
charge.
Alternator belt loose or bad.
Tighten or replace belt.
Loose or corroded terminals.
Tighten or replace as required.
Alternator faulty.
Repair or replace as required.
Low battery power.
Internal battery short.
Replace battery.
Short circuit in wiring.
Repair as required.
Engine speed is not
Speed control dial failed.
Replace control dial.
controllable.
Throttle controller failed.
Replace controller.
Speed control motor failed.
Repair or replace as required.
Blown fuse.
Replace fuse.
Wiring harness damaged.
Repair or replace as required.
Connector failed.
Repair or replace as required.
Power mode selector does
Blown fuse.
Replace fuse.
not work.
Power mode selector switch failed.
Replace switch.
Connector failed.
Replace connector.
Wiring harness damaged.
Repair or replace as required.
e-EPOS controller failed.
Repair or replace as required.
OP000013
Troubleshooting
6-1
Problem
Cause
Remedy
Working mode selector does
Blown fuse.
Replace fuse.
not work.
Working mode selector switch.
Replace switch failed.
Connector failed.
Replace connector.
Wiring harness damaged.
Repair or replace as required.
e-EPOS controller failed.
Repair or replace as required.
ENGINE
Problem
Cause
Remedy
Starter does not operate.
Low battery power.
Charge battery.
Poor terminal contact.
Clean and tighten connections.
Starter switch failed.
Replace switch.
Starter relay failed.
Replace relay.
Starter controller failed.
Replace controller.
Wiring harness faulty.
Replace harness.
Battery relay failed.
Replace relay.
Blown fuse.
Replace fuse.
Starter engages, engine
Fuel gelled in cold weather.
Replace fuel.
does not start.
Fuel filters plugged.
Replace filters.
Water or dirt in fuel system.
Clean system and add new fuel.
Air in fuel system.
Purge air from system.
Engine stop control failed.
Contact your DOOSAN dealer.
Engine stop relay failed.
Replace relay.
Blown fuse.
Replace fuse.
Engine starts, runs only at
Engine oil viscosity incorrect.
Change oil.
low speed or shuts down.
Clogged or dirty fuel injectors.
Clean injectors.
Fuel filters plugged.
Replace filters.
Troubleshooting
OP000013
6-2
Problem
Cause
Remedy
Engine knocks, runs
Low engine oil.
Refill.
unevenly or surges.
Plugged air intake system.
Clean system and replace filter.
Injection pump out of adjustment.
Contact your DOOSAN dealer.
Plugged fuel filter.
Replace fuel filter.
Water or dirt in fuel system.
Clean system and add new fuel.
Clogged or dirty fuel injectors.
Clean injectors.
Engine has poor power.
Plugged air intake system.
Clean system and replace filter.
Clogged or dirty fuel injectors.
Clean injectors.
Fuel filters plugged.
Replace filters.
Engine speed control cable out of
Readjust.
adjustment.
Injection pump out of adjustment.
Contact your DOOSAN dealer.
Valve backlash faulty.
Adjust backlash.
Engine runs hot.
Low coolant level.
Add coolant.
Thermostat faulty.
Replace thermostat.
Radiator cap faulty.
Replace radiator cap.
Radiator core plugged.
Clean radiator.
Oil cooler core plugged.
Clean oil cooler.
Fan belt loose or damaged.
Tighten or replace as required.
Temperature sensor faulty.
Replace sensor.
HYDRAULIC SYSTEM
Problem
Cause
Remedy
None of the controls
Hydraulic pump failed.
Contact your DOOSAN dealer.
function (loud noise from
Low hydraulic oil level.
Add hydraulic oil as required.
pumps).
Suction line plugged or damaged.
Clean or replace as required.
None of the controls
Pilot pump failure.
Contact your DOOSAN dealer.
function (no noise from
Cut off solenoid valve failed.
Replace solenoid.
pumps).
Pilot cutoff switch is ON.
Adjust pilot cutoff switch clearance.
OP000013
Troubleshooting
6-3
Problem
Cause
Remedy
All actuators have low
Low hydraulic oil level.
Add hydraulic oil as required.
power.
Suction filter clogged.
Clean filter.
Hydraulic pumps faulty.
Contact your DOOSAN dealer.
Main relief pressure too low.
Contact your DOOSAN dealer.
Hydraulic pumps excavating.
Bleed air from hydraulic pumps.
Only one or two actions
Overload relief pressure too low.
Reset pressure.
have little or no power.
Makeup check valve leaking.
Clean or replace as required.
Control valve spool faulty.
Replace valve spool.
Dirt in valve spool.
Clean or replace as required.
Actuator failed.
Repair or replace as required.
Cylinder seal failed.
Repair or replace as required.
Cylinder rod damaged.
Repair or replace as required.
Remote control valve failed.
Replace control valve.
Wrong pilot line connection.
Reconnect pilot lines.
Oil temperature too high.
Oil cooler faulty.
Contact your DOOSAN dealer.
Fan belt loose.
Tighten fan belting as required.
SWING SYSTEM
Problem
Cause
Remedy
No swinging motion.
Swing brake valve faulty.
Replace brake valve.
Hydraulic timer faulty.
Replace timer.
Low brake release pressure.
Adjust pressures.
Swing motor failed.
Replace swing motor.
Remote control valve failed.
Replace control valve.
Wrong pilot line connection.
Reconnect pilot lines.
Swing motion jerky.
Swing gear worn.
Replace swing gear.
Swing bearing damaged.
Replace bearing.
Improper lubrication.
Add grease.
Troubleshooting
OP000013
6-4
TRAVEL SYSTEM
Problem
Cause
Remedy
Travel motion does not
Center joint leaking.
Repair or replace as required.
function.
Parking brake will not release.
Repair parking brake.
Travel motor failed.
Repair or replace as required.
Remote control valve failed.
Repair or replace as required.
Wrong pilot line connection.
Reconnect pilot lines.
Travel speed is too low.
Track tension too high or too low.
Adjust tension.
Damaged rollers or idlers.
Repair or replace as required.
Track frame damaged.
Repair as required.
Parking brake will not release.
Repair parking brake.
OP000013
Troubleshooting
6-5
Troubleshooting
OP000013
6-6
OP000601
7Specification
STANDARD SPECIFICATION
SPECIFICATION
COMPONENT
METRIC
ENGLISH
Bucket
CECE
0.51 m3
0.67 yd3
capacity
PCSA
0.59 m3
0.77 yd3
Equipment weight
14.0 metric tons
15.4 tons
Engine
Model
DL06
Type
Water cooled - 6 cylinders
Rated output
96 ps @ 1,850 rpm
94.7 hp @ 1,850 rpm
Maximum torque
44.5 kg•m @ 1,400 rpm
322 ft lb @ 1,400 rpm
Fuel tank capacity
267 liters
70.5 U.S. gal.
Hydraulic
Type
Axial piston
pump
Discharging pressure
330 kg/cm2
4,700 psi
Maximum discharge quantity
2 x 114 liters/min
2 x 30.1 U.S. gpm
Hydraulic oil
Tank Level
98.8 liters
26.1 U.S. gal.
capacity
System
147.8 liters
39.0 U.S. gal.
Performance
Digging
Bucket
10.5 metric tons
11.6 tons
capability
Arm
6.2 metric tons
6.8 tons
Swing speed
10.7 rpm
Travel speed
High speed
4.7 km/h
2.9 MPH
Low speed
3 km/h
1.9 MPH
Traction force
High speed
7.25 metric tons
8.0 tons
Low speed
11.8 metric tons
13.0 tons
Gradeability
35° (70% slope)
Ground pressure
0.39 kg/cm2
5.5 psi
Ground clearance
410 mm
16.1 in
Track shoe width
600 mm
23.6 in
Upper roller qty.
1 per side
Bottom roller qty.
7 per side
OP000601
Specification
7-1
OVERALL DIMENSIONS
One - Piece Boom
H
A
I
J
B
C
O
G
F
N
M
K
D
L
E
FG009598
Figure 1
DIMENSION
4.6 m (15' 1") One - Piece BOOM
2.1 m (6' 11") Arm
2.5 m (8' 2") Arm
3.0 m (9' 10") Arm
A
7,690 mm (25' 3")
7,680 mm (25' 2")
7,640 mm (25' 0")
B
2,200 mm (7' 2")
C
5,490 mm (18' 0")
5,480 mm (17' 11")
5,440 mm (17' 10")
D
3,034 mm (9' 11")
E
3,755 mm (12' 4")
F
894 mm (2' 11")
G
2,570 mm (8' 5")
2,710 mm (8' 10")
3,090 mm (10' 1")
H
2,540 mm (8' 4")
I
1,270 mm (4' 2")
J
1,270 mm (4' 2")
K
1,990 mm (6' 6")
L
2,590 mm (8' 6")
M
600 mm (2' 0")
N
410 mm (1' 4")
O
2,773 mm (9' 1")
Specification
OP000601
7-2
Two - Piece Boom
H
A
I
J
B
C
O
G
F
N
M
K
D
L
E
FG009724
Figure 1
DIMENSION
4.98 m (16' 4") Two - Piece BOOM
2.1 m (6' 11") Arm
2.5 m (8' 2") Arm
A
8,060 mm (26' 5")
8,015 mm (26' 4")
B
2,200 mm (7' 2")
C
5,860 mm (19' 3")
5,815 mm (19' 1")
D
3,180 mm (10' 4")
E
3,968 mm (13' 0")
F
1,035 mm (3' 4")
G
2,655 mm (8' 9")
2,770 mm (9' 1")
H
2,540 mm (8' 4")
I
1,270 mm (4' 2")
J
1,270 mm (4' 2")
K
2,200 mm (7' 2")
L
2,800 mm (9' 2")
M
600 mm (2' 0")
N
455 mm (1' 5")
O
2,925 mm (9' 6")
OP000601
Specification
7-3
WORKING RANGE
One - Piece Boom
E
9
8
7
6
5
C
4
3
D
2
1
G.L
0
0
1
2
3
4
5
6
7
8
9
-1
-2
B
-3
-4
-5
-6
A
FG009599
Figure 2
4.6 m (15' 1") One - Piece BOOM
DIM.
2.1 m (6' 11") Arm
2.5 m (8' 2") Arm
3.0 m (9' 10") Arm
A
Max. Digging Reach
7,845 mm (25' 9")
8,300 mm (27' 3")
8,680 mm (28' 6")
B
Max. Digging Depth
5,250 mm (17' 3")
5,645 mm (18' 6")
6,150 mm (20' 2")
C
Max. Digging Height
8,195 mm (26' 11")
8,675 mm (28' 5")
8,745 mm (28' 8")
D
Max. Loading Height
5,875 mm (19' 3")
6,300 mm (20' 8")
6,415 mm (21' 0")
E
Min. Swing Radius
2,345 mm (7' 8")
2,375 mm (7' 9")
2,585 mm (8' 6")
Specification
OP000601
7-4
Two - Piece Boom
E
9
8
7
6
5
C
4
3
D
2
1
G.L
0
0
1
2
3
4
5
6
7
8
9
-1
-2
B
-3
-4
-5
-6
A
FG009725
Figure 3
4.98 m (16' 4") Two - Piece BOOM
DIM.
2.1 m (6' 11") Arm
2.5 m (8' 2") Arm
A
Max. Digging Reach
8,380 mm (27' 6")
8,805 mm (28' 11")
B
Max. Digging Depth
5,440 mm (17' 10")
5,850 mm (19' 2")
C
Max. Digging Height
8,820 mm (28' 11")
9,235 mm (30' 4")
D
Max. Loading Height
6,420 mm (21' 1")
6,810 mm (22' 4")
E
Min. Swing Radius
2,925 mm (9' 7")
2,935 mm (9' 8")
OP000601
Specification
7-5
APPROXIMATE WEIGHT OF
WORKLOAD MATERIALS
IMPORTANT
Weights are approximations of estimated average volume
and mass. Exposure to rain, snow or ground water; settling
or compaction due to overhead weight and chemical or
industrial processing or changes due to thermal or
chemical transformations could all increase value of
weights listed in table.
LOW WEIGHT OR
MEDIUM WEIGHT OR
HIGH WEIGHT OR
DENSITY
DENSITY
DENSITY
MATERIAL
1,100 KG/M3
1,600 KG/M3
2,000 KG/M3
(1,850 LB/YD3), OR
(2,700 LB/YD3), OR
(3,370 LB/YD3), OR
LESS
LESS
LESS
3
401 kg/m
Charcoal
---------------------
---------------------
(695 lb/yd3)
3
433 kg/m
Coke, blast furnace size
---------------------
---------------------
(729 lb/yd3)
3
449 kg/m
Coke, foundry size
---------------------
---------------------
(756 lb/yd3)
3
801 kg/m
Coal, bituminous slack, piled
---------------------
---------------------
(1,350 lb/yd3)
3
881 kg/m
Coal, bituminous r. of m., piled
---------------------
---------------------
(1,485 lb/yd3)
3
897 kg/m
Coal, anthracite
---------------------
---------------------
(1,512 lb/yd3)
3
1,009 kg/m
Clay, DRY, in broken lumps
---------------------
---------------------
(1,701 lb/yd3)
3
1,746 kg/m
Clay, DAMP, natural bed
---------------------
---------------------
(2,943 lb/yd3)
3
1,506 kg/m
Cement, Portland, DRY granular
---------------------
---------------------
(2,583 lb/yd3)
3
1,362 kg/m
Cement, Portland, DRY clinkers
---------------------
---------------------
(2,295 lb/yd3)
3
1,522 kg/m
Dolomite, crushed
---------------------
---------------------
(2,565 lb/yd3)
3
1,202 kg/m
Earth, loamy, DRY, loose
---------------------
---------------------
(2,025 lb/yd3)
3
1,522 kg/m
Earth, DRY, packed
---------------------
---------------------
(2,565 lb/yd3)
3
1,762 kg/m
Earth, WET, muddy
---------------------
---------------------
(2,970 lb/yd3)
Specification
OP000601
7-6
LOW WEIGHT OR
MEDIUM WEIGHT OR
HIGH WEIGHT OR
DENSITY
DENSITY
DENSITY
MATERIAL
1,100 KG/M3
1,600 KG/M3
2,000 KG/M3
(1,850 LB/YD3), OR
(2,700 LB/YD3), OR
(3,370 LB/YD3), OR
LESS
LESS
LESS
3
961 kg/m
Gypsum, calcined, (heated, powder)
---------------------
---------------------
(1,620 lb/yd3)
3
1,522 kg/m
Gypsum, crushed to 3 inch size
---------------------
---------------------
(2,565 lb/yd3)
3
1,810 kg/m
Gravel, DRY, packed fragments
---------------------
---------------------
(3,051 lb/yd3)
3
1,922 kg/m
Gravel, WET, packed fragments
---------------------
---------------------
(3,240 lb/yd3)
3
1,282 kg/m
Limestone, graded above 2
---------------------
---------------------
(2,160 lb/yd3)
Limestone, graded
1,362 kg/m3
---------------------
---------------------
1-1/2 or 2
(2,295 lb/yd3)
3
1,522 kg/m
Limestone, crushed
---------------------
---------------------
(2,565 lb/yd3)
3
1,602 kg/m
Limestone, fine
---------------------
---------------------
(2,705 lb/yd3)
3
1,282 kg/m
Phosphate, rock
---------------------
---------------------
(2,160 lb/yd3)
3
929 kg/m
Salt
---------------------
---------------------
(1,566 lb/yd3)
3
529 kg/m
Snow, light density
---------------------
---------------------
(891 lb/yd3)
3
1,522 kg/m
Sand, DRY, loose
---------------------
---------------------
(2,565 lb/yd3)
3
1,922 kg/m
Sand, WET, packed
---------------------
---------------------
(3,240 lb/yd3)
3
1,362 kg/m
Shale, broken
---------------------
---------------------
(2,295 lb/yd3)
3
529 kg/m
Sulphur, broken
---------------------
---------------------
(1,620 lb/yd3)
OP000601
Specification
7-7
Specification
OP000601
7-8
1INDEX
Numerics
Cabin Work Light Switch 2-15
1,000 Hour / 6 Month Service 4-45
Ceiling Cover 2-65
10 Hour / Daily Service 4-14
Charge Warning Light 2-28
12,000 Hour / Six Year Service 4-59
Check and Confirmation After Stopping Engine
2,000 Hour / Yearly Service 4-52
3-12
250 Hour / Monthly Service 4-29
Cigarette Lighter 2-18
4,000 Hour / Biennial Service 4-58
Circuit Breaker 2-59
50 Hour / Weekly Service 4-26
Clock 2-27, 2-41
500 Hour / 3 Month Service 4-36
Cold Weather Hydraulic System Warm-up 3-10
Cold Weather Starting 3-6
Communication
A
Error Warning 2-32
Abnormal State Warning Symbols 2-33
Indicator 2-31
Adjust Valve Clearance 4-57
Component Locations 2-4
Air Intake System 4-23
Constant Speed Button 2-17
Outer Element of Air Cleaner 4-41
Coolant Temperature Warning Light 2-29
Replace Outer Air Cleaner Element 4-53
Cooling System
Alternator and Starter 4-57
Clean Radiator, Oil Cooler and Air Conditioner
Antifreeze Concentration Tables 4-77
Condenser Coil 4-40
Antivibration Shock Mounts 4-57
Engine 4-76
Ashtray 2-69
Engine Coolant Temperature Warning Light
Audio Control Panel 2-12
2-29
Auto Idle Mode 3-21
Oil Cooler Dust Net 4-21
Auto Idle Selector Button 2-37
Radiator Coolant 4-54
Auxiliary Mode Switch 2-12
Refill Cooling System 4-21
Cracks and Faulty Welds 4-24
B
Cup Holder 2-71
Batteries 4-35
Cycle Time Tests 4-57
Battery 4-72
Box Door 2-72
D
Electrolyte Level 4-73
Description of Lubrication and Service Chart 4-10
Terminals 4-73
Digital Clock 2-27
Voltage 2-32
Display Selection 2-40
Bolt and Nut Inspection 4-61
Display Selector Button 2-39
Boom, Arm and Front Attachment Pins 4-26, 4-30
Door Side Latch 2-68
Boost Mode 3-22
Door Window Holder 2-71
Booster Button 2-20
Down Arrow Button 2-39
Booster Cable 3-7
Breaker Selection 2-49
E
Bucket 4-69
O-ring 4-70
Electrical System 4-72, 6-1
Teeth and Side Cutters 4-22
Engine 6-2
Tooth 4-69
Adjust Valve Clearance 4-57
Check and Adjust Engine 4-51
Check Warning Light 2-29
C
Coolant Temperature Gauge 2-26
Cabin Light 2-59
Coolant Temperature Warning Light 2-29
Cabin Storage Compartments 2-69
Cover 2-72
K1030026E
Index
8-1
Emergency Stop Switch 2-12
Head Bolt Torques 4-57
Fan Belt 4-32
Headlight Switch 2-14
Head Bolt Torques 4-57
Heater and Air Conditioner 2-51
Oil and Filter 4-28, 4-37
Additional Operating Instruction 2-56
Oil Level 4-15
Control Panel 2-16, 2-52
Oil Pressure Warning Light 2-28
Filter 4-38, 4-49
Shutdown 3-11
Location of Controls and Vents 2-51
Speed 2-32
Memory Function of Used Mode 2-56
Speed Control Dial 2-10
Refrigerant 4-50
Start 3-4
System 4-60
Start and Stop 3-2
Horn Button 2-20
ESC Button 2-40
Hose Clamps 4-35
Excavator Rated Lift Capacity Tables 1-48
Hour Meter 2-28
Hydraulic System 6-3
Flow Control 2-47
F
Front Hydraulic Pump Pressure 2-33
Fan Belt 4-28
General Venting 4-85
Filter / Oil Info 2-42
Hydraulic Breaker 3-34
Filter State 2-33
Hydraulic Hoses and Tubing 3-34
Flow Control 2-47
Oil and Filter 3-38
Flow Control Button 2-37
Operation 3-34
Front
Selection 3-34
Bottom Window 2-67
Hydraulic Cylinders 4-84
End Attachments 4-35
Hydraulic Oil Exchange 4-55
Hydraulic Pump Pressure 2-33
Hydraulic Oil Return Filter 4-34, 4-46
Upper Windows 2-66
Hydraulic Oil Tank 4-15
Windows 2-66
Hydraulic Oil Temperature Gauge 2-27
Fuel
Leaks in the Hydraulic System 4-17
Filter 4-43
Main System Pump 4-84
Gauge 2-26
Oil Exchange 4-55
Heater Switch 2-19
Rear Hydraulic Pump Pressure 2-33
Level 4-18
Swing Motor 4-85
System 4-44
Warm-up 3-9
Transfer Pump 4-78
Tank Drain Valve 4-28
Transfer Pump 4-78
I
Fuse
Indicator
Boxes 2-60, 4-74
Communication Indicator 2-31
Fuses 4-73
Indicator Lights
Fusible Link 2-60
Charge Warning Light 2-28
Identification 4-75
Coolant Temperature Warning Light 2-29
Engine Check Warning 2-29
Engine Oil Pressure Warning Light 2-28
G
Preheating Indicator Light 2-30
Gauges
Work Light 2-30
Engine Coolant Temperature Gauge 2-26
Inspecting Engine Before Starting 3-2
Fuel Gauge 2-26
Instrument Panel 2-21, 2-24
Hour Meter 2-28
Intermittent Speed Button 2-17
Hydraulic Oil Temperature 2-27
Multifunction Gauge 2-27, 2-31
General Venting 4-85
L
Language 2-41
Leaks in the Fuel System 4-18
H
Leaks in the Hydraulic System 4-17
Handling a New Excavator 3-1
Levers
Handling of Accumulator 4-81
Adjusting Reclining 2-62
Hanger 2-70, 2-71
K1030026E
Index
8-2
Adjusting the Seat Forward 2-61
P
Adjusting the Seat's Angle 2-61
Panels
Angle Adjustment of Armrest 2-62
Air Conditioner Control Panel 2-16
Safety Lever 2-21
Audio Control 2-12
Lifting 3-42
Heater and Air Conditioner 2-51
Lifting With Sling 5-5
Heater and Air Conditioner Control Panel 2-52
Lights
Instrument 2-21
Cabin 2-59
Instrument Panel 2-24
Loading and Unloading 5-1
Wiper Switch 2-16
Locations of Safety Labels 1-5
Parking Excavator 3-32
Long Term Storage 4-86
Password
Lubrication and filters 3-2
Activated 2-25
Lubrication and Service Chart 4-8
Set Password 2-45
Password Activated 2-25
M
Photo Sensor 2-22
Magnetic Clutch 4-60
Pilot Cutoff Switch 2-59
Main Menu 2-38
Pilot Filter 4-35, 4-47
Maintenance in Special Conditions 4-87
Pins and Bushings 4-35
Maintenance Intervals 4-12
Power Boost Selection 2-49
Miscellaneous Access Doors 2-72
Power Mode 3-20
Mode Selection 3-20
Power Mode Selector Button 2-36
Mode Selector Buttons 2-36
Power Socket 2-18
Multifunction Gauge 2-27, 2-31
Preheating Light 2-30
Preliminary Work Machine Setup for Maintenance
4-4
N
Preventive Maintenance 4-1
Nuts and Bolts 4-35
Pump Pressure
Front Pump 2-33
O
Rear Pump 2-33
Oil Cooler Dust Net 4-21
Oil Level of Travel Reducer 4-33
Q
Opening the Window 2-66
Quick Clamp Operation Selection 2-50
Operating
Quick Clamp Switch (Optional) 2-11
Instructions 3-20
Precautions 3-27
R
Techniques 3-42
Operation 3-1
Radiator Coolant 4-54
Operation In
Rear Hydraulic Pump Pressure 2-33
Extreme Cold 3-44
Refill Cooling System 4-21
Extreme Heat 3-45
Rotating Buttons 2-20
High Altitudes 3-47
Rainy or Humid Conditions 3-46
S
Salt Water Areas 3-47
Safety Lever 2-21, 3-13
Operation of All Switches 4-24
Safety Precautions 4-3
Operation Selection Display 2-49
Seat 2-61
Operation Under Unusual Conditions 3-44
Seat Adjustment
Operational Checks Before Starting Engine 3-3
Adjusting Reclining 2-62
Operational Controls and Panels 2-8
Adjusting the Seat Forward 2-61
Operator's Area 2-6
Adjusting the Seat's Angle 2-61
Operator's Compartment Light 2-59
Adjustment of Lumbar Support 2-62
Outer Air Cleaner Element 4-53
Air Suspension Seat 2-64
Outer Element of Air Cleaner 4-41
Angle Adjustment of Armrest 2-62
Overall Dimensions 7-2
Headrest 2-62
Overload Alarm Selection 2-50
Left ad Right Control Stand Location 2-64
Overload Warning Switch (Optional) 2-19
Left and Right Control Stand Elevation Height
K1030026E
Index
8-3
2-64
Engine Speed Control 3-20
Seat Belt 2-63, 4-23
Engine Speed Control Dial 2-10
Seat Warmer Switch (Optional) 2-19
ESC Button 2-40
Selection Button 2-39
Flow Control Button 2-37
Selection of
Fuel Heater 2-19
Breaker 2-49
Headlight Switch 2-14
Overload Alarm 2-50
Horn Button 2-20
Power Boost Selection 2-49
Intermittent Speed Button 2-17
Quick Clamp Operation 2-50
Overload Warning (Optional) 2-19
Shear 2-49
Pilot Cutoff Switch 2-59
Serial Numbers 4-2
Power Mode Selector Button 2-36
Set Password 2-45
Power Socket 2-18
Setting Clock 2-41
Quick Clamp (Optional) 2-11
Shear Buttons 2-21
Rotating Buttons 2-20
Shear Selection 2-49
Seat Warmer (Optional) 2-19
Shutdown
Selection Button 2-39
Check and Confirmation After Stopping Engine
Shear Buttons 2-21
3-12
Starter Switch 2-10
Engine Shutdown 3-11
Travel Speed Selector Switch 2-14
Parking Excavator 3-32
Travel/Swing Alarm (Optional) 2-18
Side Door 2-72
Trenching Mode Selector Button 2-37
Specification 7-1
Up Arrow Button 2-38
Standard Specification 7-1
Warning Light 2-15
Starter Switch 2-10
Washer Button 2-17
Starting Engine Using a Booster Battery 3-7
Wiper Switch (Lower) 2-16
Start-up
Symbols
Cold Weather Hydraulic System Warm-up 3-10
Air Cleaner Clogged Warning 2-35
Cold Weather Starting 3-6
Hydraulic Oil Overheat Warning 2-34
Engine Start 3-4
Overload Warning (Optional) 2-36
Hydraulic System Warm-up 3-9
Pilot Filter Clogged Warning 2-34
Inspection Before Starting Engine 3-2
Return Filter Clogged Warning 2-35
Operational Checks Before Starting Engine 3-3
Starting Engine Using a Booster Battery 3-7
T
Stereo 2-57
Table of Recommended Lubricants 4-6
Audio Control Panel 2-12
Towing Procedure 3-33
Structural Damage 4-57
Track Assemblies 4-28
Suction Strainer 4-55
Track Tension 4-82
Sun Visor 2-70
Transportation 5-1
Swing
Travel 3-14
Bearing 4-27
Control Lever Operation 3-16
Gear and Pinion 4-36
Instructions 3-17
Motor 4-85
Reduction Device 4-33, 4-34, 4-48
Reduction Device 4-20, 4-29, 4-45, 4-52
Speed Selector Switch 2-14
System 6-4
System 6-5
Switches
Travel/Swing Alarm Switch (Optional) 2-18
Auto Idle Selector Button 2-37
Trenching Mode Selector Button 2-37
Automatic Travel Speed Control 3-14
Troubleshooting 6-1
Auxiliary Mode 2-12
Booster Button 2-20
U
Cabin Work Light Switch 2-15
Unloading and Loading 5-1
Cigar Lighter 2-18
Up Arrow Button 2-38
Constant Speed Button 2-17
Display Selector Button 2-39
Down Arrow Button 2-39
V
Engine Emergency Stop 2-12
Venting and Priming Hydraulic System 4-84
K1030026E
Index
8-4
General Venting 4-85
Door Window Holder 2-71
Hydraulic Cylinders 4-84
Front 2-66
Main System Pump 4-84
Front Bottom 2-67
Swing Motor 4-85
Front Upper 2-66
Opening 2-66
Sun Visor 2-70
W
Wiper Switch (Lower) 2-16
Warning Light Switch 2-15
Wiper Switch Panel 2-16
Washer Button 2-17
Work Levers (Joysticks) (ISO Style) 3-23
Water Separator 4-19
Work Light Indicator Light 2-30
Weight of Workload Materials 7-6
Work Mode 3-21
Window Washer Liquid 4-22
Working Range 7-4
Windows
K1030026E
Index
8-5