Doosan Mega 500-V (TIER II). Operation and Maintenance Manual (2001)

Bucket cylinder heads

(left,

right),

2 points. Greased from

two remote grease points

(1,

Figure 34).

Figure 36

Loader arm foot ends,

locations on each side of

machine. Greased from two

remote grease points (2, Figure

34).

Figure 37

F: Grease Rear Axle Pivot

Rear Axle pivot

(1, Figure

38),

locations on each side of machine.

Use remote grease fittings mounted

on frame shown in Figure 38.

AHO0390L

Figure 38

Figure 39

4-22 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

GREASE STEERING CYLINDER ROD AND

BASE ENDS

Steering cylinder rods, 2 locations, one on

each side of machine.

Figure 40

Steering cylinder head ends, 2 locations.

Use remote grease fittings mounted on

frame.

Figure 41

GREASE UPPER AND LOWER CENTER PINS

Center pins, upper (Figure 42) and lower (Figure 43). Two locations on each side of machine.

Figure 42

Figure 43

CHANGE ENGINE OIL AND FILTER (INITIAL)

NOTE: Engine oil and filter must be changed after first 50 hours of operation to comply with new

machine break-in requirements. After first change, oil and filter should be changed every

250 hours. Follow procedure under 250 hour maintenance interval (See page 4-30).

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-23

HYDRAULIC FULL FLOW FILTER REPLACEMENT (INITIAL)

NOTE: Replace hydraulic full flow filter after first 50 hours of operation and every 250 Hours

thereafter. Follow procedure under 250 hour maintenance interval (See page 4-27)

CHECK WATER PUMP BELT TENSION - ALTERNATOR, AND AIR CONDITIONER BELT (INITIAL)

NOTE: Water pump belt tension must be checked after first 50 hours of operation to comply with

new machine break-in requirements. After first check, water pump belt must be checked

every 250 hours. Follow procedure printed under 250 hour maintenance interval (See

page 4-29).

CLEAN EXTERIOR OF RADIATOR, OIL COOLER AND AIR-CONDITIONER EVAPORATOR

Dust and dirt accumulation on fins of radiator, oil cooler, and additional transmission cooler greatly

reduce their cooling efficiency. Use compressed air, water and steam to clean fins on radiator, oil

cooler, and transmission cooler.

NOTE: On an especially dusty job site, clean fins every 50 hours. On other job sites, clean fins

every 500 hours (See page 4-35).

4-24 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

Unscrew element cover (5, Figure

46).

Cover is filled with oil. Dispose of oil.

Remove O-ring (3, Figure 46) and filter

element (4).

Use a non flammable, non-toxic solvent to

clean out cover (5, Figure 46).

Insert a new filter element (4, Figure 46)

into cover (5). Install a new O-ring (3).

Screw cover (5, Figure 46) onto filter head

(1).

Figure 46

CHECK ENGINE AIR CLEANER PRE-

CLEANER

The engine is equipped with a pre-cleaner.

Dust, insects, rainwater etc., can be

present in the air. The pre-cleaner collects

this material and discharges it. This

prevents material from being drawn into air

cleaner. The pre-cleaner does not need

periodic cleaning or replacement.

Figure 47

4-26 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

HYDRAULIC FULL FLOW FILTER REPLACEMENT

WARNING!

The hydraulic oil will be hot after normal machine operation. Allow system to cool before

attempting to service any of the hydraulic components.

The hydraulic tank is pressurized. Loosen hydraulic oil fill cap slightly to allow pressurized air to

vent. After pressure has been released, it is safe to remove either the fill cap or service covers or

drain water from the tank.

IMPORTANT!

Make sure to clean any dirt or water from top of the hydraulic tank, especially around fill port and

filter ports.

NOTE: Replace hydraulic full flow filter after first 50 hours of operation and every 250 Hours

thereafter.

Loosen breather cap on hydraulic

reservoir. (See Figure 10 on page 4-10).

Clean filter cover

(2, Figure

48) and

reservoir around cover.

Remove bolts (1, Figure 48) from cover

(2).

Lift cover (2, Figure 48) and O-ring (4) off

reservoir. Control spring

(3) that sits

beneath cover. Remove spring (3).

Remove valve (5, Figure 48) and filter

element (6) from reservoir.

Clean underside of cover (2, Figure 48).

Set a new element (6, Figure 48) and

valve

(5) down into reservoir. Press

element down onto its base until top of

element is approximately 4 mm (0.157 in)

below edge of reservoir.

Figure 48

Install a new O-ring (4, Figure 48) on cover

(2). Set spring (3) into place on element

(6).

Set cover (2, Figure 48) into place over

element (6). Install bolts (1) through cover

(2) and tighten them.

10.

Tighten breather cap on reservoir.

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-27

DRAIN WATER FROM HYDRAULIC OIL TANK

WARNING!

Be certain that hydraulic oil has cooled before draining water and sediment. Hot oil could splash

and cause burns.

The hydraulic tank is pressurized. Press button in center of breather to allow pressurized air to

vent. After pressure has been released, it is safe to remove either the fill cap or service covers.

Position machine on firm, level ground.

Lower boom and position bucket on

ground. Turn “Off engine.

Position a container under hydraulic

reservoir drain plug. Open reservoir

breather cap (See Figure 10 on page 4-

10). Loosen drain cock from bottom of

reservoir (Figure 49). Allow all water and

sediment to drain out. Tighten drain cock.

Figure 49

CLEAN AIR CLEANER

CAUTION!

Never remove air cleaner element while

engine is running. This will allow dirt to be

sucked into engine and cause serious

engine damage. Always turn engine "OFF"

before servicing air cleaner.

AQO0170L

Figure 50

Locate the air filter assembly (Figure 51).

Remove access cover and remove outer

element of air filter assembly.

NOTE: If indicator light on instrument

panel comes "ON," this

indicates that air cleaner needs

to be serviced.

NOTE: Replace outer element every

1500 hours of service.

Figure 51

4-28 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

Clean outer filter by blowing compressed

air from inside of filter towards the outside.

Do not use more than 205 kPa (30 psi) air

pressure.

Clean the inside of air filter housing and

inside of air filter housing cover.

CAUTION!

Never clean the inside of air filter

HAOC570L

housing while the inner element is

not installed.

Figure 52

Properly reinstall air filter and cover.

Tighten cover wing nut by hand. Do not

use any tools to tighten wing nut.

CHECK WATER PUMP BELT TENSION

IMPORTANT

A loose water pump belt can cause engine

overheating, poor charging, and/or

premature belt wear. A belt that is too tight

can cause damage to the water pump,

alternator bearing or belt.

NOTE: Water pump belt tension must

be checked after first 50 hours

Figure 53

of operation to comply with new

machine break-in requirements.

After first check, water pump

belt must be checked every 150

hours. After first tension check,

belt must be checked every 150

hours.

Apply 10 kg (22 lb) of force to midpoint of water pump belt. (Figure 53). The water pump belt should

deflect 10 mm (0.4 in). If belt deflects more than this, loosen control link and move idler pulley (2) to

tighten belt tension until deflection is 10 mm (0.4 in). Inspect water pump belt for damage. If belt is

damaged, replace it.

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-29

CHANGE ENGINE OIL AND FILTER

NOTE: Engine oil and filter must be changed after first 50 hours of operation to comply with new

machine break-in requirements. After first change, oil and filter should be changed every

250 hours.

CAUTION!

Never attempt to change oil or filter on a hot engine. Hot oil could splash and cause burns. Allow

engine to cool down before changing oil or filter.

Position a larger container under drain

cock beside left wall of fuel tank. Loosen

drain cock and allow all engine oil to drain

out. Tighten drain cock.

NOTE: Oil warming is good when

replacing oil. If machine is cold,

operate the engine to bring the

coolant temperature up to

about 40°C (104°F). When the

needle

the

coolant

temperature gauge reaches the

middle of the "WHITE ZONE,"

the temperature is about 40°C

Figure 54

(104°F).

Replace engine oil filter. The engine oil

filter is a spin-on type (Figure 55). Remove

and discard filter.

Install new filter, Apply a small amount of

oil around filter gasket. Screw filter on

head until gasket contacts head by hand,

turn filter

3/4~1 turn more with filter

wrench.

NOTE: See

“Fluid Capacities” on

page 4-5 for capacity.

Refill engine with correct oil through oil fill

port. Refer to Lubrication Table of this

Figure 55

manual for recommended oil for the

operating conditions.

Start engine and check engine oil pressure

light.

Shutdown engine. Lock for signs of leaks

at filter. Recheck oil level.

4-30 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

REPLACE DCA4 COOLANT FILTER CARTRIDGE

CAUTION!

Pressurized radiator tank.

Spray of hot coolant can cause burn.

Stop engine and allow radiator and coolant to cool completely, then open cap slowly to relieve

pressure.

CAUTION!

Hot coolant and engine components can cause burn.

Avoid contact with coolant or engine components.

Park the machine on a level surface, apply

the parking brake, lower the attachment to

the ground, and stop the engine.

Press the button on the radiator tank cap to

release any remaining pressure, and remove

the cap slowly (Figure 56).

Figure 56

Turn the coolant shutoff valve "OFF."

Figure 57

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-31

Remove and properly dispose of the

coolant filter.

Clean the filter head gasket surface.

Apply a light film of clean engine oil to the

gasket surface of a new DCA4 coolant

filter cartridge.

Figure 58

Install the filter firmly by hand. Follow the

instructions supplied with the filter.

"OPEN" the coolant shutoff valve and

install the radiator cap.

CAUTION!

Severe engine damage will result if

the coolant shutoff valve is left

closed.

Figure 59

Run the engine and check for coolant

leaks.

10. Idle the engine for about five minutes to

purge all air from the coolant.

11. After air has been purged from the system,

stop the engine and check the coolant

level again.

12. If needed, add required amount of the

coolant.

4-32 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

REPLACE FUEL FILTER

WARNING!

Exchange filter after waiting for engine to cool. Be careful of fire hazards. Do not smoke.

Locate fuel

filter

inside

engine

compartment.

Position a small container under fuel filter.

Drain filter by opening drain valve on

bottom of filter.

Unscrew fuel filter from head assembly.

Discard fuel filter.

Figure 60

Cleaning filter head.

Figure 61

Install new fuel filter. Screw filter on head

until gasket contacts head, turn filter 1/3-1/

2 turn more.

NOTE: Coat fuel filter gasket with fuel.

NOTE: Fill fuel filter with clean fuel.

This will help reduce fuel

system priming.

Start engine. After engine has run for a

couple of minutes, shutdown engine and

lock for leaks.

If engine does not start, fuel system may

Figure 63

need priming. Prime fuel system using the

following procedure:

A. Loosen plug on top of fuel filter head.

B. Unscrew and pump the hand operated primer pump near fuel injection pump. Pump primer until

fuel is present at plug hole in fuel filter head.

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-33

C. Tighten plug in fuel filter head.

D. Continue to pump primer pump until a strong resistance is felt. Screw primer pump knob back

into housing.

E. Start engine and lock for signs of leaks.

AXLE DIFFERENTIAL AND PLANETARIES OIL REPLACEMENT (INITIAL)

NOTE: The differential and planetaries oil should be drained and refilled after first 250 hours of

operation. There after every 1500 hours of operation. (See page 4-42)

CHECK DIFFERENTIAL GEAR OIL

Park the machine on a level surface, apply the parking brake, lower the attachment to the ground, and

stop the engine.

Remove the oil level plug from the front axle housing, using a 12 mm hex (Allen) wrench.

If the oil level is lower than the plug, add the specified oil through the plug hole.

Magnetic plugs are used for axle housing. Wipe off the small amount of the metallic powder that

usually sticks to the plugs. If abnormal debris is found, determine the cause and correct it. Refer to

the Shop Manual for the proper correction procedure.

If there is any sign of water in the oil, drain and replace the oil. Oil containing water looks milky.

Retighten the level plug.

Check the rear axle level following the same steps.

CHECK PLANETARY GEAR OIL

Check the oil level on all four wheels

Move the machine on a level surface so that the oil level mark on the planetary gear housing comes

to the horizontal position.

Turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

Remove the oil drain plug on the housing, using a 22mm hex (Allen) wrench.

If the oil level is lower than the plug, add the specified oil through the plug hole.

Magnetic plugs are used for planetary gear housing. Wipe off small amount of metallic powder that

usually sticks to the plugs. If abnormal debris is found determine the cause and correct it. Refer to the

Shop Manual for the proper correction procedure.

If there is any sign of water in the oil, drain and replace the oil. Oil containing water looks milky.

Retighten the plug.

REPLACING TRANSMISSION OIL AND FILTER (INITIAL)

NOTE: Transmission oil and filter must be changed after first 250 hours of operation to comply

with new machine break-in requirements. After first change, oil and filter must be changed

every 1000 hours. Follow procedure under 1000 hour maintenance interval (See page

4-24).

4-34 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

500 HOUR / 3 MONTH SERVICE

PERFORM ALL 10 HOUR / DAILY, 50, 150, AND 250 HOUR SERVICE CHECKS

CLEAN EXTERIOR OF RADIATOR, OIL

COOLER AND AIR-CONDITIONER

EVAPORATOR

Dust and dirt accumulation on fins of

radiator, oil cooler, and additional

transmission cooler greatly reduce their

cooling efficiency. Use compressed air,

water and steam to clean fins on radiator,

oil cooler, and transmission cooler.

NOTE: On an especially dusty job site,

clean fins every 50 hours. On

other job sites, clean fins every

Figure 64 RADIATOR AND OIL COOLER

500 hours.

Figure 65 AIR-CONDITIONER EVAPORATOR

CLEAN AIR CONDITIONING FILTER

The unit is equipped with an air filtration system which filters out dirt and dust particles from air being

circulated into operator’s cab. The air conditioning filter is in the right side switch panel console.

Open access cover on the lower right side

of cab on the outside to gain access to

filter.

Figure 66

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-35

Remove filter element and inspect it for

damage.

Use compressed air to clean filter element.

If element is very dirty use a mild soap and

water solution to clean it.

Figure 67

NOTE: If water was used to clean filter element be sure it is completely dry before installation.

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 element is damaged, replace

damaged filter by a new one.

WARNING!

All service and inspection of the air conditioning system should be performed with the

starter switch in the "O" (OFF) position.

4-36 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

1,000 HOUR / 6 MONTH SERVICE

PERFORM ALL 10 HOUR / DAILY, 50, 150, 250, AND 500 HOUR SERVICE CHECKS

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 engine. Make sure to lock out and tag the controls notifying

personnel that service work is being performed.

Do not remove the radiator cap unless it is required. Observe the coolant level in the

coolant recovery tank.

WARNING!

Vent air in intercooler. Be sure to vent air

from intercooler to prevent damage to

engine.

Figure 68

Slowly open the radiator cap (Figure 68) to

allow any pressure to escape.

NOTE: Do not remove the coolant filter.

Place a container under the radiator and

open the drain valve (Figure 69).

Figure 69

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-37

Open heater shutoff valve (Figure 70) to

allow coolant to drain from heater core.

Install drain plug, and close vent and drain

valve after coolant has completely drained

from system.

Fill cooling system with a flushing solution.

NOTE: When filling engine with

flushing solution open vent

(Figure

68) on intercooler to

allow air to escape. Close vent

when coolant is present.

AQO0370L

Figure 70

Run engine at low idle until the coolant

temperature gauge reaches the "GREEN

ZONE." Run engine for another 10 minutes.

Alter allowing engine to cool.

Drain flushing fluid and fill system with water.

Run engine again to allow water to completely circulate.

10.

Drain water and fill system with proper anti-freeze mixture for ambient temperature. Refer to coolant

concentration table (See page 4-14)

NOTE: When filling engine with coolant, open vent (Figure 68) on intercooler to allow air to

escape. Close vent when coolant is present.

11.

Run engine without radiator cap installed, so that all air will be purged from system. Fill radiator to fill

neck.

12.

Drain and fill radiator coolant recovery tank.

DRAIN AND REPLACE TRANSMISSION OIL AND FILTER

NOTE: Transmission oil and filter must be changed after first 250 hours of operation to comply

with new machine break-in requirements. After first change, oil and filter must be changed

every 1000 hours. Follow procedure under 1000 hour maintenance interval (See page

4-24).

Start machine and drive it until transmission fluid has warmed to 65 - 93°C (149 - 200°F). Park

machine on a level area.

Place transmission lever in "NEUTRAL." Apply parking brake. Turn "OFF" engine. Block tires.

NOTE: See “Fluid Capacities” on page 4-5 for capacity.

4-38 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

Remove drain plug. Allow all transmission

fluid to drain into a receptacle. Properly

dispose of drained fluid. Clean drain plug.

Install drain plug in transmission.

Remove inlet strainer.

Use a

nonflammable, non-toxic solvent to clean

strainer.

Inspect gasket on inlet strainer. Replace

gasket if it is damaged. Install inlet strainer.

Remove breather filter. Clean breather

filter and install it.

Figure 71

Rotate filter counterclockwise to remove it.

Clean filter head.

10. Grease filter gasket and gasket mating

surface on filter head.

11. Thread filter onto filter head. Tighten filter

1/2 turn after filter gasket contacts filter

head. Filter should be torqued to 1.6 to 2.1

kg m (11.5 to 15 ft lb).

Figure 72

12. Fill transmission with fluid through fluid

supply pipe. Add fluid until fluid level

reaches low mark on dipstick.

13. Start engine. Idle engine for two minutes.

14. With engine idling, check transmission

fluid level. Add fluid until level reaches high

mark on dipstick.

15. Idle engine until transmission fluid

temperature reaches 82 - 93°C (180 -

200°F). Check fluid level with engine idling.

Level must reach high mark on dipstick.

Figure 73

16. Check filter for leaks while engine is

running.

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-39

CLEAN FUEL TANK AND STRAINER

WARNING!

Escaping fuel flammable and harmful to skin.

•

Do not smoke while draining moisture and sediment from tank.

•

Do not drain with engine running.

•

Do not allow fuel to remain on skin for an extended period of time.Wash thoroughly

with soap and water.

NOTE: It is easiest to clean the fuel tank when the fuel is almost empty.

Park the machine on a level surface, apply

the parking brake, lower the attachment to

the ground, and stop the engine.

Open the drain cock (Figure 15) on the

bottom of the fuel tank.

Drain the remaining fuel into a suitable

container.

Figure 74

Remove the nuts with a 17mm wrench to

remove the inspection cover (Figure 75).

Clean inside of the tank and suction

stainer.

Install the inspection cover with a new

gasket. Tighten the nuts. Do not

overtighten.

Close the drain cock.

Fill the fuel tank.

Check for any leaks at cover and plug.

Figure 75

4-40 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

CHECK AIR CONDITION REFRIGERANT

WARNING!

Mixing of tobacco smoke and freon is deadly.

Do not smoke while servicing or recharging air conditioning system.

Apply the parking brake and lower the attachment to the ground.

Remove the cover.

Press the "HI" flow control switch to set maximum air flow.

Set the temp. control switch fully to the cool position and fully open the cab doors.

Slightly accelerate the engine to about the middle speed range (compressor speed 1500-1800 rpm.)

Compare the flow of bubbles in the sight glass with the drawings in the following table.

CAUTION!

Overfill refrigerant may cause dangerous high pressure and poor cooling action; and low

refrigerant level may cause compressor damage.

Always maintain refrigerant in normal level.

Amount of

Appearance of the Sight Glass

Solutions

Refrigerant

Almost clear.

Normal

Any bubbles disappear if the engine

speed is increased to 1500 rpm

High

No bubble is seen

Contact your local loader dealer

for inspection and recharging

refrigerant.

Low

A flow of bubbles is visible

CHECK AND ADJUST ENGINE

Contact your nearest loader dealer or local Cummins

Engine dealer for checking and adjusting the following items:

•

Engine Compression Pressure

•

Injection Pressure

•

Injection Timing

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-41

1,500 HOUR / 9 MONTH SERVICE

PERFORM ALL 10, 50, 150, 250, AND 500 HOUR SERVICE CHECKS

REPLACE OUTER AND INNER AIR CLEANER ELEMENTS

CAUTION!

Never remove air cleaner element while engine is running. This will allow dirt to be sucked into

engine and cause serious engine damage. Always turn engine "OFF" before servicing air

cleaner.

Replace inner element when outer element is replaced.

After removing outer element, remove wing nut and inner element.

Clean out inside of air cleaner housing. DO NOT use compressed air to blow out housing.

Install new inner element, and secure it into position with wing nut. DO NOT clean and re-use inner

element.

Install new outer element, and secure it into position with wing nut.

Install air cleaner cover.

NOTE: Make sure that all gaskets on wing nuts and cover are properly installed and seated.

AXLE DIFFERENTIAL AND PLANETARIES OIL REPLACEMENT

NOTE: Oil in both front and rear axle must be replaced after first 250 hours of operation to comply

with new machine break-in requirements. After that, axle oil check should be done every

250 hours of operation and replacement should be done every 1500 hours.

Each axle contains a center differential, and a planetary in each end. The same oil lubricates center

differential and planetaries in axle ends, but oil flows very slowly between these points. When checked, oil

must be checked and refilled at all three places at the same time. To drain and replace oil in an axle,

perform the following steps:

Drive machine onto a level surface.

Position wheels on axle being drained so

that axle end level plugs are in the lowest

position. Apply parking brake. Block

wheels.

Clean area around level plugs on both

ends of axle. Remove plugs.

NOTE: See

“Fluid Capacities” on

page 4-5 for capacity.

Figure 76

4-42 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

Clean area around level plug (1, Figure

77) and drain plug

(2) on center

differential. Remove level plug

(1) and

drain plug

(2). Allow oil to drain into a

container.

Install drain plug (2, Figure 77) into center

differential, and tighten.

Pump oil into plug hole for level plug on

center differential. Add oil until oil level is

even with bottom of plug hole. Go to level

plug holes on axle ends. Add oil to these

openings until oil level is even with bottom

Figure 77 FRONT AXLE

of plug hole. Recheck level on center

differential. Add oil if necessary. When oil

level is satisfactory at all three level plug

holes, install and tighten level plugs at all three locations.

Repeat procedure for other axle.

Figure 78 REAR AXLE

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-43

2,000 HOUR / ANNUAL SERVICE

PERFORM ALL 10 HOUR / DAILY, 50, 150, 250, 500 AND 1000 HOUR SERVICE CHECKS

REPLACE HOSES

Replace hoses that carry brake fluid to wheel brakes. Also replace hoses that carry hydraulic fluid to

steering cylinders.

It is difficult to determine condition of many hoses. The best way to ensure safe operation and to

maintain maximum performance is to replace hoses on a regular basis. If any brake or steering hoses

become damaged or appear defective in any way, replace them immediately despite time interval

since their last replacement.

BLEED BRAKES

When brake hoses or brake tubes are replaced, air can be introduced into brake hydraulic system. Air can

cause brakes to operate intermittently, which is a dangerous condition. Never operate machine with air in

brake hydraulic system. A spongy feel when pressing brake pedal is a sign that air is present in brake

hydraulic system.

To bleed air out of brake hydraulic system,

perform the following steps:

Start engine and place transmission in

"NEUTRAL."

Figure 79

Remove rubber cap from bleeder screw on

wheel.Place one end of a plastic hose (2,

Figure 80) over bleeder screw (1). Place

other end of hose in a container (3) filled

with brake fluid.

Station one person in operator’s cab, and

one person at bleeder screw on wheel

being bled.

Open bleeder screw (1, Figure 80). Then

press down on brake pedal until it rests on

floor of cab. Hold pedal down on floor of

cab. Close bleeder screw while pedal is

being held down. After bleeder screw has

HLB3018L

been closed, allow brake pedal to return to

Figure 80

upright position. Continue to open bleeder

screw and press down pedal as described

in this step, until fluid expelled from

bleeder hose has no air bubbles present.

4-44 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

Securely close bleeder screw (1, Figure 80). Install rubber cap on bleeder screw.

Perform bleeding procedure on other three wheels.

DRAIN AND REPLACE HYDRAULIC OIL

CAUTION!

Be certain that hydraulic oil has cooled before draining it. Hot oil could splash and cause burns.

Raise boom to its highest position. Tilt

bucket back as far as possible, and turn

"OFF" engine.

NOTE: See

“Fluid Capacities” on

page 4-5 for capacity.

Figure 81

Position a catch tank beneath hydraulic

reservoir drain plug. Open reservoir

breather cap. (See Figure 10 on page 4-

10). Remove drain plug from bottom of

reservoir. (Figure 82). Allow all hydraulic

oil to drain out.

Figure 82

Figure 83

Figure 84

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-45

Without starting engine, operate controls to dump bucket. (Figure 83). Then operate controls to lower

boom. (Figure 84). This will drain oil out of boom and bucket cylinders.

Replace full flow hydraulic filters as described under “Loosen breather cap on hydraulic reservoir.

(See Figure 10 on page 4-10).” on page 4-27.

Remove and clean pump inlet strainer

(Figure 85) inside hydraulic reservoir.

A. Remove bolts

(8, Figure

85) that

retain strainer cover (9).

B. Remove strainer cover (9, Figure 85)

and strainer (7) from reservoir.

C. Remove strainer (7, Figure 85) from

strainer cover.

D. Clean strainer

(7, Figure

85) in a

nonflammable, non toxic solvent.

E. Mount strainer

(7, Figure

85) on

strainer cover (9).

Insert strainer

(7, Figure

85), and

cover (9), into reservoir.

G. Install and tighten bolts (8, Figure 85)

that retain cover (9).

Install reservoir drain plug. Refill reservoir

Figure 85

by pouring oil in through breather cap

opening. Install and tighten breather cap.

Figure 86

Figure 87

Start engine and operate controls to raise and lower bucket a few times. (Figure 86). Raise and lower

boom a few times. (Figure 87). Lower bucket to ground.

Check reservoir sight gauge. (See Figure 9 on page 4-10). Oil level must be between upper limit and

lower limit on sight gauge. Remove breather cap and add oil if necessary.

4-46 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

CLEAN HYDRAULIC OIL SUCTION

STRAINER

Carefully remove bolts and cover

(1,

Figure 88) from top of hydraulic oil tank.

There is a spring (2) under the cover that

will force the cover up.

Remove spring (2, Figure 88) and strainer

(4), by pulling on rod (3).

Clean inside and outside of strainer.

Replace strainer if it is broken.

Position strainer on boss portion of suction

pipe.

Fill hydraulic oil tank. Check level using

sight gauge on side of tank.

Place spring on rod and assemble cover.

Figure 88

CHECK VIBRATION DAMPER

Park the machine on a level surface, apply

the parking brake, lower the attachment to

the ground, and stop the engine.

Check the damper on the fan end of the

engine crankshaft.

If dents, cracks, or any deformations are

found, contact your nearest loader dealer

for replacement.

Figure 89

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-47

CHECK BRAKE ACCUMULATOR

Test the brake accumulator for proper precharge of Nitrogen gas

WARNING!

Pressurized Nitrogen gas in brake accumulator may explode causing serious injury or death.

Never service brake accumulator unless trained properly.

Park the machine on a level surface, apply the parking brake and lower the attachment to the ground.

Run the engine at low idle for five minutes to fill the brake accumulator with oil.

Stop the engine.

Turn the key to the "ON" position.

Count the number of times you can depress the right hand brake pedal before the brake warning light

comes on.

If the number counted is less than five (5) there is some problem with the accumulator. Contact your

nearest loader dealer.

CHECK STEERING, BRAKE, DRIVE SHAFT, ENGINE, AND FUEL SYSTEM

4-48 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

SEVERE CONDITIONS MAINTENANCE

OPERATING CONDITION

REQUIRED MAINTENANCE

Mud, Water, Rain

Check for loose fittings, obvious damage to machine, or any

fluid leakage.

After completing operations, clean mud, rocks, or debris from

machine. Inspect for damage, cracked welds, or loosened

parts.

Perform all daily lubrication and service.

If machine was working in salt water or other corrosive

materials, be sure to flush equipment with fresh water.

Extremely Dusty

Hot

Clean engine air filter on a more frequent basis.

Environment

Clean radiator and oil cooler fins to remove dirt and dust.

Clean fuel system intake strainer and fuel filter more frequently.

Inspect starter motor and alternator, and clean as often as

necessary.

Rocky Terrain

Check wheels, tires, rims, and valve stems for damage or

excessive wear.

Inspect for loose or damaged fittings and bolts.

On a more frequent basis, inspect bucket and boom for

damage or excessive wear.

Install a top guard and front guard as necessary for protection

against falling rock.

Extreme Cold

Use proper grade of fuel for cold temperatures.

Use a gauge to check antifreeze to be sure that it will provide

protection for coldest temperature expected.

Use a hydrometer to check condition of batteries. In extremely

cold weather, remove batteries at night and store them in a

warm area.

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-49

FUEL TRANSFER PUMP

WARNING!

Do not dry operate fuel pump for more than 15 seconds.

•

Cooling and lubrication of pump is achieved by fuel passing through the pump. If the

pump is dry operated, the heat generated by the moving parts will cause damage to

the pump rotors, vanes and seals. To prevent unnecessary wear and / or damage to

the pump do not dry operate the fuel pump for more than 15 seconds.

Do not operate the pump for more than 15 minutes at a time.

•

Continuous usage of pump over the recommended time interval will cause

overheating of motor result in causing motor damage.

Do not use refueling pump for other types of fuel. (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 the strainer installed on the inlet hose. This will prevent any

foreign materials from being introduced into the pump. Always maintain the pump and all of

its components in a clean condition.

•

If dirt or other foreign materials enter the 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 the flow of fuel.

Be careful not to overfill or spill fuel.

Make sure the direction of check valve is in line with the flow direction of fuel.

If any parts or components of the pump become lost, damaged or inoperable, immediately

replace it with a new one.

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.

This transfer pump is used to transfer fuel from a refueling source to fuel tank. A check valve is installed in

the inlet hose to prevent fuel from flowing backward 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 motor, will automatically shut off the circuit if motor is overheating to protect

motor from damage.

4-50 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

HAOP401L

Figure 90

Remove strainer cap (4, Figure 90) from inlet hose.

NOTE: Keep strainer cap in a safe location to reseal strainer after refueling is complete.

Insert inlet hose (5, Figure 90) into refueling tank.

Turn fuel pump switch to “ON” position.

NOTE: The transfer pump rate of flow

is approximately

20 liters

minute. Use extra care not to

over fill fuel tank so that fuel

does not over flow.

Once fuel transfer is completed,

immediately turn switch to “OFF” position

to stop pump.

Lift inlet hose from fueling source and turn

switch to “ON” position for 2~3 seconds to

drain remaining fuel from hose to fuel tank.

Figure 91

Replace strainer cap (4) to inlet strainer

and return hose to storage position.

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-51

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 “I” (ON) position and

operate pilot control valve lever and brake pedal. Even though the engine is shutdown hydraulic

actuated components may move while releasing pilot pressure. Keep all personnel away from

machine while performing this operation.

•

Set pilot cutoff switch to "O" (OFF) 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;

Lower front attachment

(bucket) on the

ground.

Stop the engine.

Set pilot cutoff switch on "I" (ON) position.

Turn starter switch "ON."

Fully move pilot control valve lever in all

directions.

Repeatedly press brake until brake oil

Figure 92

pressure warning light turns "ON." Press

the pedal another eight to nine times.

Set pilot cutoff switch on "O"

(OFF)

position.

Remove accumulator by unscrewing it

slowly.

4-52 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

CHECK HYDRAULIC PRESSURES

Hydraulic pressures for most systems can be

check by using the remote test ports shown in

Figure 93.

Port Number

Description

Main Pump Pressure

Transmission System

Pressure

Brake Charge Pressure

HAOP341S

Pilot Control Valve Lever

Figure 93

(Joystick) Activation

Pressure

MAIN PUMP PRESSURE

Attach gauge to (Port 1, Figure 94)

Relief cartridge for main pump must open

at 200⁺⁵kg/cm²(2,918⁺⁷⁰ psi).

Figure 94

Adjust screw on relief valve cartridge (1,

Figure 95). Loosen lock nut and turn screw

clockwise to raise relief pressure. Turn

screw counterclockwise to lower relief

pressure.

Tighten lock nut after pressure has been

adjusted.

Figure 95

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-53

TRANSMISSION SYSTEM PRESSURE

Attach gauge to (Port 2, Figure 93)

Pressure 16-18 kg/cm² (228-256 psi)

BRAKE CHARGE PRESSURE

Attach gauge to (Port 3, Figure 93).

Relief pressure for unloading is 140 kg/

cm² (1,991 psi). Relief pressure for loading

is 120 kg/cm² (1,707 psi).

Figure 96

PILOT CONTROL VALVE LEVER (JOYSTICK)

ACTIVATION PRESSURE

Attach gauge to (Port 4, Figure 94).

Adjust relief cartridge (Figure 97) on pilot

parking valve. Relief pressure should be

+43

set at 37

-2

kg/cm² (526

-28

psi).

Loosen lock nut on adjusting screw. Turn

adjusting screw clockwise to raise relief

pressure.

Turn

adjusting

screw

counterclockwise to lower relief pressure.

Tighten lock nut after adjustment has been

Figure 97

made.

STEERING PUMP PRESSURE

Attach gauge to steering valve port,

(Figure 94).

Figure 98

4-54 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

Adjust relief valve cartridge on amplifier

(Figure 99). Cartridge must be adjusted to

open at 185 ±5 kg/cm² (2,630±70 psi).

Unscrew remove plug and washer. Adjust

screw that is beneath plug. Turn screw

clockwise to raise relief pressure. Turn

screw counterclockwise to lower relief

pressure. One turn varies 65kg/cm².

Install plug and washer after pressure has

been adjusted.

Figure 99

SERVICE BRAKE OUTLET PRESSURE

Attach gauge to brake pressure test

(Figure 100) port of front axle.

Outlet pressure should be 60 kg/cm² (853

psi).

Figure 100

PARKING BRAKE RELEASE PRESSURE

Attach a pressure gauge to parking brake

port (Figure 101).

Parking brake pressure should be 88 kg/

cm².

Figure 101

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-55

TIRES AND WHEELS

Properly inflated tire

(2, Figure

103) is an

important factor in determining tire performance

and tire life. A tire that is under-inflated

(1,

Figure 103) does not properly support machine,

and will wear out quickly. Over-inflated tires (3,

Figure 103) have poor traction and puncture

easily.

Use a pressure gauge to measure tire pressure.

Always measure tire pressure before machine

has been working, when tires are cold. Use

table below to determine correct pressure for

front or rear tires when driving machine, or when

working machine.

Figure 103 BIAS PLY TIRES ONLY

Check tires for damage and embedded objects.

Check valve stems for damage.

Working Pressure

Driving Pressure

Tire Dimension

Remarks

Front Tire

Rear Tire

Front Tire

Rear Tire

29.5-25-22PR

Bias Ply Tire

3.5 kg/cm²

3.3 kg/cm²

2.8 kg/cm²

2.0 kg/cm²

(Standard)

(50 psi)

(47 psi)

(40 psi)

(29 psi)

WHEEL NUT TORQUE

Tighten wheel nuts to 85 kg•m (615 ft lb).

WARNING!

If a wheel and tire must be removed from

machine and replaced, or if a tire must be

replaced on wheel, allow this task to be

performed only by experienced service

personnel. A tire rim could be propelled

off wheel and cause serious bodily injury

or death. See Figure 104.

Figure 104

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-57

CHECK TIRE FOR DAMAGE

WARNING!

Improper servicing or changing tires and rims can cause explosion resulting in serious injury or

death.

Do not service or change tires and rims unless properly trained and equipped.

Contact your nearest loader dealer or tire manufacturer’s local dealer for tire servicing or

changing.

WARNING!

Overheated tire may explode causing serious injury or death.

If overheated tire is suspected, do not approach tire to distance of less than15m (50ft).

Stay away until tire and rim cool down.

If the following defects are found in tires, for

safety reasons the tires should be replaced with

new tires.

For the replacement contact loader dealer or a

tire manufacturer’s local dealer.

•

Bead wire is broken or bent, or the

tire is greatly deformed.

•

Wear is excessive and the carcass

ply (including breaker) is exposed for

more than 1/4 of the circumference.

•

Damage to the carcass exceeds 1/3

Figure 105

of the tire width.

•

Tire layers are separated.

•

Radial cracks reach the carcass.

•

Deformation or damage which makes

the tire unsuitable for use.

4-58 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

ELECTRICAL SYSTEM

CHECK BATTERY CONDITION

WARNING!

Before starting any battery service work, make sure to shut the engine off and turn the starter

key to the "OFF" position.

The batteries create hydrogen gas. An explosion hazard exists, particularly with a deeply

discharged battery. Make sure that open flames, burning objects or sparks are kept away from

the battery compartment.

Battery electrolyte is diluted sulfuric acid. Take extreme caution when handling the batteries.

The electrolyte can cause severe chemical burns. If any electrolyte gets on your clothing or skin,

wash it off immediately with large quantities of water. If the electrolyte gets into your eyes, flush

them immediately with a large quantity of water and contact a doctor at once.

When installing a battery, wear safety glasses at all times.

When removing a battery, remove the Negative (-) or ground terminal first, and then the Positive

(+) terminal. This will prevent sparks or arcing that could cause an explosion. When installing a

battery, connect the Positive terminal first and then the Negative terminal. Make sure to fully

tighten the terminal clamps.

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 of battery electrolyte level.

NOTE: The battery installed at the

factory is a Maintenance Free

(MF) type. Electrolyte under

normal conditions

should

remain at its proper level.

Inspect charge condition of battery by

looking at the indicator light built into

battery.

•

GREEN: Normal.

HJB5002L

•

BLACK: Insufficient charging - check

Figure 106

alternator.

•

TRANSPARENT: Insufficient battery

fluid - replace with new battery.

NOTE: Colors may vary from one battery manufacturer to another. Always refer to instructions on

battery.

The batteries should always be replaced in pairs. Using an old battery with a new one will

shorten the life span of the new battery.

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-59

BOLT TORQUE CHART

Tightening Torque Specifications for Metric Bolts (For coated threads, pre-lubricated assemblies)

Grade

Gr. 8.8

Gr. 10.9

Gr. 12.9

Dia.

Kg•m

ft lb

Kg•m

ft lb

Kg•m

ft lb

5 mm x std

0.59

4.3

0.79

5.7

1.0

7.2

6 mm x std

1.00

7.3

1.38

1.66

8 mm x std

2.49

3.46

4.15

8 mm x 1.0

2.76

3.87

4.56

10 mm x std

4.84

6.92

8.30

10 mm x

1.0

4.84

7.05

8.30

12 mm x std

8.57

11.89

14.52

105

12 mm x

1.5

9.00

12.59

14.94

108

14 mm x std

13.55

18.95

137

23.10

167

14 mm x

1.5

14.94

108

21.02

152

24.89

180

16 mm x std

20.88

151

29.46

213

35.54

257

16 mm x

1.5

22.54

163

31.53

228

38.03

275

18 mm x std

28.90

209

40.52

293

48.41

350

18 mm x

1.5

32.50

235

45.92

332

55.04

398

20 mm x std

40.94

296

57.95

419

69.01

499

20 mm x

1.5

46.05

333

64.03

463

77.03

557

22 mm x std

54.90

397

77.86

563

93.08

673

22 mm x

1.5

61.00

441

86.02

622

105.00

759

24 mm x std

71.00

513

100.00

723

120.00

868

24 mm x

2.0

78.00

564

109.95

795

130.00

940

27 mm x

2.0

115.06

832

160.00

1157

195.00

1410

4-60 Inspection, Maintenance and Adjustment

022-00029AE Operation and Maintenance Manual

LONG TERM STORAGE

CLEANING

Pressure wash machine. Inspect machine for any damage or missing parts. Drive machine to check

steering linkage for damage.

HYDRAULIC SYSTEM

Start engine and allow it to idle for a few minutes. Drive machine around for 2 - 3 minutes. Raise and lower

boom 2 - 3 times. Crowd and dump bucket 2 - 3 times. This will circulate hydraulic fluid through all hydraulic

systems.

LUBRICATION

Perform all daily maintenance procedures listed in this section (Section 4.) Grease all grease fittings in

steering linkage. Apply a coating of light oil to all exposed cylinder rods. Apply a coating of light oil to all

control linkages and all control valve spools. Check condition of oil coating each month and add to coating

where necessary.

BATTERY

Disconnect cables from battery, or remove battery from machine. If battery is removed, fully charge battery

and store it.

COOLING SYSTEM CARE

If cooling system does not need antifreeze and is filled with water only, add an anti-rust additive. If

temperatures below freezing are expected, add antifreeze to protect system to level of cold expected. See

antifreeze protection Table 4-1. Use a hydrometer to check level of antifreeze protection once each month.

If desired, cooling system can be completely drained. If system is drained, place a sign in operator’s cab to

warn operator that there is no coolant in engine.

022-00029AE Operation and Maintenance Manual

Inspection, Maintenance and Adjustment 4-61

5TRANSPORTATION

LOADING MACHINE ON A TRAILER

When transporting the machine observe the

various road rules, road transportation vehicle

laws and vehicle limit ordinances, etc.

It is a good idea to obtain special platform for

loading and unloading the machine.

Park the trailer on a flat firm roadbed. Keep

a fairly long distance between the road

shoulder and the machine.

Properly apply the brakes of the trailer and

place wheel chocks in front of and behind

the tires to ensure that the trailer does not

move.

Figure 1

Fix the ramp in line with the centers of the

trailer and the machine.

Determine the position of the ramp, then

slowly load the machine onto to the

specified part of the trailer.

NOTE: Have someone in clear view

and in a safe position provide

directions while loading.

Lower the bucket and lock control lever

using the pilot cutoff switch.

Apply the parking brake and set the

Figure 2

articulation stopper in the "LOCKED"

position.

Tape over the exhaust stack outlet to

prevent turbo "Wind-milling" damage

Place blocks in front of and behind the

tires to prevent the machine from moving.

Fasten the machine to the trailer with

chains or cables at lower part of the rear

chassis. Additional chains or cables may

be used but do not damage brake lines or

cylinder rods.

IMPORTANT

Figure 3

Brake pipe runs on axle housing.

Do not fasten axle housing.

022-00029AE Operation and Maintenance Manual

Transportation 5-1

10. Determine the route for transporting the machine by taking into account the width, height and weight

of the machine and the truck.

SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING

To make safe lifts, the following items must be

evaluated by operator and work site crew.

•

Condition of ground support

•

Wheel loader configuration and

attachments

•

Weight, lifting height and lifting radius

•

Safe rigging of load

•

Proper handling of suspended load

Taglines on opposite sides of load can be very

helpful in keeping a suspended load secure, if

Figure 4

they are anchored safely to control points on

ground.

5-2 Transportation

022-00029AE Operation and Maintenance Manual

6TROUBLESHOOTING

ENGINE

Problem

Possible Causes

Remedies

Starter does not operate

Blown fuse

Replace fuse

Low battery power

Charge battery

Poor terminal contact

Clean and tighten connections

Starter switch failed

Replace switch

Starter relay failed

Replace relay

Starter control failed

Replace controller

Wiring harness faulty

Replace harness

Battery relay failed

Replace relay

Starter engages, engine

does

Blown fuse

Replace fuse

not start

Fuel gelled in cold weather

Replace fuel

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

Replace stop control

Engine stop relay failed

Replace relay

Engine starts, runs only at low

Engine oil viscosity incorrect

Change oil

speed or shuts down

Clogged or dirty fuel injectors

Clean injectors

Fuel filters plugged

Replace filters

Engine stop motor cable out of

Readjust

adjustment

Engine speed control cable out

Readjust

of adjustment

Engine knocks, runs unevenly or

Low engine oil

Refill

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

022-00029AE Operation and Maintenance Manual

Troubleshooting 6-1

Problem

Possible Causes

Remedies

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

Readjust

of 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

Engine oil pressure warning light

Low engine oil level

Add oil

turns "ON," and buzzer sounds

Wrong grade oil for weather

change oil

conditions

Clogging oil filter element

Change filter and oil

Defective alarm switch

Oil leakage from pipe or joint

Contact your DOOSAN dealer

Clogging suction strainer

Excessive engine wear

Defective oil pump

Coolant temp, warning light

Low engine coolant level

Add coolant

turns "ON."

Loose/slipping/broken fan belt

Adjust or replace belt

Clogging radiator fins

Clean

Scale or mineral build up inside

Flush or professionally clean

radiator

Defective alarm switch (gauge is

in green)

Contact your DOOSAN dealer

Low water pump flow

Thermostat stuck or missing

6-2 Troubleshooting

022-00029AE Operation and Maintenance Manual

Problem

Possible Causes

Remedies

Engine does not start when the

Fuel filter element clogging

Replace fuel filter

starter motor is turning

Starter motor speed too low

Booster Battery may be used

(Also

see

ELECTRICAL

TROUBLESHOOTING)

Defective engine shut off

solenoid

Fuel pump failure

Contact your DOOSAN dealer

Incorrect fuel injection timing

Compression pressure too low

Defective injectors

Unstable (rough) idling

Air in fuel lines

Tighten fuel connections and

filter

Fuel filter element clogging

Replace fuel filter

Fuel pump failure

Contact your DOOSAN dealer

Incorrect fuel injection timing

Insufficient power

Air cleaner element clogging

Clean or replace element

Fuel filer element clogging

Replace fuel filter

Throttle linkage adjustment

Check and adjust linkage

wrong

Engine oil level too high

Check dipstick and correct level

Incorrect valve clearance

Piston ring wear

Contact your DOOSAN dealer

Defective injectors

Fuel pump failure

HYDRAULIC SYSTEM

Problem

Possible Causes

Remedies

None of the controls function

Hydraulic pump failed

Contact your DOOSAN dealer

(loud noise from pumps)

Low hydraulic oil level

Add hydraulic oil as required

Suction

line

plugged or

Clean or replace as required

damaged

None of the controls function (no

Pilot pump failure

Contact your DOOSAN dealer

noise from pumps)

Cutoff solenoid valve failed

Replace solenoid

Safety limit switch is "ON"

Adjust limit switch clearance

022-00029AE Operation and Maintenance Manual

Troubleshooting 6-3

Problem

Possible Causes

Remedies

All actuators have low power

Low hydraulic oil level

Add hydraulic oil as required

Suction filter clogged

Clean filter

Hydraulic pumps faulty

Contact your DOOSAN dealer

Main relief pressure too low

Contact your DOOSAN dealer

Hydraulic pumps cavitating

Bleed air from hydraulic pumps

Only one or two actuators have

Overload relief pressure too low

Reset pressure

little or no power

Make-up 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

Debris in exterior of cooler

Clean exterior of cooler

Oil cooler faulty

Contact your DOOSAN dealer

Fan belt loose

Tighten fan belting as required

Actuators on one side of boom

Overload relief valve is not

Repair valve or replace

have little power or do not

operating properly

operate

Damaged hydraulic hose

Replace hose

Loose hydraulic fittings

Tighten fittings

Internal damage to control valve

Replace control valve

housing

Control valve spool damaged

Replace control valve

Sediment inside control valve

Clean and repair valve

Check valve internal leakage

Repair or replace valve

Damaged cylinder or pump

Repair or replace pump or

cylinder

Cylinder internal leakage

Repair or replace cylinder

Damaged cylinder rod

Replace rod

Pilot valve failure

Replace pilot valve

6-4 Troubleshooting

022-00029AE Operation and Maintenance Manual

TRAVEL SYSTEM

GENERAL

Problem

Possible Causes

Remedies

Machine will not travel

Transmission clutch pressure

Adjust pressure

incorrect

Transmission charge pump

Replace pump

damaged

Damage to transmission control

Repair wiring

valve wiring harness

Burned travel relay or fuse

Replace relay or fuse

Forward/Reverse solenoid for

Clean and repair

transmission

control

valve

sticking

Damaged transmission clutch

Repair or replace clutch

Damaged drive shaft

Repair or replace

Damaged transmission or axle

Repair or replace

Wheel brakes not releasing

Repair brakes

Parking brake not releasing

Repair parking brake

Machine will travel but has little

Fluid

pressure

low

Repair clutch

power

transmission clutch

Transmission fluid low

Add fluid

Damage to torque converter

Repair or replace

Engine malfunction

See Engine Troubleshooting

Table

Brake valve

Disassemble and clean

Unusual transmission noise

Low transmission fluid, or low

Add fluid or change fluid

quality fluid

Worn transmission parts

Replace parts

Broken gears or bearings

Replace parts

Transmission fails to operate

Damaged transmission clutch

Replace discs

discs

Damaged wires in transmission

Repair wires

control wire harness

022-00029AE Operation and Maintenance Manual

Troubleshooting 6-5

Problem

Possible Causes

Remedies

Drive shaft vibration Noisy

Bent drive shaft

Replace drive shaft

universal joints

Loose universal joints

Tighten bolts that secure joints

Worn or damaged universal joint

Replace universal joint

Loose universal joints

Tighten bolts that secure

universal joints

Lack of lubrication

Lubricate universal joints

Worn slip joint spline

Replace slip joint

Noisy Front or Rear Axle

Worn or broken gears

Replace gears

Low oil level, poor quality oil

Add oil, change oil

Worn bearings

Replace bearings

Worn shaft spline

Replace spline

TRANSMISSION ERROR CODES

The first number of the error code is the category that it is grouped into. They are as follows for the first

number:

Digital Input Signals

Analog Input Signals

Speed Signals

Analog Current Output Signals

Digital Output Signals

A Digital Output Signals

B Clutch Errors

D Power Supply

E High Speed Signals

F General Errors

Error Code

Meaning of Error Code

Remarks

Number

Logical error at gear range signal.

Logical error at direction select signal.

Short circuit to battery voltage at clutch cutoff input.

6-6 Troubleshooting

022-00029AE Operation and Maintenance Manual

Error Code

Meaning of Error Code

Remarks

Number

Short circuit to ground or open circuit at clutch cutoff input.

Short circuit to battery voltage at load sensor input.

Not used.

Short circuit to ground or open circuit at load sensor input.

Not used.

Short circuit to battery voltage or open circuit at temperature sensor

input.

Short circuit to ground at temperature sensor input.

Short circuit to battery voltage at engine speed input.

Short circuit to ground or open circuit at engine speed input.

Logical error at engine speed input.

Short circuit to battery voltage at turbine speed input.

Short circuit to ground or open circuit at turbine speed input.

Logical error at turbine speed input.

Short circuit to battery voltage at internal speed input.

Short circuit to ground or open circuit at internal speed input.

Logical error at internal speed input.

Short circuit to battery voltage at output speed input.

Short circuit to ground or open circuit at output speed input.

Logical error at output speed input.

Short circuit to battery voltage at clutch K1.

Short circuit to ground at clutch K1.

Open circuit at clutch K1.

Short circuit to battery voltage at clutch K2.

Short circuit to ground at clutch K2.

Open circuit at clutch K2.

Short circuit to battery voltage at clutch K3.

Short circuit to ground at clutch K3.

Open circuit at clutch K3.

Short circuit to battery voltage at converter clutch.

Not used.

Short circuit to ground at converter clutch.

Not used.

022-00029AE Operation and Maintenance Manual

Troubleshooting 6-7

Error Code

Meaning of Error Code

Remarks

Number

Open circuit at converter clutch.

Not used

Short circuit battery voltage at clutch K4.

Short circuit to ground at clutch K4.

Open circuit at clutch K4.

Short circuit to battery voltage at clutch KV.

Short circuit to ground at clutch KV.

Open circuit at clutch KV.

Short circuit to battery voltage at clutch KR.

Short circuit to ground at clutch KR.

Open circuit at clutch KR.

Short circuit battery voltage at relay reverse warning alarm.

Short circuit to ground at relay reverse warning alarm.

Open circuit at relay reverse warning alarm.

Short circuit to battery voltage at relay starter interlock.

Short circuit to ground at relay starter interlock.

Open circuit at relay starter interlock.

Short circuit to battery voltage at park brake solenoid.

Short circuit ground at park brake solenoid.

Open circuit at park brake solenoid.

Slippage at clutch K1.

Slippage at clutch K2.

Slippage at clutch K3.

Slippage at clutch K4.

Slippage at clutch KV.

Slippage at clutch KR.

Short circuit to battery voltage at power supply for sensors.

Short circuit to ground at power supply for sensors.

6-8 Troubleshooting

022-00029AE Operation and Maintenance Manual

Error Code

Meaning of Error Code

Remarks

Number

Low power at battery.

High power at battery.

Error at switch 1 for valve power supply.

Error at switch 2 for valve power supply.

Short circuit to battery at speedometer output.

Not used.

Short circuit to ground or open circuit at speedometer output.

Not used.

Short circuit to battery voltage at display output.

Not used.

Short circuit to ground or open circuit at display output.

Not used.

Error at communication on CAN.

General EEPROM fault.

Configuration lost.

Application error.

022-00029AE Operation and Maintenance Manual

Troubleshooting 6-9

STEERING

Problem

Possible Causes

Remedies

Steering Wheel is hard to turn

Sediment blocking direction

Clean and repair

change spool orifice, inside

priority valve

Sediment blocking amplifying

Clean and repair

spool orifice, inside priority valve

Sediment blocking load sensing

Clean and repair

line orifice, inside priority valve

Priority valve spool sticking,

Clean and repair

inside steering valve

Incorrect relief valve pressure

Adjust pressure

drop, inside priority valve

Steering pump failure

Repair or replace

Leaking steering cylinder

Repair cylinder

Rust on steering column bearing

Lubricate

and spline

Tire air pressure is low

Inflate to proper pressure

High initial

resistance

Air in load sensing line, inside

Bleed system to remove air

movement of steering wheel

priority valve

Sediment blocking orifice of load

Clean and repair

sensing line, inside priority valve

Sediment in direction change

Clean and repair

spool, inside priority valve

Damage to control spring

Replace priority valve

damping inside priority valve

Steering wheel shakes

Chattering bearing in axle end

Replace bearing

differential

Tire pressure not equal in left

Equalize pressure

side and right side tires

6-10 Troubleshooting

022-00029AE Operation and Maintenance Manual

BRAKING

Problem

Possible Causes

Remedies

Reduced brake action

Low secondary pressure in

Repair or replace brake valve

brake valve

Worn brake discs

Replace brake discs

Damaged brake discs

Replace brake discs

Damaged brake valve block

Replace valve

Air in brake hydraulics due

Repair leak, bleed system

to leak in brake hose

After bleeding brakes, brakes

Damaged brake discs

Replace discs

are not fully released

Damaged brake disc return

Replace return springs

spring

ELECTRICAL SYSTEM

Problem

Possible Causes

Remedies

Battery has no power and will

Damaged battery plates

Replace battery

not accept a charge

Alternator not charging properly

Repair or replace alternator

Bad ground

Clean and tighten

Loose electrical connector

Clean and tighten

Alternator

belt

loose

Tighten or replace

damaged

Battery will accept a charge but

Internal battery short

Replace battery

discharges soon after

Wiring harness short

Repair wire

022-00029AE Operation and Maintenance Manual

Troubleshooting 6-11

7SPECIFICATIONS

GENERAL SPECIFICATIONS

MEGA 500-V (TIER II)

Item

Specification

Standard Bucket Capacity

4.8 m³ (6.28 yd³)

Vehicle Weight [W/ROPS CANOPY]

28,800 kg (63,490 lb) [29,600 kg (65,260 lb)]

Engine

Type

Cummins QSM11 w/Electronic Governor

Horsepower

340 ps (335 hp) @ 2,100 rpm

Max. Torque

174 kg•m (1,255 ft lb) @ 1,400 rpm

Transmission

Full Automatic Power -Shift

Full Automatic Power Shift

Speeds

4 Forward, 3 Reverse

Brake Systems

Travel Brakes

4 Wheel, Wet Disk

Parking Brake

SAHR, Dry Disc Type

Performance

Travel Speed

7 - 35 km/h (4.35 - 21.75 MPH)

Steering Angle

± 40°

Min. Tire Turning Radius

6,140 mm (20’ 2'')

Safe Operating Load

8,640 kg (19,050 lb)

Max. Breakout Force

27,000 kg (59,520 lb)

Bucket Rise Time

6.5 Seconds

Bucket Dump Time

1.3 Seconds

Bucket Descent Time

3.4 Seconds

Maximum Gradeability

30° (58%)

022-00029AE Operation and Maintenance Manual

Specifications 7-1

Doosan Mega 500-V (TIER II). Operation and Maintenance Manual (2001) - page 3