Doosan DL250. Operation and Maintenance Manual (2006)

Grease Upper and Lower Center Pins

Center pins, upper

(Figure

47) and lower (Figure

48).

Two locations on right side of machine.

FG001641

Figure 47

FG001642

Figure 48

Replace Engine Oil and Filter

(After First 50 Hours)

NOTE: Replace engine oil and filter after first 50 hours on a new

machine and every 500 hours thereafter.(See page 4-50)

Replace Hydraulic Full Flow Filter

(After First 50 Hours)

NOTE: Replace hydraulic full flow filter after first 50 hours of

operation or rebuild and every

1,000 Hours

thereafter. Follow procedure under

500 hour

maintenance interval (See page 4-39)

Check Air Conditioner and Alternator

Belt Tension (After First 50 Hours)

Air conditioner and alternator belt tension must be

checked after first 50 hours of operation to comply with

new machine break-in requirements. After first check,

air conditioner and alternator belt must be checked

every

250 hours. Follow procedure printed under

250

hour maintenance interval

“Check Air Conditioner and

Alternator Belt Tension” on page 4-42.

Inspection, Maintenance and Adjustment

OP000436

4-39

Clean Exterior of Radiator, Oil Cooler

and Air Conditioner Condenser

Dust and dirt accumulation on fins of radiator (1), CAC

cooler

(4), oil cooler

(2), and additional transmission

cooler

(3), 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 work site, clean fins

every 50 hours. On other work sites, clean fins

every 500 hours.(See page 4-48)

FG004071

Figure 49

Clean Air Conditioner Outer Filter

This unit is equipped with an air-conditioning system. There

are two filters (1 and 2, Figure 50) for air conditioner. They

filter out dirt and dust particles from air being circulated into

operator's cabin. They are located under the right side

control panel.

Open access cover on the lower right side of cabin on

the outside, to gain access filter.

Remove filter (1, Figure 50) and inspect it for damage.

Use compressed air to clean filter. If element is very

dirty use a mild soap and water solution to clean it.

NOTE: Clean air-conditioning filter every 50 hours and

replace a new one every 500 hours of service.

NOTE: If water was used to clean filter be sure it is

completely dry before installation.

NOTE: In the event that the unit it being operated in a

dusty environment, the cleaning and

replacement must be performed more

frequently if filter is damaged, replace damaged

with a new one.

FG003904

Figure 50

WARNING!

All service and inspection of the air-conditioning

system must be performed with the starter switch

in the "O" (OFF) position.

Inspection, Maintenance and Adjustment

OP000436

4-40

250 HOUR / MONTHLY SERVICE

Perform All Daily 10 Hour and 50 Hour

Service Checks

Check Engine Air Intake Precleaner

The engine is equipped with a precleaner. Dust,

insects, rainwater etc., can be present in the air. The

precleaner collects this material and discharges it. This

prevents material from being drawn into air cleaner.

The precleaner does not need periodic replacement.

Figure 51

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. Unscrew the cap of

breather on the top of hydraulic tank 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. Shut down engine.

Position a container under hydraulic tank drain plug.

Open tank breather cap (See Figure 20 on page 4-28).

Loosen drain valve at bottom of tank (Figure 52). Allow

all water and sediment to drain out. Tighten drain

valve.

NOTE: Dispose of drained fluids according to local

regulations.

FG002211

Figure 52

Inspection, Maintenance and Adjustment

OP000436

4-41

Turbocharger

The turbocharger is lubricated and cooled by the engine

lubrication system.

Important for the function of the turbocharger is that:

•

lubrication and cooling is safeguarded by

- not racing the engine immediately after it has

been started.

- the engine is allowed to run at low idle for a

couple of minutes before it is turned off.

•

engine oil is changed and oil filters are replaced

at prescribed intervals.

•

the air cleaner is serviced regularly and that the

exhaust system and lubricating oil lines do not

leak.

In case jarring noises can be heard, or if the turbocharger

vibrates, it must be reconditioned or replaced immediately.

Only authorized dealer workshops should carry out work

on the turbocharger.

Figure 53

Check Air Conditioner and Alternator

Belt Tension

Loosen the tension adjusting bolts of the alternator, air con.

compressor and air compressor, then take off the cooling

fan.

Adjustable Link

for alternator belt

Air-con belt

Alternator belt

Adjustable link

for Air-con belt

FG006244

Figure 54

Inspection, Maintenance and Adjustment

OP000436

4-42

Grease Drive Shafts

Grease fitting for center bearing,

1 location. Use remote

grease fitting mounted on front frame (3, Figure 55).

Remote Grease

Reference Number

Fittings

1 and 2,

Steering Cylinder

50 Hours

Head Ends

Drive Shaft

FG001640

250 Hours

Center Bearing

Figure 55

FG002212

Figure 56

Transmission Oil and Filter

(After First 250 Hours)

NOTE: Transmission oil and filter must be changed after first

250 hours of operation to comply with new machine

break-in requirements.

NOTE: After first change, oil and filter must be changed

every 1,000 hours. Follow procedure under 1,000

hour maintenance interval. (See page 4-55)

Inspection, Maintenance and Adjustment

OP000436

4-43

Clean Outer Filter of Air Cleaner

NOTE: Clean outer filter every 250 hours / 3 months of

service.

NOTE: If air cleaner clogged warning light (Figure 57) on

instrument panel comes "ON" the air cleaner must be

F/R

serviced.

NOTE: When working in severely dusty conditions, the

service interval should be shortened.

FG008103

Figure 57

WARNING!

Never clean or attempt to remove the air cleaner filter if

the 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.

Locate the air cleaner assembly.

NOTE: When it reaches every 250 hours or If indicator

light

(Figure

57) on instrument panel comes

"ON" the air cleaner must be serviced.

NOTE: Replace outer filter after cleaning 4 times or

every 1,000 hours / 6 months service.

Remove and clean rubber evacuator valve

(1, Figure

59) from bottom of air cleaner housing cover

(2).

Inspect seal lips for wear or damage. Replace valve if

necessary.

Figure 58

NOTE: Install evacuator valve with lips parallel to the

cover.

Remove the access cover (2, Figure 59) by loosening

the latches (3).

Remove the outer filter (4, Figure 59) from the housing.

Do not remove inner filter (5).

FG000702

Figure 59

Inspection, Maintenance and Adjustment

OP000436

4-44

Clean the outer filter

(4, Figure

59) by blowing

compressed air from the inside of the filter towards the

outside. Do not use more than

205 kPa (30 psi) air

pressure.

WARNING!

If using compressed an to clean the filter, make

sure that proper eye protection is worn.

HAOC570L

Figure 60

Check outer filter by shinning a light through it. If small

holes or thinner parts are found on the element after

cleaning it, replace the filter.

Clean the inside of the air cleaner body and the inside

of the air cleaner cover. Do not use compressed air.

Properly install the air filter and cover.

After filter service be sure to install cover with arrows

pointing "UP."

NOTE: If after cleaning the outer filter, the air cleaner

FG000412

clogged indicator remains "ON," replace the

Figure 61

outer and inner filters. Do not clean inner filter.

Water Trap

Take care of fuel spillage by using a vessel or a plastic

hose.

Drain the water trap every 250 hours.

Draining water from the fuel has to be done by hand.

A nonreturn valve in the filter head prevents the fuel from

running back to the tank. As no fuel can run back, the

pressure will remain and as a consequence no water will be

FG008506

drained unless new fuel is pumped in.

Figure 62

Proceed as follows:

•

Place the end of the hose in a vessel.

•

Loosen draining nipple (2).

•

Pump with hand pump (3) on the primary filter

head until all water has been forced out of water

trap (1).

•

Tighten the draining nipple.

open

NOTE: Take care of waste oil and liquid in an

environmentally safe way!

FG000438

Figure 63

Inspection, Maintenance and Adjustment

OP000436

4-45

500 HOUR / 3 MONTH SERVICE

Perform All Daily, 10, 50 and 250 Hour

Service Checks

Replace Hydraulic System Brake and

Pilot Filter

Replace filter in pilot filter. Perform the following steps:

Vent hydraulic oil tank.

FG006243

Figure 64

Unscrew element cover (5, Figure 65). Cover is filled

with oil. Dispose of oil.

Remove O-ring (3, Figure 65) and filter (4).

Use a nonflammable, nontoxic solvent to clean out

cover (5, Figure 65).

Insert a new filter (4, Figure 65) into cover (5). Install a

new O-ring (3).

Screw cover (5, Figure 65) onto filter head (1).

Figure 65

Inspection, Maintenance and Adjustment

OP000436

4-46

Replace Fuel Prefilter

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 prefilter. Drain fuel by

opening drain valve on bottom of filter.

NOTE: Dispose of drained fluids according to local

regulations.

Unscrew fuel filter from head assembly. Discard fuel

filter.

After cleaning filter head, install new fuel filter. Screw

filter on head until gasket contacts head, turn filter

1/3

FG006241

1/2 turn more.

Figure 66

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, shut down engine and look for signs of leaks.

If engine does not start, fuel system may 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.

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 look for signs of leaks.

Inspection, Maintenance and Adjustment

OP000436

4-47

Fuel Filter (Spin-On Type)

General Information

DOOSAN Common Rail Fuel System

The DOOSAN Common Rail fuel system requires the use of

two fuel filters. The prefuel filter have the following

characteristics:

•

water separating

•

30-micron rating

•

hand priming pump

•

chassis mounted.

FG006241

Figure 67

The pressure side main fuel filter must have the following

characteristics:

•

5-micron rating

•

engine mounted

FG006240

Figure 68

Remove

Disconnect the wiring harness from the fuel heater, if

equipped.

Loosen and remove the fuel filter.

Make sure the seal ring does not stick to the filter head.

Remove the ring with an O-ring pick, if necessary.

NOTE: Both fuel filters must be removed at the same time.

Install new filter. Apply a small amount of oil around filter

gasket.

Figure 69

Screw filter on head until gasket contacts head by hand,

turn filter

3/4 - 1 turn more with filter wrench.

Inspection, Maintenance and Adjustment

OP000436

4-48

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.

Unscrew fuel filter from head assembly. Discard fuel

filter.

NOTE: Dispose of drained fluids according to local

regulations.

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

FG000478

reduce fuel system priming.

Figure 70

Clean Exterior of Radiator, Oil Cooler

and Air Conditioner Condenser

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 work site, clean fins

every 50 hours. On other work sites, clean fins

FG001647

every 500 hours.

Figure 71

FG002217

Figure 72

Inspection, Maintenance and Adjustment

OP000436

4-49

Clean Inner Air Conditioner Filter

This unit is equipped with an air-conditioning system. There

are two filters

(1 and 2, Figure 73) for air conditioner. The

filters out dirt and dust particles from air being circulated

into operator's cabin. They are located under the right side

control panel.

Open access cover on the lower right side of cabin on

the outside to gain access filter.

Remove filter (2, Figure 73) and inspect it for damage.

Use compressed air to clean filter. If element is very

dirty use a mild soap and water solution to clean it.

NOTE: Clean air-conditioning filter every 500 hours and

replace with a new one every 1,000 hours of

service.

NOTE: If water was used to clean filter be sure it is

completely dry before installation.

NOTE: In the event that the unit it being operated in a

dusty environment, the cleaning and

replacement must be performed more

frequently if filter is damaged, replace damaged

FG003904

with a new one.

Figure 73

WARNING!

All service and inspection of the air-conditioning

system must be performed with the starter switch

in the "O" (OFF) position.

Replace Axle Differential and Planetaries

Oil Replacement (After First 500

Hours)

NOTE: The differential and planetaries oil must be drained

and refilled after first 500 hours of operation. There

after every 1,500 hours of operation. (See page 4-61)

Inspection, Maintenance and Adjustment

OP000436

4-50

Replace Engine Oil and Filter

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.

NOTE: Change engine oil and filter after first 50 hours on a

new machine and every 500 hours thereafter. Refer

“DL06 Industrial Engines Oil Drain Intervals by

Duty Cycle (Hours)” on page 4-19

Position a larger container under drain valve beside left

wall of fuel tank. Loosen drain valve and allow all

engine oil to drain out. Tighten drain valve.

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 of the coolant temperature

gauge reaches the middle of the "WHITE

ZONE," the temperature is about 40°C (104°F).

NOTE: Dispose of drained fluids according to local

FG002215

regulations.

Figure 74

Replace engine oil filter (Figure 75). Engine oil filter is

a spin-on type. 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

“Axle Oils DL400, DL300, DL250” on

page 4-16 for capacity and

“Table of

Recommended Lubricants” on page 4-14 of this

manual for recommended oil for the operating

FG006237

conditions.

Figure 75

Fill engine with correct oil through oil fill port.

Start engine and check engine oil pressure warning

light.

Shut down engine. Look for signs of leaks at filter.

Recheck oil level.

Inspection, Maintenance and Adjustment

OP000436

4-51

1,000 HOUR / 6 MONTH SERVICE

Perform All Daily 10, 50, 250 and 500

Hour Service Checks

Air Cleaner

CAUTION!

Never remove air cleaner filter 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.

Engine, Air Cleaner

The degree of engine wear depends largely on the

cleanliness of the induction air. The air cleaner prevents

dust and other impurities from entering the engine.

Therefore, it is very important that the air cleaner must be

checked regularly and maintained correctly.

Figure 77

Primary Filter, Maintenance and Replacement

When the alarm text "Clogged Air Filter" is shown or every

1,000 hours, the filter must be replaced or be cleaned. The

period of operation between filter replacements vary

depending on the working environment of the machine. In

certain environments the filter needs to be replaced more

often.

•

The filter can be cleaned according to instructions

which your authorized dealer will give you.

However, after the filter has been cleaned five

times or if it is damaged, it must be replaced.

Figure 78

NOTE: Make a mark on the decal at the end of the

secondary filter every time the primary

filter is replaced or cleaned.

•

In connection with replacing the filter, the cover

for the air cleaner should also be cleaned. It

works as a container for particles which have not

been trapped in the filter.

Inspection, Maintenance and Adjustment

OP000436

4-53

•

Check that all hose and pipe connections from the

air cleaner to the engine induction manifold are

tight. Check tightness of hose clamps.

•

If the alarm text remains after replacing the

primary filter, also the secondary filter must be

replaced. See

“9. Air Cleaner Clogged Warning

Light” on page 2-19

Do not, under any circumstances, run the engine without a

filter or with a damaged one.

Always have a spare filter on hand and keep the filter well

protected from dirt.

CAUTION!

Never clean the inside of air filter housing while the

inner filter is not installed.

Secondary Filter

Replace the filter every 2,000 hours or when the main filter

has been replaced three times.

The filter cannot be cleaned, but must be replaced.

The secondary filter works as a protective filter if the main

filter is damaged.

Never remove the secondary filter unless it is to be

replaced.

Figure 79

Replace Outer Air Cleaner Element

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.

FG000425

Open the side access cover at the rear of the cabin.

Figure 80

Remove the evacuator valve

(1, Figure

80) and air

cleaner cover (2, Figure 80).

NOTE: Inspect evacuator valve seal lips for wear or

damage. Replace valve if necessary. Install

evacuator valve with lips parallel to the cover.

Inspection, Maintenance and Adjustment

OP000436

4-54

Remove outer filter (4, Figure 80) from the air cleaner

housing.

Clean the air cleaner cover and the inside of the air

cleaner housing. Do not use compressed air to blow

out housing.

Install new outer filter.

Install air cleaner cover and evacuator valve.

NOTE: Make sure that all gaskets on wing nuts and

cover are properly installed and seated.

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 1,000 hours.

Use two people to perform this operation.

Start machine and drive it until transmission fluid has

warmed to 80°C (176°F). Park machine on firm, level

ground. Lower bucket to ground.

Place transmission lever in "NEUTRAL." Apply parking

brake. Shut down engine. Block tires.

NOTE: See

“Axle Oils DL400, DL300, DL250” on

page 4-16, for capacity and

“Table of

Recommended Lubricants” on page 4-14, of

this manual for recommended oil for the

operating conditions.

Remove drain plug. Allow all transmission fluid to drain

into a receptacle. Clean drain plug.

NOTE: Dispose of drained fluids according to local

regulations.

Install drain plug in transmission.

Remove inlet strainer. Use a nonflammable, nontoxic

solvent to clean strainer.

Inspect gasket on inlet strainer. Replace gasket if it is

damaged. Install inlet strainer.

FG004072

Remove breather filter. Clean breather filter and install

Figure 81

it.

Inspection, Maintenance and Adjustment

OP000436

4-55

Rotate filter counterclockwise to remove it.

10. Clean filter head.

11. Grease filter gasket and gasket mating surface on filter

head.

12. Thread filter onto filter head. Tighten filter 1/2 turn after

filter gasket contacts filter head. Filter must be torque

to 1.6 - 2.1 kg•m (11.5 - 15 ft lb).

FG002218

Figure 82

13. Fill transmission with fluid through transmission fill tube.

FG006235

Figure 83 TRANSMISSION OIL FILL CAP

14. Add fluid until fluid level is visible in lower "COLD"

portion of sight gauge (Figure 84 and Figure 85).

15. Start engine. Idle engine for two minutes. Have a

person remain in the cabin.

16. With engine idling, have second person check

transmission fluid level again. Add fluid until level

reaches "HOT" mark on sight gauge.

FG006236

Figure 84

TRANSMISSION SIGHT GAUGE

TRANSMISSION FILL TUBE

Inspection, Maintenance and Adjustment

OP000436

4-56

17. Oil level must be at "HOT" mark or above as shown in

(Figure 16).

NOTE: If oil level is above top end of sight gauge

(completely filling it), drain oil until level is at

"HOT" mark.

HOT

NOTE: If transmission cannot reach an operating

temperature of 80°C (176°F), then the oil level

COLD

must be visible in the sight gauge below the

"HOT" mark. Periodically check oil level during

the workday to ensure that oil level does not rise

HAAD4540

above top end of sight gauge.

Figure 85 TRANSMISSION SIGHT

18. Check filter for leaks while engine is running.

GAUGE

Clean Fuel Tank and Strainer

WARNING!

Fuel is flammable and harmful to skin.

•

Do not smoke while draining moisture and

sediment from fuel tank.

•

Do not drain fuel 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 easier to clean the fuel tank when it is almost

empty.

Park the machine on a level surface, apply the parking

brake, lower the attachment to the ground, and shut

down engine.

Open the drain valve (Figure 86) on the bottom of the

fuel tank.

Drain the remaining fuel into a suitable container.

NOTE: Dispose of drained fluids according to local

regulations.

FG002205

Figure 86

Inspection, Maintenance and Adjustment

OP000436

4-57

Remove bolts, inspection cover and gasket (Figure 87)

from fuel tank.

Clean inside of the tank and suction stainer.

Install the inspection cover with a new gasket. Tighten

the bolts. Do not overtighten.

Close drain valve.

Fill fuel tank.

Check for any leaks at cover and plug.

FG002223

Figure 87

Replace Inner Air Conditioner Filter

NOTE: This unit is equipped with an air filtration system

which filters out dirt and dust particles from air being

circulated into operator's cabin. This filter must be

cleaned out every 500 hours and replaced with a new

one every 1,000 hours. For filter replacement See

“Clean Inner Air Conditioner Filter” on page 4-50

NOTE: In the event that the equipment is being operated in a

dusty environment, the cleaning and replacement

must be performed more frequently.

Check Air Conditioner 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 attachment to the

ground.

Remove the cover.

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

flow.

Set the temperature control switch fully to the cool

position and fully open the cabin doors.

Slightly accelerate the engine to about the middle

speed range (compressor speed 1500 - 1800 rpm).

Inspection, Maintenance and Adjustment

OP000436

4-58

Compare the flow of bubbles in the sight glass 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.

FG004075

Figure 88

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 bubbles are seen.

Contact your local DOOSAN

loader dealer for inspection and

recharging refrigerant.

Low

A flow of bubbles is visible.

Check and Adjust Engine

Contact your nearest DOOSAN loader dealer.

Contact engine manufacturer for checking and adjusting the

following items:

•

Engine Compression Pressure.

•

Injection Pressure.

•

Injection Timing.

Inspection, Maintenance and Adjustment

OP000436

4-59

Replace Hydraulic Full Flow Filter

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 or rebuild and every 1000 Hours thereafter.

Loosen breather cap on hydraulic tank. (See Figure 20

on page 4-28).

Clean filter cover (2, Figure 89) and tank around cover.

Remove bolts (1, Figure 89) from cover (2).

Lift cover (2, Figure 89) and O-ring (4) off tank. Control

spring (3) sits beneath cover. Remove spring (3).

Remove valve (5, Figure 89) and filter (6) from tank.

Clean underside of cover (2, Figure 89).

Set a new element (6, Figure 89) and valve (5) down

into tank. Press element down onto its base until top of

element is approximately 4 mm (0.157") below edge of

tank.

Install a new O-ring

(4, Figure

89) on cover

(2). Set

spring (3) into place on element (6).

FG006233

Set cover

(2, Figure

89) into place over element

(6).

Figure 89

Install bolts

(1) through cover (2) and tighten them.

10. Tighten breather cap on tank.

Inspection, Maintenance and Adjustment

OP000436

4-60

1,500 HOUR / 9 MONTH SERVICE

Perform All Daily 10, 50, 250 and 500

Hour Service Checks

Replace Axle Differential and Planetaries

Oil

NOTE: Oil in both front and rear axles must be replaced after

first

500 hours of operation to comply with new

machine break-in requirements. After that, axle oil

check must be done every 500 hours of operation

and replacement must be done every 1,500 hours.

Each axle contains a center differential, and a planetary on

each end. The same oil lubricates the center differential and

planetaries. These sections of the axle are connected, but

the oil flows very slowly between them. When checked, oil

must be checked and refilled at the level/fill plug on the

differential housing.

To drain and replace oil in an axle, perform the following

steps:

Drive machine onto a level surface. Apply parking

brake. Block wheels.

Clean areas around drain plugs on both ends of axle.

Remove plugs and allow oil to drain into a suitable

container.

NOTE: See

“Axle Oils DL400, DL300, DL250” on

page 4-16 for capacity and

“Table of

FG002220

Recommended Lubricants” on page 4-14 of this

manual for recommended oil for the operating

Figure 90

conditions.

NOTE: Dispose of drained fluids according to local

regulations.

NOTE: Plug Size: M24 x 1.5

Tightening Torque: 7.1 kg•m (51 ft lb)

Inspection, Maintenance and Adjustment

OP000436

4-61

Clean area around level plug (1, Figure 91) and drain

plug

(2) on center differential. Remove level plug

(1)

and drain plug

(2). Allow oil to drain into a suitable

container.

NOTE: Plug Size (1, Figure 91):

M36 x 1.5

Tightening Torque: 13.2 kg•m (95 ft lb)

Plug Size (2, Figure 91):

M24 x 1.5

FG002221

Tightening Torque: 7.1 kg•m (51 ft lb)

Figure 91

Install drain plug

(2, Figure

91) into center differential,

and tighten. Install drain plugs on both ends of axle,

and tighten.

Pump oil into level plug hole on center differential. Add

oil until oil level is even with bottom of plug hole.

Recheck level on center differential. Add oil if

necessary. When oil level is satisfactory at the level

plug hole, install and tighten level plug.

NOTE: Allow oil time to fill planetaries.

Repeat procedure for other axle.

NOTE: Plug Size (1, Figure 92):

M36 x 1.5

Tightening Torque: 13.2 kg•m (95 ft lb)

Plug Size (2, Figure 92):

M24 x 1.5

Tightening Torque: 7.1 kg•m (51 ft lb)

FG002222

Figure 92

Inspection, Maintenance and Adjustment

OP000436

4-62

Axle Brake Disk Wear Measurement

NOTE: A wear measurement on the multidisk brake

must be made at least once a year, especially in

case of a change in braking behavior like, e.g.

•

Braking noise.

•

Braking power reduced.

•

Deceleration changed.

•

Brake fluid level changed.

•

Braking pressure changed.

A wear measurement must be made on both output

sides.

Remove screw plug, actuate brake and determine

"Dimension X" according to Figure

93 and Figure

using a feeler gauge. "Dimension X" corresponds with

the thickness of an inner brake disk on the piston side.

FG006232

Figure 93

NOTE: If Dimension X less than or equal to 4.0 mm

(0.16 in), the lined disks on both sides must be

replaced.

Install level plug with a new O-ring.

NOTE: Tightening Torque: = 7.1 kg•m (51 ft lb)

Figure 94

Inspection, Maintenance and Adjustment

OP000436

4-63

2,000 HOUR / YEARLY SERVICE

Perform All Daily, 10, 50, 250, 500 and

1,000 Hour Service Checks

Replace Inner Air Cleaner Element

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 filter when outer filter is replaced.

After removing outer filter, remove wing nut and inner

filter.

Clean out inside of air cleaner housing. Do not use

compressed air to blow out housing.

Install new inner filter, and secure it into position with

wing nut. Do not clean and reuse inner filter.

Install new outer filter, 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.

Check Steering, Brake, Drive Shaft,

Engine, and Fuel System

Replace Pipes and 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.

Inspection, Maintenance and Adjustment

OP000436

4-64

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."

FG006231

Figure 95

Remove plug (Figure 96) on axle. Increase the height

of bleeder

(1, Figure

96) by using special tool

(4,

Figure 96). Place one end of a plastic hose (2, Figure

96) over bleeder screw (1). Place other end of hose in

a container (3) filled with brake fluid.

NOTE: Dispose of drained fluids according to local

regulations.

Station one person in operator's cabin, and one person

at bleeder screw on axle being bled.

Open bleeder screw (1, Figure 96). Then press down

on brake pedal until it rests on floor of cabin. Hold

pedal down on floor of cabin. Close bleeder screw

while pedal is being held down. After bleeder screw

has been closed, allow brake pedal to return to 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.

Securely close bleeder screw

(1, Figure

96). Install

plug in axle.

Perform bleeding procedure on other three locations.

Figure 96

Inspection, Maintenance and Adjustment

OP000436

4-65

Replace Radiator Coolant

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. See

“Engine Cooling System” on

page 4-75, for further details.

NOTE: This unit was factory filled with propylene glycol.

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

FG002206

controls notifying personnel that service work is being

performed.

Figure 97

Do not remove the radiator cap unless it is required.

Observe the coolant level in the coolant recovery tank.

Slowly open the radiator cap (Figure 97) to allow any

pressure to escape.

NOTE: See

“Fluid Capacities” on page 4-19 for

capacity.

Place a container under the radiator and open the

drain valve (Figure 98).

NOTE: Dispose of drained fluids according to local

regulations.

FG002225

Figure 98

Inspection, Maintenance and Adjustment

OP000436

4-66

Replace Hydraulic Oil and Clean Oil

Suction Strainer

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 shut down engine.

NOTE: See

“Fluid Capacities” on page 4-19 for

capacity.

Figure 99

Position a catch tank beneath hydraulic tank drain plug.

Open tank breather cap.

(See Figure

20 on page 4-

28). Remove drain plug from bottom of tank.

(Figure

100). Allow all hydraulic oil to drain out.

FG004076

Figure 100

Figure 101

Inspection, Maintenance and Adjustment

OP000436

4-67

Figure 102

Without starting engine, operate controls to dump

bucket.

(Figure

101). Then operate controls to lower

boom. (Figure 102). This will drain oil out of boom and

bucket cylinders.

Replace full flow hydraulic filters as described under

“Loosen breather cap on hydraulic tank. (See Figure 20

on page 4-28).” on page 4-60.

Remove and clean pump inlet strainer

(Figure

103)

inside hydraulic tank.

A. Carefully remove bolts and cover (1), from top of

hydraulic oil tank. There is a spring (2) under the

cover that will force the cover up.

B. Remove spring (2, Figure

103) and suction filter

(4) by pulling on rod (3).

C. Clean in side and outside of strainer. Replace

strainer if it is broken.

D. Position strainer on boss portion of suction pipe.

E. Fill hydraulic oil tank. Check level using sight

gauge on side of tank.

Install tank drain plug. Refill tank by pouring oil in

through breather cap opening. Install and tighten

breather cap.

FG006228

Figure 103

Start engine and operate controls to raise and lower

bucket a few times.

(Figure

104). Raise and lower

boom a few times.

(Figure

105). Lower bucket to

ground.

Check tank sight gauge. (See Figure 19 on page 4-28).

Oil level must be between upper limit and lower limit

on sight gauge. Remove breather cap and add oil if

necessary.

Figure 104

Inspection, Maintenance and Adjustment

OP000436

4-68

Figure 105

Check Brake Accumulator

WARNING!

Pressurized Nitrogen gas in brake accumulator may

explode causing serious injury or death.

Never service brake accumulator unless properly trained.

Test the brake accumulator for proper precharge of Nitrogen

gas:

Park the machine on a level surface, apply the parking

brake, lower the attachment to the ground.

Run the engine at low idle for five minutes to fill the

brake accumulator with oil.

Shut down engine.

Turn the starter switch to "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 DOOSAN dealer.

Inspection, Maintenance and Adjustment

OP000436

4-69

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

“Replace Pipes and Hoses” on

page 4-64, every year. 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.

Inspection, Maintenance and Adjustment

OP000436

4-70

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.

Inspection, Maintenance and Adjustment

OP000436

4-71

BOLT TORQUE CHART

Tightening Torque Specifications for

Metric Bolts (For coated threads,

prelubricated 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

mm x

1.0

2.76

3.87

4.56

mm x std.

4.84

6.92

8.30

mm x

1.0

4.84

7.05

8.30

mm x std.

8.57

11.89

14.52

105

mm x

1.5

9.00

12.59

14.94

108

mm x std.

13.55

18.95

137

23.10

167

mm x

1.5

14.94

108

21.02

152

24.89

180

mm x std.

20.88

151

29.46

213

35.54

257

mm x

1.5

22.54

163

31.53

228

38.03

275

mm x std.

28.90

209

40.52

293

48.41

350

mm x

1.5

32.50

235

45.92

332

55.04

398

mm x std.

40.94

296

57.95

419

69.01

499

mm x

1.5

46.05

333

64.03

463

77.03

557

mm x std.

54.90

397

77.86

563

93.08

673

mm x

1.5

61.00

441

86.02

622

105.00

759

mm x std.

71.00

513

100.00

723

120.00

868

mm x

2.0

78.00

564

109.95

795

130.00

940

mm x

2.0

115.06

832

160.00

1157

195.00

1410

Inspection, Maintenance and Adjustment

OP000436

4-72

ELECTRICAL SYSTEM

Check Battery Condition

WARNING!

Before starting any battery service work, make sure to

shut the engine off and turn the starter switch to the "I"

(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.

HJB5002L

Figure 106

Inspection, Maintenance and Adjustment

OP000436

4-73

Inspect charge condition of battery by looking at the

indicator light built into battery.

•

GREEN: Normal.

•

BLACK: Insufficient charging - check alternator.

•

TRANSPARENT: Insufficient battery electrolyte

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.

Inspection, Maintenance and Adjustment

OP000436

4-74

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 2.1 kg/cm² (30

psi). 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

OP000436

4-75

Types of Antifreeze

There are two main classifications of antifreeze available on

the market today.

Ethylene Glycol - Standard Life Antifreeze

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%

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%

Inspection, Maintenance and Adjustment

OP000436

4-76

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 shut down, 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) to ground.

Shut down engine.

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

Turn starter switch to "I" (ON) position.

Fully move pilot control valve lever in all directions.

Repeatedly press brake until brake oil pressure warning

FG006227

light turns "ON." Press the pedal another eight to nine

Figure 107

times.

Set pilot cutoff switch on "O" (OFF) position.

Turn key to "O" (OFF) position and remove from starter

switch.

Remove accumulator by unscrewing it slowly.

Inspection, Maintenance and Adjustment

OP000436

4-77

HYDRAULIC PRESSURE

CHECKS

Hydraulic pressure for most systems can be check by using

the remote test ports shown in (Figure 108).

Reference

Description

Pressure

Number

TPM

TP2

TPS

Main Pump Pressure

TPU

TP1

200 ±5 kg/cm²

(TPM)

Brake Charge Pressure

120 kg/cm²

(TP2)

FG006226

Steer Pump Pressure

Figure 108

(TPS) at Only Steering

220 ±5 kg/cm²

Relief

Transmission Clutch

16 - 18 kg/cm²

Pressure (TM)

Unloading Valve Pressure

160 ±5 kg/cm²

(TPU)

Control Lever Activation

Pressure (TP1) at E/G

28 ±2 kg/cm²

High Idle

Control Valve Pressure

Attach gauge to port (1, Figure 108).

Relief valve cartridge on control valve

(Figure

109)

must be adjusted to open at

200 ±5 kg/cm²

(2,844 ±70psi)

FG004350

Figure 109

Inspection, Maintenance and Adjustment

OP000436

4-78

Brake Charge Pressure

Attach gauge to port (2, Figure 108).

Adjust relief valve cartridge on brake, pilot and fan

motor supply valve

(Figure

110). Relief pressure

(Figure

110) for brake charging is

120 ±5 kg/cm²

(1,707 ±70 psi).

FG005115

Figure 110

Steering Pump Pressure

Attach gauge to port (3, Figure 108).

Adjust relief valve cartridge on EHPS valve

(Figure

111). Cartridge must be adjusted to open at

220 ±5

kg/cm² (3,130 ±70 psi).

Remove plastic plug Adjust screw that is beneath plug.

Turn screw clockwise to raise relief pressure. Turn

screw counterclockwise to lower relief pressure.

FG006208

Install plastic plug after pressure has been adjusted.

Figure 111

Transmission Clutch Pressure

Attach gauge to port (4, Figure 108).

It is not impossible to adjust pressure.

NOTE: Transmission clutch pressure is

kg/cm²

+28

(228

psi).

Unloading Valve Pressure

Attach gage to port (5, Figure 108)

Relief pressure for unloading is

160 ±5 kg/cm²

(2,320 ±70 psi).

Adjust screw on unloading cartridge (C1) (Figure 108)

Loosen lock nut on adjusting screw. Turn adjusting

screw clockwise to raise relief pressure. Turn adjusting

screw counter clockwise to lower relief pressure.

FG008122

Tighten lock nut after adjustment has been made.

Figure 112

Inspection, Maintenance and Adjustment

OP000436

4-79

Control Lever Activation Pressure

Attach gauge to port (5, Figure 108).

Adjust relief cartridge

(Figure

113) on brake and pilot

and fan motor supply valve. Relief pressure must be

set at 28 ±2 kg/cm²

(398 ±28 psi).

Loosen lock nut on adjusting screw. Turn adjusting

screw clockwise to raise relief pressure. Turn adjusting

screw counterclockwise to lower relief pressure.

FG002227

Tighten lock nut after adjustment has been made.

Figure 113

Service Brake Outlet Pressure

Attach gauge to brake pressure test port (Figure 114)

of front axle.

Outlet pressure must be 60 kg/cm² (855 psi).

FG002231

Figure 114

Parking Brake Release Pressure

Attach pressure gauge to parking brake port.

Parking brake pressure must be 70 - 120 kg/cm² (996

1,710 psi).

FG002232

Figure 115

Inspection, Maintenance and Adjustment

OP000436

4-80

Fan Motor Pressure and Fan rpm

The motor intergrates a proportional pressure relief valve,

the fan speed

(and thus the cooling performance) can be

infinitely controlled depending on two different simultaneous

input signals from temperature sensors.

The cooling fan controller processes the two input signals

and controls the valve coil current. The proportional relief

valve has a fail safe characteristic, this means, max. relief

valve setting is adjusted automatically if the voltage supply

is interrupted

(e.g. broken wire). This results in a max. fan

speed and therefore in a max. cooling performance.

Standard

Fan Motor Pressure

90 ±5 kg/cm²

(1,280 ±70 psi)

Fan rpm

1,200

Figure 116

Reference

Description

Number

Engine

Cooling Fan

Cooling Pump

Temperature Sensor (T/M Oil)

Cooler

Temperature Sensor

Cooling Fan Controller

(Coolant Water)

Transmission

Fan Motor

Inspection, Maintenance and Adjustment

OP000436

4-81

Checking the Relief Pressure of Fan

Motor

FG001747

Figure 117

Reference

Description

Number

Fan Motor

Outlet Line

Fan Guard

Relief Valve

Inlet Line

Proportional Relief Valve

Drain Line

Reversable Solenoid Valve

Maximum Fan Speed, Checking

Open the radiator grille in order to connect the

pressure gauge.

Connect the pressure gauge to the pressure port

(6)

on the inlet hose (3). Check the maximum pressure by

fully depressing the accelerator pedal and reading the

pressure gauge. Maximum fan motor pressure: 100 ±2

kg/cm² (The fan speed is approximately

1200 rpm at

this time)

Inspection, Maintenance and Adjustment

OP000436

4-82

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 two

- three minutes. Raise and lower

boom two

- three times. Crowd and dump bucket two

three 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 cabin to warn operator that there is no coolant in

engine.

Inspection, Maintenance and Adjustment

OP000436

4-83

PARKING BRAKE ADJUSTMENT

Emergency Release of the Parking

Brake

Special design with

extended guide bolt

FG008053

Figure 118

If the parking brake cannot be released by normal hydraulic

system pressure, or if the engine will not start, it must be

manually released before towing can take place.

Before releasing parking brake make sure that wheels

have wheel chocks placed in front of and behind them,

to prevent machine from moving when parking brake is

released.

2876A

Figure 119

Inspection, Maintenance and Adjustment

OP000436

4-84

Release the screw cap (6, Figure 112) and unscrew.

Release the lock nut

(5, Figure

112) and turn the

adjusting screw

(4) counterclockwise until the brake

disk is free.

Install lock nut

(5, Figure

112) and screw cap (6) and

tighten both as far as possible. This will protect the

parking brake assembly from dirt.

NOTE: Now, the vehicle does not have any brake

function. The vehicle must be secured against

FG002232

moving away with proper means. Before putting

the vehicle into operation again, the brake has

Figure 120

to be adjusted according to adjusting

regulations.

Adjusting regulations

During this adjusting process, the parking brake must be

released, i.e. the bank of cup springs (3, Figure 112) must

be completely pretensioned.

Park vehicle on an even surface and place wheel

chocks in front of and behind tires. Only then release

the parking brake.

Release the screw cap (6, Figure 112) and unscrew.

Release the lock nut

(5, Figure

112)

(size

24 or 30)

and turn the adjusting screw

(4) with socket wrench

(size

8 or 10) clockwise until the two brake pads

(1)

and (2) make contact with the brake disk.

Turn the adjusting

screw

(4,

Figure

112)

counterclockwise and set the clearance specified in the

following table.

Type

Adjusting Screw

Clearance (mm)

Revolutions

min.

0.5

1/4

Small

M 16 (size 8)

Rated clearance

1.0

1/2

max

1.5

3/4

min.

1.0

2/5

Large

M 20 (size 10)

Rated clearance

2.0

4/5

max

3.0

1 1/5

Hold the adjusting screw

(4, Figure

112) in position

with the hexagonal socket wrench and lock with the

lock nut (5).

Mount the screw cap (6, Figure 112) and tighten as far

as possible manually.

Actuate the brake valve several times and check the

braking efficiency of the parking brake on slope.

Inspection, Maintenance and Adjustment

OP000436

4-85

TIRES

Inflating Tires

Recommended tire pressures should normally be followed.

Special operations may justify a different pressure. In such

cases, follow the instructions from the tire manufacturer and

do not exceed the maximum permissible pressures,

(See

page 4-88)

The tire pressure may have been raised before the machine

was delivered from the factory. Therefore, check and adjust

the tire pressure according to recommendations, before

putting the machine to work for the first time.

WARNING!

Repair work on tires and rims must be carried out by

persons who have been especially trained for this.

The instructions stated below apply to an inflated tire

where the pressure needs to be increased. If the tire

has lost all pressure, a trained service engineer must be

called in.

•

When checking the air pressure, the tire must be

cold and the machine not have a load.

•

Ask all other persons to leave the danger area (in

front of the rim).

•

Stand by the tire tread as shown in the figure.

Tire installed on a split rim may explode causing

injury or in the worst case death.

•

Use a long air hose

(with a self attaching air

chuck) which allows you to stand outside the

danger area.

•

Tires on stored wheels

(spare wheels) must be

kept laying down on their side, and only be

inflated sufficiently to keep the rim parts in

position.

Wheel Nut, Tightening Check

After having changed a tire or if the wheel has been

removed and installed for any other reason, the wheel bolts

must be check for tightness after eight hours of operation.

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

Inspection, Maintenance and Adjustment

OP000436

4-86

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 121.

Figure 121

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 DOOSAN loader dealer or tire

manufacturer's local dealer for tire servicing or

changing.

WARNING!

An overheated tire may explode causing serious injury

or death.

If overheated tire is suspected, do not approach tire to

distance of less than 15 m (50 ft).

Stay away until tire and rim cool down.

If the following defects are found in tires, for safety reasons

the tires must be replaced with new tires.

For the replacement contact DOOSAN 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 of the tire

Figure 122

width.

Inspection, Maintenance and Adjustment

OP000436

4-87

•

Tire layers are separated.

•

Radial cracks reach the carcass.

•

Deformation or damage which makes the tire

unsuitable for use.

Recommended Air Pressure

Working Pressure

Driving Pressure

Tires

Remarks

Front

Rear

Front

Rear

+0.1

4.1

Bar

3.5

Bar

4.1

Bar

3.5

Bar

20.5-25-16PR

Bias Ply Tire

(Standard)

(60

psi)

(50

psi)

(60

psi)

(50

psi)

+0.1

3.5

Bar

3.0

Bar

3.5

Bar

3.0

Bar

20.5R25

Radial Ply Tire

(Option)

(50

psi)

(44

psi)

(50

psi)

(44

psi)

The recommended tire pressures are based on the rated

load for each handling case.

In case of heavier loads, especially during loading and

carrying operations, a higher tire pressure is required.

Contact the tire manufacturer for information about which air

pressure is the correct one for the load to be handled and

transported over a particular distance.

If L5 tires are used for loading and carrying operations, due

attention must be paid to the transporting distances. Radial

tires are to be preferred for loading and carrying operation,

as the buildup of heat is less in this type of tire.

Inspection, Maintenance and Adjustment

OP000436

4-88

OP000039

5Transportation

LOADING AND UNLOADING

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 each control lever using the

pilot cutoff switch.

Apply the parking brake and set the articulation stopper

in the "LOCKED" position.

Tape over the exhaust stack outlet to prevent turbo

"Windmilling" 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 2

Brake pipe runs on axle housing.

Do not fasten axle housing.

Transportation

OP000039

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.

Tag lines on opposite sides of load can be very helpful in

keeping a suspended load secure, if they are anchored

Figure 3

safely to control points on ground.

Transportation

OP000039

5-2

OP000040

6Troubleshooting

ENGINE

Problem

Possible Cause

Remedy

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

Readjust.

of adjustment.

Engine speed control cable

Readjust.

out of adjustment.

Engine knocks, runs unevenly

Low engine oil.

Add oil.

or surges.

Plugged air intake system.

Clean system and replace

filter.

Injection pump out of

Contact your DOOSAN dealer.

adjustment.

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.

Troubleshooting

OP000040

6-1

Problem

Possible Cause

Remedy

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

Readjust.

out of adjustment.

Injection pump out of

Contact your DOOSAN dealer.

adjustment.

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 oil cooler.

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

Low engine oil level.

Add oil.

light turns "ON," and buzzer

Wrong grade oil for weather

change oil.

sounds.

conditions.

Clogged oil filter.

Change filter and oil.

Defective alarm switch.

Contact your DOOSAN dealer.

Oil leakage from pipe or joint.

Clogged 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.

Clogged radiator fins.

Clean.

Scale or mineral build up

Flush or professionally clean.

inside radiator.

Defective alarm switch (gauge

Contact your DOOSAN dealer.

is in green).

Low water pump flow.

Thermostat stuck or missing.

Engine does not start when

Fuel filter clogged.

Replace fuel filter.

the starter motor is turning.

Starter motor speed too low.

Booster Battery may be used.

(Also see ELECTRICAL

Defective engine shutoff

Contact your DOOSAN dealer.

TROUBLESHOOTING.)

solenoid.

Fuel pump failure.

Incorrect fuel injection timing.

Compression pressure too low.

Defective injectors.

Troubleshooting

OP000040

6-2

Problem

Possible Cause

Remedy

Unstable (rough) idling.

Air in fuel lines.

Tighten fuel connections and

filter.

Fuel filter clogged.

Replace fuel filter.

Fuel pump failure.

Contact your DOOSAN dealer.

Incorrect fuel injection timing.

Insufficient power.

Air cleaner filter clogged.

Clean or replace element.

Fuel filer element clogged.

Replace fuel filter.

Throttle linkage adjustment

Check and adjust linkage.

wrong.

Engine oil level too high.

Check dipstick and correct

level.

Incorrect valve clearance.

Contact your DOOSAN dealer.

Piston ring wear.

Defective injectors.

Fuel pump failure.

HYDRAULIC SYSTEM

Problem

Possible Cause

Remedy

None of the controls function

Hydraulic pump failed.

Contact your DOOSAN

(loud noise from pumps).

dealer.

Low hydraulic oil level.

Add hydraulic oil as

required.

Suction line plugged or damaged.

Clean or replace as

required.

None of the controls function

Pilot pump failure.

Contact your DOOSAN

(no noise from pumps).

dealer.

Cutoff solenoid valve failed.

Replace solenoid.

Relief cartridge of pilot parking

Clean or replace as

valve stuck.

required.

Safety limit switch is ON.

Adjust limit switch

clearance.

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.

Troubleshooting

OP000040

6-3

Problem

Possible Cause

Remedy

Only one or two actuators

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.

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

Overload relief valve is not

Repair valve or replace.

boom have little power or do

operating properly.

not 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.

Troubleshooting

OP000040

6-4

TRAVEL SYSTEM

General

Problem

Possible Cause

Remedy

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

Fluid pressure low in transmission

Repair clutch.

little power.

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 disks.

disks.

Damaged wires in transmission

Repair wires.

control wire harness.

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.

Troubleshooting

OP000040

6-5

STEERING

Problem

Possible Cause

Remedy

Steering Wheel is hard to turn.

Sediment blocking direction

Clean and repair.

change spool orifice, inside priority

valve.

Sediment blocking amplifying spool

Clean and repair.

orifice, inside priority valve.

Sediment blocking load sensing

Clean and repair.

line orifice, inside priority valve.

Priority valve spool sticking, inside

Clean and repair.

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 to

Air in load sensing line, inside

Bleed system to remove

movement of steering wheel.

priority valve.

air.

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 damping

Replace priority valve.

inside priority valve.

Steering wheel shakes.

Chattering bearing in axle end

Replace bearing.

differential.

Tire pressure not equal in left side

Equalize pressure.

and right side tires.

Troubleshooting

OP000040

6-6

BRAKING

Problem

Possible Cause

Remedy

Reduced brake action.

Low secondary pressure in brake

Repair or replace brake

valve.

Worn brake disks.

Replace brake disks.

Damaged brake disks.

Replace brake disks.

Damaged brake valve block.

Replace valve.

Air in brake hydraulics due to leak

Repair leak, bleed system.

in brake hose.

After bleeding brakes, brakes

Damaged brake disks.

Replace disks.

are not fully released.

Damaged brake disk return spring.

Replace return springs.

ELECTRICAL SYSTEM

Problem

Possible Cause

Remedy

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 or damaged.

Tighten or replace.

Battery will accept a charge

Internal battery short.

Replace battery.

but discharges soon after.

Wiring harness short.

Repair wire.

Troubleshooting

OP000040

6-7

OP000437

7Specification

GENERAL SPECIFICATIONS

DL250

ITEM

SPECIFICATION

Standard Bucket Capacity (BOT / BOC)

2.5 m³ (3.25 yd³) / 2.6 m³(3.38 yd³)

Vehicle Weight

14,000 kg (30,864 lb) - standard

Engine (SAE J1995 Gross)

Emission

U.S EPA Tier3 (EU Stage IIIA)

Maker and Model

DOOSAN DL06

Type

Turbo Charged, Air to Air Intercooled Direct Injection

Injection System

Common-rail Controlled by Electronic ECM

Max. Horse Power

172 ps (127 kw) / 1800 rpm

Rated Horse Power

165 ps (121 kw) / 2100 rpm

Max. Torque

82 kg•m (804 N.m) / 1400 rpm

Transmission

Full Automatic Power -Shift

Full Automatic Power Shift

Speeds

4 Forward, 3 Reverse

Brake Systems

Travel Brakes

4 Wheel, Wet Disk (Sinter Metal Disk)

Parking Brake

SAHR, Dry Disk Type

Performance

Travel Speed

6.6 (4.1) /11.5 (7.1) / 22.5 (14) / 34 (21) km/h (MPH)

Steering Angle

±40°

Min. Tire Turning Radius

5,450 mm (17' 10")

(Out Tire Edge)

Safe Operating Load

4,320 kg (9,523 lb)

Max. Breakout Force

13,200 kg (29,100 lb)

Boom Rise Time

5.4 ±0.5Sec.

Bucket Dump Time

1.3 ±0.3 Sec.

Boom Down Time

3.3 ±0.4 Sec.

Maximum Gradeability

30° (58%)

Specification

OP000437

7-1

Doosan DL250. Operation and Maintenance Manual (2006) - page 3