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Doosan DX190W. Operation and Maintenance Manual (2006) - page 3

CUP HOLDER

There is a cup holder on the right side of the compartment (1,

Figure 164). Open the access cover and lower it to a horizontal

position.

1

FG000205

Figure 164

DOOR WINDOW HOLDER

1

When the machine is being operated with the cabin door window

opened, window vibration can be reduced by tightening knob (1,

Figure 165) against the window.

FG000206

Figure 165

EMERGENCY GLASS BREAKING

TOOL

The excavator is equipped with a glass breaking tool. It is to the

upper right corner of the cabin. This tool can be used in case of

an emergency situation which requires the breaking of glass to

exit from the cabin. Grip the handle firmly and use the sharp

point to break the glass.

FG000178

WARNING!

Figure 166

Protect your eyes when breaking the glass.

Operating Controls

OP000528

2-73

MISCELLANEOUS ACCESS

COVERS AND DOORS

Side Door

Open the side access door and slide prop rod (1, Figure 167) in

slot (2) until it locks at the end of slot.

1

2

FG008145

Figure 167

Battery Box Door

Opening

Open door until locking device (1, Figure 168) latches.

Closing

While holding door, press locking device to release lock and

close door.

FG008146

Figure 168

Engine Cover

Open the cover and slide prop rod (1, Figure 169) in the slot (2)

until it locks in notch at the end of slot to support the cover.

2

To close cover, move end of prop rod out of notch so it can slide

in slot.

1

FG008147

Figure 169

Operating Controls

OP000528

2-74

Dozer Cylinder Protection Cover

Unlock chain (Figure 170) connection between dozer cylinder

protection cover and chassis frame out of this chassis frame.

Completely open the dozer cylinder protection cover.

CAUTION!

In order to avoid malfunction when opening dozer cylinder

protection cover, you must work it after fixing the facilities

on a planar ground surface and then putting down the dozer

FG008148

blade. When opening dozer cylinder protection cover, take

Figure 170

heed so that the cover would not be shut off by external

shock etc.

Operating Controls

OP000528

2-75

SWING LOCK PIN AND

MECHANISM

This wheel excavator is equipped with a swing lock device,

which should be used when transporting or traveling on streets.

The device consists of a pin and two holes which must be

aligned and through which the pin is placed. This serves to keep

the swing device from accidentally moving and causing damage

to other vehicles or people in its path.

The swing lock pin is stored in the rear left section of battery

compartment (Figure 171).

FG006556

Figure 171

Make sure the upper section is facing forward. Align upper

structure of machine with lower frame and make sure holes are

in alignment. Insert lock pin into hole (Figure 172) between left

boom cylinder and right boom cylinder.

FG006557

Figure 172

WHEEL CHOCKS

A pair of wheel chocks are supplied with the machine, there are

stored on the lower frame directly below the cabin. When the

upper structure is facing the front of the machine.

These wheel chocks should be used at all times when it is

necessary to secure the machine for repairs or for transport.

FG008150

Figure 173

Operating Controls

OP000528

2-76

Operational Checks Before Starting

Engine

WARNING!

When leaving operator's seat, set the safety lever and stand

on "LOCK" (Figure 1) position, if not a serious accident

could occur by accidentally moving the travel or work

levers.

FG006173

1.

Set safety lever and stand on "LOCK" (Figure 1).

Figure 1

2.

Fasten seat belt. Check for proper operation and condition.

3.

Set all operation levers in "NEUTRAL".

NOTE: Be careful not to touch any switches when

starting engine.

F

N

R

FG002266

Figure 2

4.

Set parking brake switch to the "I" position. This will ensure

that the parking brake is "APPLIED".

O

I

FG002178

Figure 3

5.

Rotate the starter switch to the "I" (ON) position (Figure 4).

Check all indicator lights. A warning buzzer will sound for

O

about 2 seconds. After 2 seconds, all lights except the

I

following will turn "OFF".

•

Engine coolant temperature gauge

•

Charging warning light

•

Fuel gauge

•

Hydraulic oil temperature gauge

•

Engine oil pressure warning light

FG000084

Figure 4

•

Engine rpm (0 rpm) digital readout

Operation

OP000529

3-3

NOTE: If all of the indicator lights do not come "ON"

when the key is first turned, there is a problem.

A warning buzzer will sound for about 2 seconds.

The sound of the engine control motor may be heard while

it rotates to the correct starting position.

Engine Start

WARNING!

Start the engine after sounding horn and making sure that

there are no people or obstacles in the area.

1.

Perform all steps in “Operational Checks Before Starting

Engine” on page 3-3.

2.

Set engine speed control dial slightly above "LOW IDLE"

(Figure 5).

3.

Sound horn.

HAOB34L

Figure 5

4.

Enter password.

NOTE: If the security system is "LOCKED", a four-digit

02/05 [MO] 11:30

password will be required to start the engine. If the

system is "UNLOCKED", no password will be

ENTER

required and this display screen will not appear.

PASSWORD

C

H

E/G SPEED

0 RPM

FG001445

Figure 6

Operation

OP000529

3-4

" "

5.

Turn starter switch to

(START) position (Figure 7).

Engine should start in approximately 5 seconds.

O

I

WARNING!

If the engine does not start after approximately 15

seconds of cranking, release the starter switch. Wait

about 5 minutes and repeat above step.

FG000085

Figure 7

6.

After engine has started, release key. Key will return to the

"I" (ON) position (Figure 7).

O

I

7.

Follow procedures in

“Hydraulic System Warm-up” on

page 3-10.

FG006181

Figure 8

8.

After warming unit, check all operating indicators to make

4

5

6

7

sure that all engine systems (oil pressure, coolant, etc.) are

in the normal operating range. If any problems are noticed,

shut down engine. Normal indicators are:

CHECK

P

02/05 [MO] 11:30

2

1

3

E/G SPEED

1700 RPM

FG007104

Figure 9

INDICATOR

No.

INSTRUMENT PANEL LIGHT OR GAUGE

READING

1

Engine Coolant Temperature Gauge

Blue Range

2

Fuel Gauge

Blue Range

3

Hydraulic Oil Temperature Gauge

Blue Range

4

Charging Warning Light

OFF

5

Engine Oil Pressure Warning Light

OFF

6

Engine Coolant Temperature Warning Light

OFF

7

Engine Check Warning Light

OFF

Operation

OP000529

3-5

9.

Check color of exhaust smoke.

•

No color or light blue - Engine is running in good

condition.

•

Black - Incomplete combustion. Check cause.

•

White or dark blue - Engine is burning engine oil.

Check cause.

10.

Check for usual engine vibration and noises. If any are

heard or felt, investigate cause.

NOTE: If engine coolant temperature gauge pointer

moves into the red zone, the engine coolant

temperature warning light will turn "ON", a

warning buzzer will sound, and the engine

speed will be automatically reduced. Allow the

engine to run at low idle speed until the

temperature gauge registers in the blue zone

again. When the blue zone is reached, allow the

engine to idle for an additional three

- five

minutes before shutting down the engine. If not

allowed to idle, heat surge may develop which

will damage the engine. Allowing the engine to

idle will dissipate heat. Check the coolant level,

look for a loose fan belt, inspect for debris

around radiator, and so on.

Cold Weather Starting

WARNING!

DO NOT USE STARTING FLUIDS. The preheat system could

cause the starting fluid to explode. Starting fluids should

never be used.

1.

Perform all steps in "Operational Checks Before Starting

Engine."

2.

Set engine speed control dial slightly above "LOW IDLE"

(Figure 10).

3.

Sound horn.

HAOB34L

Figure 10

Operation

OP000529

3-6

4.

Turn starter switch to the "I" (ON) position (Figure 11).

When preheat cycle is completed, the preheat indicator

O

light (1, Figure 12) will turn "OFF".

I

FG000084

Figure 11

1

CHECK

P

FG007105

Figure 12

5.

After the preheat completion, immediately turn starter

" "

O

switch to

(START) position

(Figure

13). Engine

I

should start in approximately five seconds.

WARNING!

If the engine does not start after approximately fifteen

seconds of cranking, release the starter switch. Wait

FG000085

about five minutes and repeat above step.

Figure 13

6.

After engine has started, release key. Key will return to the

"I" (ON) position (Figure 13).

7.

After the engine starts, check all operating indicators to

make sure that all engine systems (oil pressure, coolant,

etc.) are in the normal operating range. If any problems are

noticed, shut down engine.

8.

Follow "Hydraulic System Warm-up" procedures in this

section. (See page 3-10)

Operation

OP000529

3-7

Starting Engine With a Booster Cable

WARNING!

1.

An explosive gas is produced while batteries are in

use or being charged. Keep flames or sparks away

from the battery area.

2.

Charge batteries in a well ventilated area.

HAOA440L

3.

Always wear eye protection when starting a machine

Figure 14

with jumper cables.

4.

Improper jump starting procedures can cause an

explosion resulting in personal injury.

5.

Jump start vehicles on dry ground or concrete. Do not

jump start the machine on a steel floor, because the

floor is always grounded.

6.

When starting from another machine, make sure the

machines do not touch.

7.

Always connect the auxiliary battery positive

(+)

terminal too depleted battery positive (+) terminal first.

Then connect auxiliary battery negative (-) terminal to

the frame of the depleted battery machine second.

8.

Connect positive cable first when installing cables and

disconnect the negative cable first when removing.

IMPORTANT

The machine has a 24V (-) negative ground electrical

system. Use the same capacity 24V booster batteries when

jump starting engine.

If the batteries are drained during starting procedures, jump start

engine using auxiliary or booster batteries according to the

following procedure;

Connecting the Booster Batteries

1

1.

Shut down engine of the machine on which booster

RED

batteries (3, Figure 15) are mounted.

2.

Connect one end of red cable (1, Figure 15) to the positive

(+) terminal of the machine batteries (4), and the other end

to the positive (+) terminal of the booster batteries.

3.

Connect one end of black cable (2, Figure 15) to the

3

4

negative (-) terminal of the booster batteries (3), and then

BLACK

make ground connection to the upper frame (5) of the

2

5

machine to be started with the other end of black (-) cable

ARO0440L

(2, Figure 15). When making the last connection to upper

Figure 15

frame, be sure to connect the cable end as far away from

Operation

OP000529

3-8

Hydraulic System Warm-up

WARNING!

If a problem or abnormal operation occurs, immediately

shut down engine. Allow excavator to reach normal

operating temperature before starting work, especially in

cold weather.

The correct operating temperature of the hydraulic oil is 50° -

80°C (120° - 175°F). Make sure to follow the procedures listed

here for hydraulic fluid warm-up.

1.

Run engine for approximately five minutes set at the

middle of the speed range, without a load.

HAOB410L

Figure 16

2.

Set safety lever

(Figure

17) and stand on "UNLOCK"

position.

Unlock

Lock

FG007022

Figure 17

3.

Slowly cycle boom, arm and bucket cylinders about five

times without a load to circulate the oil through the system.

Do this for five minutes.

4.

Check for clearance and fully raise the front attachment.

Swing clockwise 3 revolutions. Swing counterclockwise 3

revolutions.

5.

Travel forward and reverse at low speed for two

revolutions of the drive wheel.

FG000380

Figure 18

Operation

OP000529

3-10

Hydraulic System Warm-up - Cold

Weather

1.

Run engine at "LOW IDLE" (no load) for five minutes

(Figure 19).

HAOB290L

Figure 19

2.

Run engine for approximately five minutes set at the

middle of the speed range, without a load (Figure 20).

HAOB410L

Figure 20

3.

Set safety lever

(Figure

21) and stand on "UNLOCK"

position.

Unlock

Lock

FG007022

Figure 21

4.

Slowly cycle boom, arm and bucket cylinders about five

times without a load to circulate the oil through the system.

Do this for five minutes.

FG000380

Figure 22

Operation

OP000529

3-11

5.

Set engine speed control dial to "HIGH IDLE" (Figure 23).

6.

Repeat Step 4 for five minutes. If working speeds continue

to be slow, continue to operate, but use extreme caution

because the machine function may be erratic.

7.

Check for clearance and fully raise the front attachment.

Slowly swing clockwise

3 revolutions. Slowly swing

counterclockwise 3 revolutions.

8.

Travel forward and reverse at low speed for two

revolutions of the drive wheel.

HAOB550L

Figure 23

Engine Shut Down

NOTE: Allow engine to idle for three - five minutes before

shutting down the engine. If not allowed to idle, heat

surge may develop which will damage the engine.

Allowing the engine to idle will dissipate heat.

1.

Park excavator on level and firm ground.

2.

Lower front end attachment to ground and make sure all

operating controls are in "NEUTRAL."

FG006558

Figure 24

3.

Set safety lever on "LOCK" position, and raise the lift stand

by pulling up lever (1, Figure 25).

1

Unlock

Lock

FG007113

Figure 25

4.

Set engine speed control dial to "LOW IDLE" (Figure 26).

Allow engine to idle for three - five minutes.

HAOB290L

Figure 26

Operation

OP000529

3-12

5.

Shut down engine by turning key to "O" (OFF) position

(Figure 27).

O

I

6.

Remove key from starter switch.

Check and Confirmation After Stopping

Engine

1.

Repair excavator, if there are any coolant or oil leaks.

2.

Inspect front attachment and chassis frame for abnormal

FG000175

appearances. Correct any problems.

Figure 27

3.

Fill fuel tank.

4.

Get rid of any accumulated flammable materials such as

leaves and paper etc. in engine compartment.

5.

Clean all mud, etc. from chassis frame and tires. Make

sure that all steps and hand holds are clean, and that the

operator's compartment is clean.

Operation

OP000529

3-13

SAFETY LEVER

WARNING!

When stopping engine or leaving the operator's seat,

"LOCK" the safety lever, otherwise, a serious accident may

occur by accidental movement of travel and work levers.

Whenever leaving the operator's seat, make sure the engine

is shut down and the safety lever is "LOCKED."

Especially, when adjusting the seat, control stands, or

raising the front window, lower window, or ceiling cover,

never forget to lock the safety lever in its "LOCKED"

position.

FG002254

Figure 28

Be careful not to move the work levers (joysticks) when moving

safety lever.

1.

Push safety lever (Figure 28) down into the "LOCKED"

position. When safety lever is in the "LOCKED" position,

the front attachment swing, dozer and outrigger movement

will be disabled even though a lever is moved. ("LOCKED"

condition is made by safety function separately constituted

in case also of stand fitting)

NOTE: Lower bucket

(front attachment) to ground.

Place all control levers in "NEUTRAL" and shut

down engine, before using the safety lever.

2.

Set safety lever and stand (Figure 29) on "RELEASE/

UNLOCK" position, by pulling it up before starting work.

(Whereas stand also must become release condition by

your lowering the stand for your normal work condition)

NOTE: When the engine is not running, but the safety

lever is "RELEASED" and the starter key is

tuned "ON", moving the work levers (joysticks)

may result in movement. The charged

accumulators in the system will provide pilot

pressure for control valve spool movement.

FG002651

Figure 29

Operation

OP000529

3-14

Before Traveling

1.

Check all tires to make sure that they are properly inflated

and are not damaged.

2.

Make sure that all excess mud, stone, etc. has been

removed from the tires.

3.

Fully raise and secure all outriggers and the dozer blade,

be sure to lock the outrigger legs(Figure 30).

4.

Make sure that the upper section is facing forwards.

5.

Store the front attachment in the "TRANSPORT" position

and set the Function Lock in the "TRAVEL" position. (See

Figure 31 on page 3-16)

"Lock"

6.

Set the ram cylinder toggle switch in the "UNLOCK"

position.

7.

Before moving the excavator, make sure that the swing

lock pin has been engaged. (See “Swing Lock Pin and

Mechanism” on page 2-76.) This will prevent the excavator

"Unlock"

from accidentally rotating during traveling.

FG006559

Figure 30

FG006560

Figure 31

Operation

OP000529

3-16

Over the Road Traveling Procedures

1.

Make sure that the "Brake Oil Pressure" warning light is

"OFF".

2.

After making sure that the front attachment is facing

forward, release the parking brake.

3.

Using the right-hand control arm, select either forward or

reverse travel direction and step on the accelerator pedal.

NOTE: The accelerator pedal functions in two ways. If

the manual engine speed control dial is at the

lowest setting, the accelerator pedal controls

both engine speed and a hydraulic

proportioning valve that controls the actual

travel speed. If the manual engine speed control

dial has been set to a higher rpm, the

accelerator pedal functions only as a hydraulic

proportioning valve control, enabling control of

only travel speed and not engine rpm.

4.

Test the brakes before beginning over the road travel.

5.

During forward motion you can shift from speed range II to

speed range III. Downshifting from speed range III to

speed range II should not be done if the machine is

traveling at a high rate of speed. Damage to the

transmission could result.

WARNING!

Don’t change to creep speed during running in low or

high speed.

It cause a damage to equipment.

You should select creep speed after stopping an

equipment.

In normal travelling drive in low or high speed.

6.

To stop the machine, slowly release the accelerator pedal.

The dynamic braking action of the machine's momentum

against the engine's back pressure will begin to slow the

machine. Step on the brake to bring the machine to a full

and controlled stop.

IMPORTANT

If the engine speed is controlled by the manual engine

speed control dial, when the machine comes to a stop,

the engine will continue to run at the preset rpm. If the

engine speed is being controlled by the accelerator

pedal, it will decrease and the machine will slow down

as the pedal is released.

Operation

OP000529

3-17

NOTE: As the brake pedal is applied, and if it is

pressed all the way to the floor, a mechanical

lock will engage and hold the pedal in the fully

1

applied position

(1, Figure

32). Step on the

release lever and the brake pedal will return to

the upright position.

7.

After traveling a long distance, the front attachment,

outriggers or dozer blade may begin to drift due to normal

internal hydraulic leakage. Position the machine in a safe

location and move the function lock to the full front function

position and reposition the front attachment, outriggers or

FG002653

dozer blade.

Figure 32

Traveling On A Work Site

WARNING!

When traveling, keep bucket from 200 - 300 mm (8 - 12 in)

above ground.

Do not travel backwards on a slope.

Never turn or travel crosswise on a slope.

FG008152

Choose a safe alternate route before climbing a slope.

Figure 33

If excavator starts to slip or becomes unstable, lower the

bucket immediately into the ground using it as a brake.

Avoid working on slopes, because there is a danger of

overturning by coming unbalance while swinging and

performing front attachment operations.

It is very dangerous to swing towards bottom of slope with

a loaded bucket.

In unavoidable cases level the slope with fill soil, to make

the vehicle as horizontal as possible.(Figure 33)

Do not travel on slopes over 30° due to turnover danger.

1.

Avoid obstacles, never drive over them.

2.

Keep away from the shoulders or edges of slopes or

excavations.

3.

Always travel directly up or down a slope, never sideways.

4.

Avoid changing directions or sudden starts or stops on a

slope.

5.

On a slope, make sure to fully extend the arm and lower

the boom until the bucket is 20 - 30 cm (8" - 12") above

the ground. (See Figure 34 on page 3-19.) If the machine

starts to slide or slip, lower the bucket to the ground to

regain control. If the engine stalls, lower the bucket, make

sure that all controls are in the "NEUTRAL" position and

restart the engine.

Operation

OP000529

3-18

6.

Never travel up or down a slope with a vertical angle

greater than 20°, or sideways on a slope with a vertical

angle of greater than 5°.

Traveling On A Slope

1.

If the engine stops when traveling on a slope, lower the

bucket to the ground, make sure all controls are in the

"NEUTRAL" position and restart the engine.

2.

Before driving down a slope, test the brakes to make sure

that they are fully functional.

3.

Never drive down a slope with the transmission in

"NEUTRAL."

4.

When driving down a slope, allow the dynamic braking

action of the machine's momentum against the engine's

back pressure to slow the machine. Step on the brake to

bring the machine to a full and controlled stop. Do not over

use the brakes on a slope or they can burn out.

5.

Make sure to fully warm up the engine and the hydraulic

system before attempting to travel on a slope.

Wheel Chocks

FG006561

Figure 34

Operation

OP000529

3-19

Parking

1.

Slowly release the pressure on the accelerator pedal.

FG002656

Figure 35

2.

Step on the brake to fully stop the machine.

FG002657

Figure 36

3.

Be certain to set the work levers

(joysticks) and

transmission select lever to "NEUTRAL".

F

F

N

R

R

FG002185-2

Figure 37

4.

If you are using the manual speed control dial, reduce the

engine speed to "LOW IDLE".

HAOB290L

Figure 38

Operation

OP000529

3-20

5.

Lower bucket, dozer blade and outrigger to ground.

FG006562

Figure 39

6.

Set parking brake switch to the "I" position. This will ensure

that the parking brake is "APPLIED".

O

I

FG002178-1

Figure 40

7.

Shut down engine by turning key to "O" (OFF) position

(Figure 41).

O

I

8.

Remove key from starter switch.

FG008623

Figure 41

9.

If the machine is parked on a slope, insert the wheel

chocks on the downhill side of the wheels to secure the

machine. (See Figure 34 on page 3-19.) wheel chocks are

supplied with the machine. There are stored on the lower

frame directly below the cab. When the upper structure is

facing the front of the machine.

FG008150

Figure 42

Operation

OP000529

3-21

Travel Problems

1.

If a problem develops during the travel mode, move the

machine to the side of the road as safely as possible.

2.

Determine the cause of the problem and correct it if

possible.

3.

If a hydraulic leak develops, lower the bucket and the

dozer blade to the ground, shut down the engine, and

release the air pressure from the hydraulic tank. Contain

the hydraulic fluid if possible.

Cruise Control

Engaging Cruise Control

WARNING!

The Cruise Control set button will set only the engine rpm,

not road speed. The engine rpm is set by rotating the

manual engine speed setting dial.

1.

Using the foot control pedal, bring the unit to the

appropriate travel speed.

2.

Rotate the engine speed control dial to match the rpm

setting shown on the tachometer. (Figure 43)

HGB3013L

Figure 43

3.

Press the button on the end of the right-hand control arm

inwards. (Figure 44) This button will maintain the engine

rpm setting dialed in by the manual engine speed control

dial. The foot control pedal will not affect this setting.

F

F

4.

Rotate the engine speed control dial to either increase or

N

decrease travel speed.

R

R

Disengaging Cruise Control

1.

Disengage the cruise control by pressing the brake pedal

or by shifting the travel direction control lever into

FG002660

"NEUTRAL".

Figure 44

Operation

OP000529

3-22

OPERATING INSTRUCTIONS

Engine Speed Control

Engine speed can be manually adjusted using the engine speed

control dial. Increase engine speed by rotating the control knob

clockwise. Decrease engine speed by rotating the control knob

counterclockwise.

IMPORTANT

The engine speed control system has been set at the

HAOA690L

factory and should not require adjustment as part of routine

Figure 45

maintenance.

In the event that the automatic speed control system fails, the

e-EPOS controls automatically defaults and reduces engine

speed. Manual control of engine speed can be done by using

either the manual engine speed control dial, which will allow the

operator to set and hold a specific engine speed, or the

Accelerator Pedal for variable engine speed.

NOTE: If the automatic speed control system has failed, the

e-EPOS controls automatically defaults and the

machine will not function at full rated capacity.

IMPORTANT

If the engine rpm is being manually adjusted, the equipment

will not function in its optimum capacity. Please contact a

DOOSAN distributor or service center for repairs.

A

O

W

I

B

FG002663

Figure 46

Engine speed can be controlled by either the manual accelerator

pedal or the manual speed control dial.

With the travel/work mode selector switch in the "TRAVEL

MODE" position, all hydraulic controls are locked out. Full

Operation

OP000529

3-23

engine speed range control is available through either the

accelerator pedal or the manual engine speed control dial (A -

B, Figure 46).

With the travel/work mode selector switch in the "WORK MODE"

position, all hydraulic components are activated.

Steering Wheel

The steering wheel allows the precise steering of the excavator.

FG002661

Figure 47

Accelerator Pedal

The accelerator pedal controls the engine speed for traveling in

the excavator.

The accelerator pedal functions in two ways. If the manual

engine speed control dial is at the lowest setting, the accelerator

pedal controls both engine speed and a hydraulic proportioning

valve that controls the actual travel speed. If the manual engine

speed control dial has been set to a higher rpm, the accelerator

pedal functions only as a hydraulic proportioning valve control,

enabling control of only travel speed and not engine rpm.

FG002656

Figure 48

Brake Pedal

1

The brake pedal operates the brake system. When the pedal(1,

Figure 49) is pressed to its maximum position, it will lock into

2

position. To release the brake pedal from the locked position,

press down on the release pedal(2, Figure 49).

FG002662

Figure 49

Operation

OP000529

3-24

Mode Selection

More efficient work can be done by choosing a proper power

and work mode combination, suitable to type of work and

conditions. Use the mode selection according to following guide.

Power Mode

2

1.

When the starter switch is turned "ON" the power mode is

automatically defaulted to the standard setting.

2.

Select a proper power mode using button (1, Figure 50)

1

before starting work.

1

2

3.

When the power mode button (1, Figure 50) is pressed, a

signal sounds, changing the power mode to either "ON" or

"OFF". When the power mode is turned "ON", the LED

indicator (2, Figure 50) turns "ON".

5

6

FG000114

Deactivate the power mode by pressing it a second time.

Figure 50

When the power mode is turned "OFF", the LED indicator

(2, Figure 50) turns "OFF" and the power mode returns to

the standard mode.

Mode

Selection Point

• General work.

STANDARD MODE

• Normal speed travel.

• Minimize fuel consumption.

• Required to perform heavy work in a short period of time.

POWER MODE

• Fast speed loading.

• Fast speed travel.

Work Mode

1.

When the starter switch is turned "ON" the work mode is

automatically defaulted to the digging mode.

2.

Select the work mode using button (3, Figure 51) before

starting work.

1

2

4

3.

When the work mode button (3, Figure 51) is pressed, a

signal sounds, changing the work mode to either "Digging

Mode" or "Trenching Mode". When the trenching mode is

3

selected, the LED indicator

(4, Figure

51) turns "ON".

5

6

When the digging mode is selected, the LED indicator (4,

FG000115

Figure 51) turns "OFF".

Figure 51

4.

When the trenching mode is selected, the control valve is

set to optimum condition for trenching work.

Mode

Selection Point

Feature of Control

• General excavation.

General standard.

• Loading dump trucks.

DIGGING MODE

• Lifting and transport of heavy objects.

• Breaker.

Operation

OP000529

3-25

Mode

Selection Point

Feature of Control

• Trenching.

TRENCHING

The swing is faster and stronger

• Excavating of side wall.

MODE

than boom or arm.

• Required to constant swinging.

Auto Idle Mode

6

1.

The system will automatically reduce engine speed to idle

speed approximately four seconds after all of the control

levers are in the neutral position. When a pilot function is

activated, engine speed is automatically returned to the

5

1

2

preselected range.

2.

When the starter switch is turned "ON", the work mode is

automatically defaulted to "AUTO IDLE".

3.

When the LED indicator (6, Figure 52) is turned "ON", the

5

6

auto idle function is activated. Deactivate the auto idle

FG000116

function by again pressing the auto idle selector button (5,

Figure 52

Figure 52). At this time the LED indicator will be turned

"OFF".

WARNING!

Turn "OFF' auto idle function when performing work in

close operating area, i.e., work in a narrow area and

loading / unloading on or off a trailer.

Boost Mode

I

1.

Power boost switch is used to gain maximum digging

O

force.

2.

The power boost is activated while the lower button is

being pressed on top of the right-hand work lever

(joystick). The breaker / boost / shear selector switch must

be in the "O" (BOOST) position.

NOTE: The power boost mode does not affect forward

and reverse travel.

Do not use this switch for more than ten

seconds.

FG000117

Figure 53 RIGHT-HAND WORK LEVER

(JOYSTICK)

Operation

OP000529

3-26

Work Levers (Joysticks) (ISO Style)

WARNING!

Check surrounding area before swinging. When operating a

lever while in auto idle, do it carefully, because the engine

speed will increase rapidly

NOTE: When starting work, move joysticks slowly and check

movement of swing and front attachment and dozer

(outrigger).

This equipment is manufactured using the lever configuration

described in ISO standards. Do not change valving, hoses, etc.,

that would change this standard. The boom, arm and bucket

movements, and swing direction of work levers (joysticks) are as

follows:

1

5

Left-hand Work Lever (Joystick) (Figure 54 and Figure 56)

3

4

7

8

1.

Arm dump

2

6

2.

Arm crowd

9

3.

Left swing

4.

Right swing

10

NOTE: The swing brake is spring applied and hydraulically

released. It is always engaged when the work lever

(joystick) is in "NEUTRAL" or the engine is shut

FG002664

down.

Figure 54

NOTE: The following is not a mechanical malfunction but a

proper phenomenon of the excavator. When

operating the arm, it may stop momentarily. When

the arm is operated, the weight of the arm may cause

it to move faster than the amount of oil being

supplied. In some cases while swinging or moving,

the relief valves may make some noise. This is

normal and does not affect the performance of the

equipment.

Right-hand Work Lever (Joystick) (Figure 54 and Figure 56)

FG002669

Figure 55

5.

Boom down

6.

Boom up

7.

Bucket crowd

8.

Bucket dump

NOTE: Even after stopping the engine, the front can be

lowered to the ground by operating joystick. Set

safety lever on "UNLOCK" position and turn starter

switch "ON".

Operation

OP000529

3-27

Dozer Blade and Outrigger Control Lever (Figure 54 and

Figure 56)

9.

Blade/Outrigger down

10. Blade/Outrigger up

The dozer blade control lever is on the left control stand. To

lower blade, push lever forward; to raise blade, pull lever

backwards.

Whenever dozer blade is being used to level ground, make sure

to set travel speed control to "LOW SPEED" Attempting to use

dozer blade in "HIGH SPEED" will cause damage to drive

system.

6

4

3

2

5

7

10

1

9

8

FG006563

Figure 56

Reference

Reference

Description

Description

Number

Number

1

Arm Dump

6

Boom Up

2

Arm Crowd

7

Bucket Crowd

3

Left Swing

8

Bucket Dump

4

Right Swing

9

Blade/Outrigger Down

5

Boom Down

10

Blade/Outrigger Up

Operation

OP000529

3-28

Independent Outriggers (Option)

If the machine is equipped with the optional independent

outriggers.

Independent outriggers are operated with dozer control lever

and select switches.

Select the outriggers with one or more of the switches, and then,

push the lever forward to lower the outriggers, pull the lever

11

backwards to raise the outriggers.

11. Outrigger down

2

FG006195

12. Outrigger up

Figure 57

Chassis attachment

select switches

FG006204

Figure 58

Two-Piece Boom (Option)

13

13. Upper Boom Up

14. Upper Boom Down

14

FG006564

Figure 59

13

FG006209

Figure 60

Operation

OP000529

3-29

OPERATING PRECAUTIONS

WARNING!

Do not rest your feet on the travel pedals during normal

machine operation. Unexpected machine travel may occur

in this situation.

1.

Before starting work, investigate terrain and soil condition.

Level ground and drain area if necessary.

2.

Install window guards when working where there is a

possibility of falling rocks or other objects.

FG006565

Figure 61

3.

Check strength of supported structures in advance before

working on them. If insufficient, reinforce it. If any doubt

exists about structural strength, refuse to operate unit.

4.

It is possible that the boom, arm or bucket may come into

contact with the upper or lower structure of the machine

(Especially tires). There are digging conditions which could

allow this to happen.

FG006566

Figure 62

5.

Never allow any person (material) etc. come within realm

of equipment work range. Always mind surroundings when

working and particularly take heed when in narrow place

so that rear part would not be hit when turning.

FG006567

Figure 63

Operation

OP000529

3-30

6.

Do not continually "bottom out" the hydraulic cylinders.

Machine damage may occur if the cylinders are fully

extended or retracted, example: arm cylinder fully retracted

and the bucket cylinder is extended to rotate the bucket

into the ground.

FG006568

Figure 64

7.

Do not use machine travel or swing when the bucket is in

the ground to provide additional breakout force. See Figure

65.

FG006569

Figure 65

8.

Do not use machine weight to provide additional breakout

force. See Figure 66.

9.

When working on soft or muddy ground, make sure that

the machine is not sinking.

FG006570

Figure 66

10. When working close to the excavated edge, make sure

that the ground the machine is sitting on is solid.

FG006571

Figure 67

Operation

OP000529

3-31

11. Do not excavate underneath the machine. See Figure 68.

FG006572

Figure 68

12. Make sure that there is adequate clearance from overhead

electrical supply lines. See Figure 69.

FG006573

Figure 69

13. If the excavation is in an underground location or in a

building, make sure that there is adequate overhead

clearance and that there is adequate ventilation. See

Figure 70.

FG006574

Figure 70

14. Do not use the bucket as a hammer or ramming device.

This is dangerous and causes damage to the front

attachment. See Figure 71.

FG006575

Figure 71

Operation

OP000529

3-32

15. Do not dig with the excavator tires raised. This can result in

structural and mechanical failures.

16. Do not operate travel lever quickly when traveling in high

range.

•

Avoid sudden starts.

•

When traveling in one direction come to a complete

stop before reversing directions. Do not rock

excavator back and forth with levers.

•

Avoid sudden stops. Return levers to neutral by

FG006576

hand. Do not let them snap back to neutral on their

Figure 72

own.

17. If the optional long fronts or attachments or heavy duty

front end attachments are used, the machine balance will

be altered. Follow these additional operating precautions.

WARNING!

Do not travel downhill with the front end attachments

raised.

Do not travel across slopes; travel straight up or down

slope.

Use extreme caution when swinging the upper frame

when positioned on a slope.

Allow extra swing stopping room. The additional

momentum generated by the longer or heavier front

end equipment will increase the amount of time

needed to stop the swing motion.

Make sure that all optional equipment has been

authorized and installed properly.

18. Do not move dirt or objects by swinging the excavator into

them. This can result in structural and mechanical failures.

DANGER!

When lifting the lower structure, place the round

90 ~ 110

bottom of the bucket on the ground and place the arm

and boom so that the angle between them are 90° ~

110°.

FG006577

Figure 73

Operation

OP000529

3-33

Working in Water

IMPORTANT

When working in water, do not exceed a slope of more than

15°. If the slope is over 15°, the rear part of the upper

structure will be immersed in water, resulting in radiator fan

damage.

FG006578

Figure 74

1.

When working in water, do not operate in water over center

of axle (1, Figure 75).

If swing bearing gets wet, immediately grease it until all old

grease is purged from bearing.

If water gets into swing gear housing, drain water

immediately by removing lower inspection cover. Apply

new grease.

After working in water, purge old grease on bucket pins.

1

2.

It is possible to work and travel in shallow water if the

FG006579

ground is stable. If the terrain is rough or if the water is

Figure 75

flowing heavy it is unsafe to operate the equipment.

3.

When working in wet soil, the equipment can sink into the

soft ground. Select solid ground to secure the equipment

before starting work.

Operation

OP000529

3-34

PARKING EXCAVATOR

WARNING!

Park excavator on firm, level ground. Avoid parking on

slopes. If excavator must be parked on a slope, block

wheels (1) using the supplied wheel chocks (See “Wheel

Chocks” on page 2-76.) and place bucket teeth in ground.

1

(Figure 76)

FG006580

Figure 76

1.

Park excavator on firm, level ground. Lower bucket to

ground as shown in Figure 77.

FG006581

Figure 77

2.

Set engine speed control dial on "LOW IDLE".

HAOB290L

Figure 78

3.

If you touch the operation lever unintentionally, it may

create a serious accident. Before leaving operator's seat,

set safety lever on "LOCK" position and raise left stand.

FG006173

Figure 79

Operation

OP000529

3-35

TOWING PROCEDURE

WARNING!

Make sure that the towing vehicle can handle the weight of

the unit being towed and that it has adequate braking

capacity.

Never use a damaged wire rope or chain. They could brake

and cause a serious accident.

Always wear gloves when handling a chain or wire rope.

When towing excavator use a wire rope or chain capable of

handling the load.

IMPORTANT

Parking brake automatically operates in case when engine

is stop so that you shall release the parking brake into

manual mode when towing equipment.

1.

Fix equipment by wheel chock so that equipment would not

move.

2.

Release the parking brake into manual mode.

3.

Mount wire rope at equipment.

4.

Remove chock and tow equipment

5.

Operate the parking brake again in manual mode after

finishing towing.

CAUTION!

When towing equipment, towing speed shall be less than 10

km/h and movement distance shall be less than 5 km. Use

trailer in equipment transference if moving over

5 km

needs.

Operation

OP000529

3-36

How to release the parking brake (manual mode)

1.

Set chock under tire so that vehicle would not move.

2.

Grease at grease nipple (A) of transmission at rear side of

facilities by means of grease gun. Whence grease amount

A

shall be about 30 cc.

3.

If grease leaks through relief valve (B), the parking brake

B

release has been finished.

FG003001

CAUTION!

Figure 80

Don't operate accelerator pedal when parking brake has

been released manually.

How to let the parking brake operable again by dismissal of

release condition (manual mode)

1.

Open the bleeder

(C) of transmission and make the

equipment start.

C

2.

Set engine at low speed racing, change gear from neutral

to stage ฌ , and wait until grease leaks. Whence wait time

is about 1 min.

3.

Completely exhaust grease from transmission by gear

change between ซ ˩ ฌ by some 5 ~ 10 reciprocations.

FG003002

4.

Lock bleeder (C).

Figure 81

CAUTION!

Take heed

: grease will spout when initially opening

bleeder.

Operation

OP000529

3-37

3.

Do not use the breaker as a hammer. (Figure 82.)

Do not drop breaker from extreme heights.

The breaker is relatively heavy and drops fast. Do not drop

breaker from extreme heights or damage to upper

structure may result

FG006582

Figure 82

4.

Do not operate the breaker with the boom or arm cylinders

fully extended (bottomed out). (Figure 83.)

Leave over 100 mm (4 in) of clearance between rod end of

cylinder and cylinder head. This will help prevent damage

to cylinders during breaker operation.

FG006583

Figure 83

5.

Do not use the breaker if the hydraulic hoses vibrate

excessively.

(Figure 84.) Check the breaker's hydraulic

accumulator for damage and repair as required. If

excavator is operated under this condition, structural and

hydraulic components can become damaged.

FG006584

Figure 84

6.

Do not allow the breaker body to go into water if not

equipped for underwater operation. The breaker seal can

be damaged and allow rust, foreign material or water to

enter the hydraulic system and cause damage. Only insert

the breaker tool into water. (Figure 85.)

FG006214

Figure 85

Operation

OP000529

3-39

7.

Do not do any lifting or towing with a breaker. (Figure 86.)

FG006585

Figure 86

8.

Operate the breaker only to the front and rear of the

excavator. Do not use the breaker to either side of the

excavator. Do not swing the breaker from side to side

when operating it. (Figure 87.)

WARNING!

Operating a breaker with the upper body turned 90° to the

chassis frame can result in tipping over the machine or

reduction in service life.

HGB3033L

Figure 87

9.

Do not curl the breaker tool tip into the arm or boom when

traveling or parking the excavator. (Figure 88.)

FG006588

Figure 88

Operation

OP000529

3-40

To activate breaker

I

1.

Set breaker selector switch to "II" (BREAKER) position.

O

2.

Press lower button on top of right-hand work lever

(joystick) to activate hydraulic breaker.

3.

Release lower button on top of right-hand work lever

(joystick) to deactivate hydraulic breaker.

FG000117

Figure 89 RIGHT-HAND WORK LEVER

(JOYSTICK)

Relief Valve Adjustment

1.

Cap pipe on arm end, using a cap capable of handling

350.0 kg/cm²

(5,000 psi) under the condition of

disconnecting hose to hydraulic breaker.

2.

Adjust pump pressure using activating the breaker, and

watching the pressure displayed on the instrument panel.

Press the display selector button to show digital pressure

reading. (A separate pressure gauge is not required.)

3.

Adjust the relief valve pressure by turning the adjustment

FG007285

screw of breaker relief valve. The relief valve is installed on

Figure 90

the left side of the upper structure behind the boom. (Do

not use the overload relief valve on the lower part of control

valve for the breaker relief valve.)

WARNING!

If the relief valve pressure is adjusted while the

hydraulic breaker is connected, there is possibility

that a high-pressure spike or setting could break a

hose or pipe. Personal injury or death could result

from a hydraulic hose or pipe failure.

Operation

OP000529

3-41

Hydraulic Oil and Filter Service Intervals

When using a hydraulic breaker, the viscosity breakdown and

contamination of hydraulic oil is faster because the work

condition is more severe than during normal digging work. To

prevent the hydraulic components

(especially pump) from

having a shortened life cycle, replace the hydraulic oil and main

hydraulic oil return filter using the following schedule.

Attachment

Operation Rate

Hydraulic Oil

Filter

250 Hours (First Replacement)

Bucket Work

100%

2,000 Hours

1,000 Hours (After First Replacement)

Hydraulic Breaker

100%

500 Hours

100 Hours

Work

These service intervals only apply, when a genuine DOOSAN oil and filter are used. If any other

brands are used, the guaranteed changed interval should be reduced in half.

100

105

116

551

106

144

614

80

FILTER

692

112

171

(First Replacement)

119

214

782

60

128

275

893

HYDRAULIC OIL

137

335

1028

40

FILTER

156

412

(After First Replacement)

1196

175

500

1400

20

206

635

1658

0

500

1000

1500

2000

MACHINE OPERATING HOURS

FG000767

Figure 91

NOTE: The replacement intervals of hydraulic oil and filter

depend upon the amount of time the hydraulic

breaker is being used. These intervals should be

followed as opposed to regularly scheduled

maintenance.

Operation

OP000529

3-42

ADJUSTING THE PUMP FLOW

NOTE: For further information, see

“Flow Control” on

page 2-49.

1.

On the instrument panel, press the flow control button

, the flow control screen (Figure 92) will be displayed.

2.

Use "UP" (

) or "DOWN" (

) buttons to adjust flow rate.

3.

Press "SELECT" (

) button, to return to normal display

screen and save the flow rate setting.

02/05 [MO] 11:30

FLOW CONTROL

E

F

C

H

H

: APPLY

ESC: CANCEL

E/G SPEED 1700 RPM

<Normal Display>

<Flow Control Display>

FG001090

Figure 92

Flow Control Step

Pump Flow Setting (l/min)

1

38

2

61

3

80

4

91

5

101

6

133

7

142

8

149

9

165

10

168

Operation

OP000529

3-43

Shear Pedal Valve (Optional)

Activating Shear with Pedal Valve

1

1.

Select shear with the selector switch of the right panel.

2.

Two-way operation is possible by pressing the pedal back

2

and forth between positions (1 and 2, Figure 93). When the

pedal is in its center

(at rest) position the valve is in

"NEUTRAL" and hydraulic oil flow is stopped.

3.

Before operating the attachment, be sure to check the

function controlled by the direction of the pedal movement.

FG003010

Activating Breaker with Pedal Valve

Figure 93

1.

Select breaker with the selector switch of the right panel.

2.

Pressing end (1, Figure 93) is used to activate the breaker.

Locking the Pedal

When shear or breaker is not needed, the pedal can be locked

by using the prop rod (3) locking device.

Locking is completed when the top end of the prop (3) is

positioned into pedal hole.

3

FG003011

Figure 94

A. Location for "UNLOCKING".

B, Location for "LOCKING".

A

WARNING!

When operating breaker or shear when using button

B

on a joystick, and it is not to be controlled by the

pedal, be sure to keep the stopper in the "LOCK"

position in order for the pedal not to be activated.

FG003012

Figure 95

Operation

OP000529

3-44

Rotating Pedal Valve (Optional)

1

Attachment Rotating by Using the Pedal Valve

2

1.

Pressing end (1, Figure 96) is used to turn front attachment

(LH line high pressure).

2.

Pressing end (2, Figure 96) is used to turn front attachment

(RH line high pressure).

NOTE: Before activating the pedal, be sure to check

the function of the attachment.

FG003010

Figure 96

Locking the Pedal

When rotating is not needed, the pedal can be locked by using

the prop rod (3) locking device.

Locking is completed when the top end of the prop (3) is

positioned into pedal hole.

3

FG003011

Figure 97

A. Location for "UNLOCKING".

B, Location for "LOCKING".

A

B

FG003012

Figure 98

Attachment Rotation Using the Left-hand Work Lever

(Joystick)

For a machine equipped with an attachment that rotates,

rotation is activated while one of the control buttons is being

pressed on top of the left-hand work lever (joystick).

There are three buttons on top of the left-hand work lever. The

left and right ones are for controlling rotation.

NOTE:The middle button is for the horn.

Left button is for counterclockwise rotation, and the right one is

FG006176

for clockwise rotation.

Figure 99 LEFT-HAND WORK LEVER

(JOYSTICK)

Operation

OP000529

3-45

OPERATING TECHNIQUES

Lifting

IMPORTANT

There may be local or government regulations, about the

use of excavators for the lifting of heavy loads. Always

contact your local and government agencies in regards to

these regulations.

To prevent injury, do not exceed the rated load capacity of the

machine. If the machine is not on level ground, load capacities

will vary.

Short slings will prevent excessive load swing.

Use the lifting eye on the bucket that is provided to lift objects.

Always try to maintain the lifting eye (Figure 100) straight below

the center line of the arm and bucket pin. In this manner the

weight of the load is being primarily held only by the pin, and not

by the bucket cylinder, link, and link pins.

When a lifting eye is used, the sling/lifting device must be

fastened to the eye in a manner that will not allow it to come

loose.

The most stable position is over the corner of the machine.

For best stability, carry a load as close to the ground and

machine as possible.

HAAD3830

Figure 100

Lift capacity decreases as the distance from the machine swing

center line is increased.

Lifting Unknown Weight

When loads are not accurately known are to be lifted, the person

responsible for the job shall ascertain that the weight of the load

FRONT LIFT

does not exceed the machine LOAD RATING CHART at the

ZONE

radius at which it is to be lifted.

It is recommended that you feel your way into any lift as a

SIDE LIFT

precaution against tip-over. One method is to position the boom

ZONE

at 90° over the side of the machine. Slowly lift the load until it

SIDE LIFT

ZONE

clears the ground. A lift over the side is the most unstable, and

as the load is swung into the front zone of the excavator it will

become more stable. DO NOT INCREASE SWING RADIUS

AFTER THE LOAD IS LIFTED.

REAR LIFT

ZONE

FG006217

Figure 101

Operation

OP000529

3-46

OP000530

4Inspection, Maintenance

and Adjustment

PREVENTIVE MAINTENANCE

Routine maintenance and inspections are required to keep your

machine in the correct operating condition. The following pages

list the inspection intervals, the system or component checks,

and location references.

NOTE: The following pages list the service checks and their

required intervals. The service cycles may need to be

shortened depending on the working conditions.

Extremely hot or dusty conditions will require more

frequent service. Operational hours are determined

by the amount of time accumulated on the engine

hour meter on the control console in the cabin.

HAOA601L

Figure 1

NOTE: Besides the normal hour meter, the multifunction

gauge can be used to keep track of the hours on

CHECK

individual filters. See “Filter / Oil Info” on page 2-44.

02/05 [MO] 11:30

E

F

C

H

C

H

E/G SPEED

1700

RPM

POWER

1

2

AUTO

3

4

ESC

5

6

7

8

FG000037

Figure 2

Inspection, Maintenance and Adjustment

OP000530

4-1

Product Identification Number (P. I. N.)

Location

A P.I.N. number, is stamped on the upper frame, under the

boom foot

(Figure

3). It is also stamped on the product

identification plate (Figure 4) on the front side of the battery

frame on the outside.

NOTE: Please make note of these numbers and their

locations. These will be required whenever warranty

or service work is requested. Keep this number on

FG006590

file, incase the machine is stolen.

Figure 3

7-11, Hwasu-dong, Dong-gu,

Incheon, Korea

K1011647A

FG006329

Figure 4

Component Serial Numbers

There are many serial numbers on each traceable components

of the machine. For example, the engine serial number is

stamped on the top of the engine block, above the starter.

Additional engine information is described on a label (Figure 5)

on the rocker cover.

Please make note of these numbers and their locations. These

will be required whenever warranty service work is requested.

FG006402

Figure 5

Inspection, Maintenance and Adjustment

OP000530

4-2

PRELIMINARY WORK MACHINE

SETUP FOR MAINTENANCE

When performing maintenance specified in this manual, always

park the excavator as follows.

NOTE: Certain types of maintenance may require the

machine to be positioned differently. Always return

machine to this position.

1.

Park on firm, level ground.

2.

Lower bucket to ground.

FG006589

Figure 6

3.

Set safety lever on "LOCK" position and raise stand.

Unlock

Lock

FG006403

Figure 7

4.

Allow engine to run at low idle for a minimum of five

minutes to allow engine to cool. If this is not done, heat

surge may occur.

HAOB290L

Figure 8

Inspection, Maintenance and Adjustment

OP000530

4-4

5.

Shut down engine by turning key to "O" (OFF) position.

Remove key from starter switch.

O

I

WARNING!

If engine must be run while performing maintenance,

use extreme care. Always have one person in the

cabin at all times. Never leave the cabin with the

engine running.

FG000175

Figure 9

6.

Before starting maintenance work, hang up a tag, "Do Not

Touch When Performing Inspection or Maintenance" on

cabin door or work lever.

FG006591

Figure 10

Inspection, Maintenance and Adjustment

OP000530

4-5

TABLE OF RECOMMENDED

LUBRICANTS

NOTE: Refer to the Maintenance Intervals Table for

application points.

Ambient Temperature

Kind of

-22

-4

14

32

50

68

86

104

122

Reservoir

Fluid

°F

-30

-20

-10

0

10

20

30

40

50 °C

SAE 10W-30

Engine Oil

**

* SAE 10W-40

Pan

Engine Oil

SAE 15W-40

SAE 90 and API GL5

Swing Drive

Gear Oil

* SAE 80W-90 and API GL5

Case

SAE 140 and API GL5

ISO VG 32

***

Hydraulic Oil

Hydraulic

* ISO VG 46

Tank

Oil

ISO VG 68

* ASTM D975 No. 2

Fuel Tank

Diesel Fuel

ASTM D975 No. 1

Grease

Grease

* Multipurpose Lithium Grease NLGI No. 2

Fitting

Cooling

Add Antifreeze

Coolant

System

* (50% antifreeze - 50% distilled water)

Inspection, Maintenance and Adjustment

OP000530

4-6

Ambient Temperature

Kind of

Reservoir

-22

-4

14

32

50

68

86

104

122 °F

Fluid

-30

-20

-10

0

10

20

30

40

50 °C

SAE 10W-30

Multi-

Transmission

SAE 10W-40

purpose Oil

SAE 15W-40 ****

SAE 90

Axle Hub &

Gear Oil

SAE 80W-90 ****

Differential

SAE 140

Installed at factory.

**

Engine oil must meet ACEA-E5 or API-CI-4.

*** Hydraulic oil change interval is 2,000 hours, only when DOOSAN Genuine Oil is used. If other brands of oil

is used, guaranteed change interval is 1,000 hours.

**** Approved for the powershift transmission is oils according to the ZF list of lubricants TE-ML 07 and oils

according to the ZF list of lubricants TE-ML 05 are permitted for axles.

API: American Petroleum Institute.

ACEA: Association des Constructeurs Europens d’Automobiles.

ASTM: American Society of Testing and Material.

ISO: International Standardization Organization.

NLGI: National Lubricating Grease Institute.

SAE: Society of Automotive Engineers.

IMPORTANT

Do not mix oils from different manufacturers. DOOSAN

does not endorse specific brands but does suggest that

owners select quality oils whose suppliers provide

assurance that required standards will always be met or

exceeded.

Fluctuating daily or weekly extremes of temperature, or

operation in subzero freezing weather may make it

impractical to use straight weight lubricants. Use good

judgement in selecting lubricant types that are appropriate

for climate conditions.

Inspection, Maintenance and Adjustment

OP000530

4-7

FLUID CAPACITIES

Component

Capacity

25 liters

Oil Pan with Filter

(6.6 U.S. gal.)

Engine

24 liters

Cooling System

(6.3 U.S. gal.)

310 liters

Fuel Tank

(81.9 U.S. gal.)

116 liters

Tank Level

(30.6 U.S. gal.)

Hydraulic Oil

205 liters

System

(54.2 U.S. gal.)

2.5 liters

Transmission

(0.66 U.S. gal.)

3.8 liters

Swing Device

(1 U.S. gal.)

10.5 liters

Front Differential

(2.8 U.S. gal.)

2 x 2.5 liters

Front Hub Reduction Gear

(2 x 0.66 U.S. gal.)

Axle

14 liters

Rear Differential

(3.7 U.S. gal.)

2 x 2.5 liters

Rear Hub Reduction Gear

(2 x 0.66 U.S. gal.)

LUBRICATION AND SERVICE

CHART

Lubrication and service chart is on the inside of battery box

cover. The symbols shown here are used in the lubrication and

service chart on the next page.

Symbol

Description

Symbol

Description

Lubrication

Coolant

Gear Oil (Swing Device, Travel Device)

Air Cleaner Element

Engine Oil

Fuel Filter

Engine Oil Filter

Air Conditioner Filter

Hydraulic Oil

Drain Water

Hydraulic Oil Return Filter

Gear Oil (Axle)

Inspection, Maintenance and Adjustment

OP000530

4-8

Description of Lubrication and Service Chart

11

20

18

19

6

4

5

12, 17

21

8

7

13

26

9

2

14

2

15

1

16

25

22

10h

50h

250h

500h

1000h

2000h

23

24

10

27

3

22, 23

FG008698

Figure 11

Inspection, Maintenance and Adjustment

OP000530

4-9

SERVICE

DX210W

No.

Items to Check

Service

Qty.

Service Interval

10

50

250

500

1000

2000

1

Front Joint Pin (1)

Grease

6

F100

W10

2

Front Joint Pin (2)

Grease

11

F100

W10

3

Swing Bearing

Grease

3

Swing Gear and

4

Grease

1

Pinion

Swing Reduction

5

Grease

1

Device

Swing Reduction

Gear Oil

6

3.8 L

V

F

Device

(80W90)

Front Axle

7

Grease

4

W10

Knuckle

Engine Oil

8

Engine Oil

25 L

V

F

(RUBIA 7400)

9

Hydraulic Oil

Hydraulic Oil

205 L

V

10

Fuel Tank

Diesel

310 L

V

Coolant

11

Radiator

24 L

V

PG

(Antifreeze)

12

Fuel Prefilter

Cartridge

1

V

Hydraulic Oil

13

Element

1

F

Return Filter

14

Pilot Filter

Element

1

F

Hydraulic Oil

15

Strainer

1

C

Suction Strainer

16

Engine Oil Filter

Cartridge

1

17

Fuel Filter

Cartridge

1

F

Air Cleaner

Element

1

C

(Outer)

18

Air Cleaner

Element

1

(Inner)

Air Conditioner

Element

1

C

Filter (Outer)

19

Air Conditioner

Element

1

C

Filter (Inner)

20

Brake Filter

Element

1

F

V: Maintenance and Refill.

C: Cleaning.

F: First Time Exchange Only.

F100: Every 10 Hours For First 100 Hours.

W10: Every 10 Hours If Operating In Water.

PG: Propylene Glycol - Extended Life Antifreeze (Drain and replace using this interval.) See “Engine Cooling

System” on page 4-79, for further explanation.

: Replacement On Every Interval.

NOTE: For additional service items see list of “Maintenance Intervals” on page 4-12.

Inspection, Maintenance and Adjustment

OP000530

4-10

SERVICE DATA

DX210W

No.

Items to Check

Service

Qty.

Service Interval

10

50

250

500

1000

2000

21

Front Axle Pin

Grease

2

W10

Gear Oil

Axle Case (Front)

10.5 L

F

(80w90)

22

Gear Oil

Axle Case (Rear)

14 L

F

(80w90)

Hub Reduction

Gear Oil

2 x 2.5 L

F

Gear Case

(80w90)

23

Hub Reduction

Gear Oil

2 x 2.5 L

F

Gear Case

(80w90)

Engine Oil

24

Transmission

2.5 L

F

(15w40)

25

Dozer Blade Pin

Grease

12

F100

W10

Outrigger Frame

26

Grease

10

F100

W10

Pin

27

Drive Shaft

Grease

8

V: Maintenance and Refill.

C: Cleaning.

F: First Time Exchange Only.

F100: Every 10 Hours For First 100 Hours.

W10: Every 10 Hours If Operating In Water.

: Replacement On Every Interval.

NOTE: For additional service items see list of “Maintenance Intervals” on page

4-12.

Inspection, Maintenance and Adjustment

OP000530

4-11

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