Doosan DX190W. Operation and Maintenance Manual (2006)

10 HOUR / DAILY SERVICE

Inspect All Tires for Correct Tire Pressure

and Signs of Damage or Abnormal

Wear

Inflate tires to proper operating pressure for working

conditions. See “Tire Changing Procedure” on page 4-87.

Grease Dozer Blade Pins

Grease every 10 hours for first 100 hours and every 50

hours thereafter. (See page 4-27)

NOTE: If the unit has been running or working in water

the blade should be greased daily or every 10

hours.

Grease Outrigger Pins

Grease every 10 hours for first 100 hours and every 50

hours thereafter. (See page 4-27)

NOTE: If the unit has been running or working in water

the outrigger should be greased daily or every

10 hours.

Grease Boom, Arm and Front Attachment

Pins (for first 100 hours)

WARNING!

Do not remove the grease fitting until the pressure is

entirely bleed off by loosening grease fitting slowly to avoid

fatal wound.

FG000500

Let anybody never be in the blowing direction.

Figure 12

Be careful to any kinds of works for nipples and hydraulic

line plugs.

Grease every 10 hours for first 100 hours and every 50 or 250

hours thereafter (See page 4-25).

NOTE: If the unit has been running or working in water the

front attachment should be greased on a 10 hour /

daily basis.

Inspection, Maintenance and Adjustment

OP000530

4-15

Check Engine Oil Level

WARNING!

Allow the engine to cool before checking the oil level to

avoid burns by touching hot engine parts.

NOTE: When checking level using a dipstick always remove

and wipe it clean before making final level check.

FG006593

Shut down engine and wait for 15 minutes. This will allow

Figure 13

all oil to drain back to oil pan.

Remove dipstick (1, Figure 13) and wipe the oil off with a

clean cloth.

Insert dipstick fully in the oil gauge tube, then take it out

again.

Engine oil level must be between "HIGH" and "LOW"

marks on dipstick.

NOTE: If oil is above "HIGH" mark on dipstick, some

must be drained to return oil to proper level.

Add oil through engine oil fill cap (2, Figure 13), if the oil

level is below the "LOW" mark.

FG006334

Figure 14

Check Level of Hydraulic Oil Tank

WARNING!

The hydraulic oil will be hot after normal machine

operation. Allow the system to cool before attempting to

service any of the hydraulic components.

The hydraulic tank is pressurized. Turn the breather cap to

allow pressurized air to vent. After pressure has been

ARO1760L

released, it is safe to remove either the breather cap or Figure 15

service covers.

Inspection, Maintenance and Adjustment

OP000530

4-16

Position the machine on firm, level ground. Lower boom

and position bucket on ground as shown in Figure 16.

Set engine speed to "LOW IDLE."

FG006594

Figure 16

Set safety lever to and stand "LOCK" position.

Check level gauge by opening right access door. Oil level

must be between marks on sight gauge.

FG003366

Figure 17

If the level is below "L" mark add oil.

A. Shut down engine.

B. The hydraulic tank is pressurized. Turn the breather

cap slowly to allow the pressurized air to vent.

C. Remove upper cover hydraulic tank and add oil.

IMPORTANT

FG006595

Do not fill above "H" mark on sight gauge. Overfilling

Figure 18

can result in damage to equipment and oil leaking

from hydraulic tank due to expansion.

If oil level is above the "H" mark drain oil.

A. Shut down engine and wait for the hydraulic oil to

cool down.

B. Drain the excess oil from drain valve (Figure 19) at

the bottom of tank into a suitable container, using a

hose connected to the valve.

NOTE: Dispose of drained fluids according to local

regulations.

FG006596

Figure 19

Inspection, Maintenance and Adjustment

OP000530

4-17

Check for Leaks in Hydraulic System

Perform a daily walk-around inspection to make sure that

the hoses, piping, fittings, cylinders and hydraulic motors

are not showing any signs of leakage. If any is noted,

determine the source of the leak and repair.

Check Fuel Level

WARNING!

Use extreme safety precautions while refueling to prevent

explosions or fire.

Immediately clean up any split fuel.

At end of each work day, fill fuel tank. Add fuel through fuel

FG006597

fill tube (1, Figure 20). When working at a temperature of

Figure 20

0°C (32°F) or higher, use ASTM No. 2-D or its equivalent.

At temperatures below 0°C (32°F) use ASTM No. 1-D or its

equivalent.

Make sure that the fuel fill hose is grounded to the

excavator before fueling begins.

Check the amount of fuel in the tank by observing the fuel

tank sight gauge (2, Figure 20) and fuel gauge in monitor

panel. Fill the tank using the fill tube with the proper fuel for

the operating conditions.

NOTE: See

“Fluid Capacities” on page 4-8. for

capacity.

The excavator may be equipped with the optional battery

operated fuel fill pump. The pump assembly is located in

the battery box. Put the suction hose of the pump into the

fuel resupply tank. Turn the switch in the battery box "ON,"

and the fuel will be pumped into the excavator fuel tank.

Do not overfill the tank.

Securely tighten cap after fueling.

NOTE: If breather holes in cap are clogged, a vacuum

may form in the tank preventing proper fuel flow

to engine. Keep holes in fuel cap clean.

FG000317

Figure 21

Inspection, Maintenance and Adjustment

OP000530

4-18

Check for Leaks in Fuel System

Perform an inspection of the engine compartment to verify

that the fuel system is not leaking. If any is noted,

determine the source of the leak and repair.

Check Fuel Prefilter and Drain Water As

Required

A fuel prefilter is inside the left side access door.

Open the access door on left side of the machine.

FG006598

Figure 22

It is necessary to drain the collected water if the bowl is full

of water or sediment.

Position a small container under fuel prefilter. Drain water

or sediment by opening drain valve (2, Figure 23) on

bottom of bowl (1).

NOTE: Dispose of drained fluids according to local

regulations.

Close drain valve.

open

FG000438

Figure 23

Check Oil Level of Swing Reduction

Device

WARNING!

The gear oil is very hot after the machine has been

operating. Shut all systems down and allow them to cool.

Before fully removing any motor case inspection port plug,

etc., loosen the plug slightly to allow pressurized air to

escape.

NOTE: When checking level using a dipstick always remove

and wipe it clean before making final level check.

Inspection, Maintenance and Adjustment

OP000530

4-19

Remove dipstick (1, Figure 24) and wipe the oil from the

dipstick with a cloth.

Insert dipstick (1, Figure 24) fully into dipstick tube.

FG006599

Figure 24

When dipstick is pulled out, oil level must be between

"HIGH" and "LOW" marks on dipstick.

NOTE: If oil is above "HIGH" mark on dipstick, some

must be drained to proper level.

If the oil does not reach the "L" mark on the dipstick, add oil

through fill port (2, Figure 24).

FG000419

Figure 25

If the oil level exceeds the "H" mark on the dipstick, open

cap (3, Figure 26) of drain valve and connect hose (4) to

the valve. Drain the excessive oil into a suitable container.

NOTE: Dispose of drained fluids according to local

regulations.

FG006600

Figure 26

Inspection, Maintenance and Adjustment

OP000530

4-20

Clean Dust Net in Front of Oil Cooler and

Intercooler

IMPORTANT

If running excavator in dusty area, check dust net everyday

and clean it if dirty.

FG006625

Figure 27

WARNING!

If using compressed air or water to clean the dust net, make

sure that proper eye protection is worn.

Loosen the wing nut(s) and remove dust net.

Clean with compressed air or water.

Check Cooling System and Refill as

Required

WARNING!

Allow the engine to cool before releasing the radiator cap.

Make sure to loosen the cap slowly to release any

remaining pressure.

Radiator cleaning is performed while the engine is running.

Take extreme caution when working on or near a running

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

personnel that service work is being performed.

Do not remove the radiator cap unless it is required.

Observe the coolant level in the coolant recovery tank.

When the engine is cold, remove the radiator cap and

check the coolant level inside the radiator. Do not rely on

the level of coolant in the coolant recovery tank. Refill

radiator as required. Refer to coolant concentration table.

(See page 4-80)

Check to make sure that the coolant transfer line from the

coolant recovery tank to the radiator is free and clear of

obstructions, or not pinched.

Observe the level of coolant in the coolant recovery tank.

The normal cold engine fluid level should be between

FG006626

"FULL" and "LOW" marks on tank.

Figure 28

If the coolant is below the "LOW" mark, add coolant to this

tank.

Inspection, Maintenance and Adjustment

OP000530

4-21

Check Level of Window Washer Liquid

Open left access door and check fluid level in windshield

washer tank (Figure 29).

Open fill cap and add fluid.

NOTE: Use a washer liquid that is rated for all seasons.

This will prevent freezing during cold weather

operation.

FG003376

Figure 29

Inspect Bucket Teeth and Side Cutters for

Signs of Wear

On a daily basis, inspect the bucket teeth to make sure that

tooth wear or breakage has not developed.

Do not allow the replaceable bucket teeth to wear down to

the point that the bucket adapter is exposed. See Figure

30.

NOTE: These instructions are only for DOOSAN OEM

buckets. If you are using other manufacturers'

FG000420

buckets, refer to their specific instructions.

Figure 30 1. Point, 2. Adapter and 3. Pin

Inspect Cooling Fan Blade

WARNING!

Personal injury can result from a fan blade failure. Never

pull or pry on the fan. This can damage the fan blade(s) and

cause fan failure.

An inspection of the cooling fan is required daily. Check for

cracks, loose bolts, bent or loose blades, and for contact

Figure 31

between the blade tips and the fan shroud. Check the fan

to make sure it is securely mounted. Tighten the bolts if

necessary. Replace any fan that is damage.

Inspection, Maintenance and Adjustment

OP000530

4-22

Check Air Intake System

CAUTION!

Hot engine components can cause burns.

Avoid contact with hot engine components

Park the machine on a level surface, lower the attachment

to the ground, set safety lever and stand to "LOCK"

HAOA050L

position, and shut down engine.

Figure 32

Check the engine intake hose, and hose bands for damage

and tightness.

If damaged, wrinkled, or loose, replace or retighten or

contact your nearest DOOSAN dealer.

IMPORTANT

Severe engine damage will result from running with

unfiltered air.

Do not operate engine if any leaks or defects are found

FG006627

on air intake system.

Figure 33

Inspect Seat Belt for Proper Operation

Inspect Structure for Cracks and Faulty

Welds

During the daily walk-around inspection and when

greasing the machine, look for any visible damage to the

machine. Repair or replace any damaged parts before

operating the machine.

Check Operation of All Switches

Verify working condition of all switches before starting the

engine.

Inspection, Maintenance and Adjustment

OP000530

4-23

Check Operation of All Exterior Lights,

Horn and Control Console Indicator

and Monitor Lights

Turn engine starter switch to the "I" (ON) position and

observe all of the indicator lights.

Restore operation of any light bulbs that do not turn "ON"

at this time.

Sound the horn. Repair or replace if required.

Turn "ON" and inspect all exterior work lights. Replace any

monitors, burned out bulbs or cracked or broken housings

or lenses.

Start Engine, Check Starting Ability, and

Observe Exhaust Color at Start-up and

at Normal Operating Temperature.

Listen for Any Abnormal Sounds

Check Operation of All Controls

IMPORTANT

Cold weather operation requires that the operator fully

warm up the hydraulic oil before beginning machine

operation. Follow all warm up instructions listed in the

Operating Instruction section of this manual. Make sure to

cycle oil through all of the components, including all

cylinders, both travel motors and the swing motor. Cold

hydraulic oil in the lines and components needs to be

warmed before beginning full operation. If this is not done,

damage to the cylinders or hydraulic motors can occur.

With the engine at rated speed, operate all of the controls.

Follow cold weather hydraulic system warm-up

procedures.

Note any slow operations or unusual movements.

Determine the cause and repair the fault before operating.

Inspection, Maintenance and Adjustment

OP000530

4-24

50 HOUR / WEEKLY SERVICE

Perform All 10 Hour / Daily Service Checks

Grease Boom, Arm and Front Attachment

Pins

Grease every 10 hours for first 100 hours and every 50 hours

thereafter.

NOTE: If the unit has been running or working in water the

front attachment should be greased on a 10 hour /

daily basis.

•

Position machine as shown below and lower the front

attachment to the ground and shut down engine

•

Press the grease fitting and inject grease with the

grease gun on the marked point

•

After injection, clean off the old grease that has been

purged.

C B,E

FG006628

Figure 34

Reference

Description

Number

Arm Link Joint Pin (1 Point)

Bucket Link Joint Pin (1 Point)

Link Joint Pin (2 Points)

Bucket Cylinder Rod Pin

(1 Point)

Arm Bucket Joint Pin (1 Point)

Inspection, Maintenance and Adjustment

OP000530

4-25

A. Arm Link Joint Pin (1 Point)

B. Link Joint Pin (2 Points)

C. Arm Bucket Joint Pin (1 Point)

D. Bucket Link Joint Pin (1 Point)

FG003380

Figure 35

E. Bucket Cylinder Rod Pin (1 Point)

FG003381

Figure 36

Grease Swing Bearing

There are three grease fittings for the swing bearing. Do

not over lubricate. Purge old grease with new. Remove all

purged grease.

FG006629

Figure 37

Inspection, Maintenance and Adjustment

OP000530

4-26

Grease Dozer Blade Pin

NOTE: Grease it per 10 hours during initial period of

100 hours after buying your new vehicle, after

which period grease it per 50 hours.

NOTE: In case of performing work underwater, grease

it per 10 hours irrespective of elapsed period.

Remove chain connecting between dozer cylinder

protection cover and chassis frame out of this chassis

frame.

FG006630

Completely open the dozer cylinder protection cover.

Figure 38

Inject grease at total

10 points by 5 points per dozer

cylinder by means of using grease gun.

Neatly remove old grease that has leaked out after

greasing.

Shut dozer cylinder protection cover after finishing

greasing and then connect the chain to the chassis frame.

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

blade. When opening dozer cylinder protection cover, take

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

shock etc.

FG006631

Figure 39

Grease Outrigger Pins

Grease every 10 hours for first 100 hours and every 50 hours

thereafter.

NOTE: If the unit has been running or working in water the

outrigger should be greased on a 10 hour/daily basis.

•

Position machine as shown Figure 40 and lower the

outrigger leg to the ground and shut down engine.

•

Press the grease fitting and inject grease with the

grease gun on the marked points.

FG008154

Figure 40

•

There are a total of

8 grease points, 4 on each

cylinder of the outrigger.

•

After injection, clean off the old grease that has been

purged.

Inspection, Maintenance and Adjustment

OP000530

4-27

Grease Front Axle Pin

NOTE: If the unit has been running or working in water the

front attachment should be greased on a 10 hour /

daily basis.

Lower the front attachment to ground.

Press the grease fitting and inject grease with the grease

gun on the marked point.

After injection, clean off the old grease that has been

purged.

FG006632

Figure 41

Drain Water and Sediment from Fuel Tank

Perform this procedure before operating the machine.

Drain water and sediment from bottom of fuel tank into a

suitable container.

NOTE: Dispose of drained fluid according to local

regulations.

NOTE: Always completely fill fuel tank at end of each

workday to prevent condensation from forming

FG006633

on the inside walls of the tank.

Figure 42

Check Engine Fan Belt for Cracks, Wear

and Correct Tension (After First 50

Hours)

Inspect after first

50 hours of operation and every 150

hours thereafter. (See page 4-28)

Change Engine Oil and Filter (After First 50

Hours)

Change engine oil and filter after first 50 hours of operation

or rebuild, then every 150 thereafter. (See page 4-28)

Inspect for Any Loose or Missing Nuts and

Bolts

All nuts and bolts must be inspected after first 50 hours of

operation. There after every 250 hours.

Inspection, Maintenance and Adjustment

OP000530

4-28

250 HOUR SERVICE

Perform All 10 Hour / Daily and 50 Hour

Service Checks

Grease Arm and Front Attachment Pins

Grease every 10 hours for first 100 hours and every 250 hours

thereafter.

NOTE: If the unit has been running or working in water the

front attachment should be greased on a 10 hour /

daily basis.

•

Position machine as shown below and lower the front

attachment to the ground and shut down engine.

•

Press the grease fitting and inject grease with the

grease gun on the marked point.

•

After injection, clean off the old grease that has been

purged.

B, C, D

FG006634

Figure 43

Reference

Description

Number

Boom Cylinder Head Pin

Arm Cylinder Head Pin (1 Point)

(2 Points)

Boom, Arm Joint Pin (2 Points)

Boom Foot Pin

Arm Cylinder Rod Pin (1 Point)

(2 Points)

Bucket Cylinder Head Pin

Boom Cylinder Rod Pin

(1 Point)

(2 Points)

Inspection, Maintenance and Adjustment

OP000530

4-29

G. Bucket Cylinder Head Pin (1 Point)

FG003395

Figure 48

Check Engine Fan Belt for Cracks, Wear

10mm/10kg

FAN

and Correct Tension

COMPRESSOR

IMPORTANT

ALTERNATOR

A loose fan belt can cause engine overheating, poor

charging, and/or premature belt wear. A belt that is too tight

can cause damage to the water pump, alternator bearing or

belt.

CRANKSHAFT

FG000353

Figure 49

Inspect every 250 hours. (Inspect after first 50 hours of

operation.)

With the engine shut off, check the tension of the fan belt

by pressing downwards on the belt, midway between the

fan pulley and alternator pulley. The belt should flex

approximately 10 mm (0.4 in). See Figure 49. To adjust the

belt, loosen the alternator adjustment plate bolts, adjust the

belt tension and retighten the bolts.

Inspection, Maintenance and Adjustment

OP000530

4-31

Check Engine Fan Belt Wear

WARNING!

Keep clear of engine fan and fan drive belts when the

engine is running. Rotating fan and belt contact can cause

injury.

HAAA4030

Figure 50

WARNING!

When checking, adjusting or replacing drive belts, care

must be taken to prevent accidental cranking of the engine.

Be sure the starter switch is in the "OFF" position and the

controls are tagged.

Replace badly worn, greasy or severely cracked belts

immediately. These conditions prevent proper belt

function. Visually inspect the belt. Check the belt for

intersecting cracks. Transverse

(across the belt width)

cracks are acceptable. Longitudinal

(direction of belt

length) cracks that intersect with transverse cracks are not

acceptable. Replace the belt if it is frayed or has pieces of

material missing.

Before installing new belts, make sure all pulley grooves

are clean and not worn. Replace pulley, if damaged, or if

the grooves are worn.

All pulley support bearings, shafts, and brackets must be in

working order.

When replacing belts and pulleys, pulley alignment must

be checked with belts tensioned and brackets securely

clamped. A misalignment that can be detected by the

naked eye is detrimental to belt performance.

Do not force the belts into the pulley grooves by prying with

a screwdriver or pry bar. This will damage the belt side

cords which will cause the belts to turn and result in

complete destruction of the belts in operation.

Belts on new machines and replacement belts lose their

tension as they seat into the pulley grooves. Check the

tension of new belts at 50 hour intervals until tension is

stabilized and thereafter, every 250 hours. If the tension

falls below the required minimum, the belt slips damaging

the belts and pulley grooves.

NOTE: When operating in abrasive conditions, check

tension every 100 hours.

Inspection, Maintenance and Adjustment

OP000530

4-32

Change Breaker Filter Element (Optional)

WARNING!

The hydraulic oil will be hot after normal machine

operation. Allow the system to cool down before changing

pilot filter.

Position the machine on firm, level ground. Lover the front

FG006644

attachment to the ground and shut down engine.

Figure 51 Breaker Filter

Loosen the hydraulic oil tank breather cap to release

pressure.

Locate breaker filter assembly (Figure 51)

Position a container under the filter assembly. Remove the

drain plug and completely drain the assembly.

Using a 30 mm spanner, unscrew, unscrew filter housing

from filter bottom.

Remove O-ring from filter head.

Replace filter.

Apply a small amount of oil around the entire O-ring and

install the filter housing on the filter head.

NOTE: Tightening torque : 27 kg•m (265 N•m, 195 ft lb)

Install drain plug in bottom of filter housing.

10. After changing breaker filter, vent air from pump and check

level of hydraulic oil tank.

Change Swing Reduction Device Oil (Drain

and Refill After First 250 Hours)

NOTE: Change swing reduction device oil after 250 hours on

a new machine and every 2,000 hours thereafter.

(See page 4-53)

Replace Full Flow Hydraulic Oil Filter

(After First 250 Hours)

NOTE: Replace full flow hydraulic oil filter after 250 hours on

a new machine and every 1,000 hours thereafter.

(See page 4-56)

Change Pilot Filter (After First 250 Hours)

NOTE: Change pilot filter after 250 hours on new machine

and every 1,000 hours thereafter. (See page 4-48)

Inspection, Maintenance and Adjustment

OP000530

4-33

500 HOUR / 3 MONTH SERVICE

Perform All Daily, 50 and 250 Operating

Hour Service Checks

Grease Swing Gear and Pinion

WARNING!

Greasing swing gear and pinion must be serviced by only

one person.

Remove inspection cover and inspect the condition of the

grease. Make sure that water or other contaminants are

not noticeable.

NOTE: The upper structure must be rotated a little at a

time so that the entire face of the swing gear

can be lubricated. Use extreme caution when

performing this operation.

FG006635

Figure 52

If water or other contaminations are found, remove the

lower access cover so that the gear teeth can be

thoroughly cleaned and lubricated.

Install access covers after lubricating gear teeth.

FG003397

Figure 53

Inspection, Maintenance and Adjustment

OP000530

4-35

Change Engine Oil and Filter

NOTE: Change engine oil and filter after first 50 hours of

operation or rebuild, then every 500 thereafter.

WARNING!

DO NOT change oil on a hot engine. Allow the engine to

cool down before attempting to change the engine oil and

filter to avoid burns by touching hot engine parts.

Position a larger container under the engine. Remove cap

(1, Figure 54) and install hose (2) to drain the engine oil.

Remove hose (2) and install cap (1).

NOTE: Dispose of drained fluids according to local

regulations.

FG006636

Figure 54

Replace engine oil filter by using filter wrench. The engine

oil filter is a spin-on type. See Figure 55. Remove and

discard filter.

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

gasket. Screw filter on head until gasket contacts head,

turn filter 1/2 turn more.

FG006637

Figure 55

Refill the engine with the correct oil through the oil fill port

(Figure 56). Refer to the Lubrication Table of this manual

for the recommended oil for the operating conditions.

NOTE: See

“Fluid Capacities” on page 4-8. for

capacity.

Start engine. Run engine for five minutes at "LOW IDLE,"

and check engine oil pressure light.

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

oil level after fifteen minutes.

FG006638

Figure 56

Inspection, Maintenance and Adjustment

OP000530

4-36

Clean Air-Conditioning Outer Filter

The unit is equipped with an air filtration system which filters out

dirt and dust particles from air being circulated into operator's

cabin. This filter should be cleaned out.

NOTE: In the event that the unit is being operated in a dusty

environment, the cleaning and replacement should

be performed more frequently. If filter is damaged,

replace damaged filter with a new one.

WARNING!

All service and inspection of air-conditioning system

should be performed with the starter switch in the "O"

(OFF) position.

WARNING!

If using compressed air to clean the element, make sure

that proper eye protection is worn.

NOTE: All right and left call outs are based on the operator

being seated in the operator's seat facing the front.

Open the door in the left of the machine.

Cover

Donaldson.

FG000340

Figure 57

Open the cover by turning the knob (1, Figure 58) in the

rear of the cabin.

FG000441

Figure 58

Inspection, Maintenance and Adjustment

OP000530

4-37

Remove filter (Figure 59) and inspect for any damage.

Use compressed air to clean filter. If filter is still dirty, then

change to new one.

Reassemble in reverse order.

FG000342

Figure 59

Check and Clean Air-Conditioning Inner

Filter

WARNING!

All service and inspection of air-conditioning system

should be performed with the starter switch in the "O"

(OFF) position.

WARNING!

FG000422

If using compressed air to clean the element, make sure

Figure 60

that proper eye protection is worn.

Remove the filter by pulling out ward the knob while

pressing the upper part and lower part of the filter handle

which is inside of the left rear part of the cabin.

Use compressed air in the clean filter. If the filter is

damaged replaced by a new one.

If the filter is very dirty use a mild soap or detergent and

water to clean it.

IMPORTANT

If water was used to clean filter, be certain it is

completely dry before installing.

Inspection, Maintenance and Adjustment

OP000530

4-38

Clean Radiator, Oil Cooler, Intercooler,

Fuel Cooler and Air Conditioner

Condenser Core

WARNING!

If compressed air, steam or water hit your body directly,

there is danger of injury. Always wear protective glasses,

FG006639

mask and safety shoes during the cleaning precess. Make

Figure 61

sure that all extra personnel are clear of the work area.

Open the left door and engine cover.

Loosen the wing bolt(s) and remove dust net from in front

of oil cooler and intercooler.

Clean the outside of the radiator and oil cooler, intercooler

and fuel cooler with compressed air, steam or water. Wash

from the outside of the engine compartment inwards.

Repeat the cleaning process from the inside of the engine

compartment outwards to remove all dirt and debris.

NOTE: Clean dust net and install it after cleaning

radiator, oil cooler, intercooler and fuel cooler.

FG000768

Figure 62

Clean air conditioner condenser core with compressed air,

steam or water.

IMPORTANT

To prevent damage to the cores, apply compressed air

from an appropriated distance. Damaged core may

cause water leakage or overheating. In a dusty site,

check the core daily, irrespective of the maintenance

interval.

FG006640

Figure 63

Inspection, Maintenance and Adjustment

OP000530

4-39

Grease Drive Shaft

Front Drive Shaft Front U-joint (1 Point)

Front Drive Shaft Spline (1 Point)

FG003460

Figure 64

Front Drive Shaft Rear U-joint (1 Point)

Center Drive Shaft Front Bearing (1 Point)

FG008155

Figure 65

Center Drive Shaft Rear Bearing (1 Point)

Rear Drive Shaft Front U-joint (1 Point)

FG008156

Figure 66

Rear Drive Shaft Spline (1 Point)

Rear Drive Shaft Rear U-joint (1 Point)

FG003463

Figure 67

Inspection, Maintenance and Adjustment

OP000530

4-40

Grease Front Axle Steering Knuckle (2 X 2

points, 4 points)

FG003464

Figure 68

Clean Outer Filter of Air Cleaner

02/05 [MO] 11:30

NOTE: Clean outer filter every 500 hours / 3 months of

service.

NOTE: If air cleaner clogged warning light (Figure 69)

on instrument panel comes "ON" the air cleaner

must be serviced.

NOTE: When working in severely dusty conditions, the

service interval should be shortened.

E/G SPEED 1700 RPM

FG000264

Figure 69

WARNING!

Never clean or attempt to remove the air cleaner filter if the

engine is running.

If using compressed air to clean the filter, make sure that

proper eye protection is worn.

Locate the air cleaner assembly.

NOTE: When it reaches every 500 hours or If indicator

light

(Figure

69) on instrument panel comes

"ON" the air cleaner must be serviced.

NOTE: Replace outer filter after cleaning 5 times or

every 2,000 hours / 1 year of service.

Remove and clean rubber evacuator valve (1, Figure 70)

from bottom of air cleaner housing cover (2). Inspect seal

lips for wear or damage. Replace valve if necessary.

FG000297

NOTE: Install evacuator valve with lips parallel to the

Figure 70

cover.

Inspection, Maintenance and Adjustment

OP000530

4-41

Remove the access cover (2, Figure 71) by loosening the

latches (3).

Remove the outer filter (4, Figure 71) from the housing. Do

not remove inner filter (5).

FG003466

Figure 71

Clean the outer filter (4, Figure 71) by blowing compressed

air from the inside of the filter towards the outside. Do not

use more than 205 kPa (30 psi) air pressure.

HAOC570L

Figure 72

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 73

outer and inner filters. Do not clean inner filter.

Inspection, Maintenance and Adjustment

OP000530

4-42

Change of Fuel Prefilter

Open the left side door to access fuel prefilter.

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.

FG006640

Figure 74

Remove the bowl using supplied tool.

Remove the cartridge.

FG008157

Figure 75

Coat surface of packing (2, Figure 76) with fuel on new

cartridge (1).

Tighten the cartridge by hand until the packing comes into

contact with the surface of the filter housing head.

When it reach the surface, tighten the cartridge about 3/4

of a turn more.

Coat surface of seal (3, Figure 76) with fuel, and tighten

the bowl with tool.

FG000428

Figure 76

Inspection, Maintenance and Adjustment

OP000530

4-43

Change 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.

Open the engine cover to access fuel prefilter.

FG008158

Figure 77

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

reduce fuel system priming.

FG000478

Figure 78

Fuel System Priming

If air remains in the fuel inlet line to the engine, it may cause the

engine to run in an abnormal condition. Air may impact the

starting capability of the engine, and may also result in surging

engine speeds.

If the machine happens to have run out of fuel, or if the fuel filter

has been replaced, air may need to be bleed using the following

procedure:

Shut down engine.

FG000431

Loosen plug (1, Figure 79) on the fuel prefilter head.

Figure 79

Pump the hand operated primer pump (2, Figure 79) on the

fuel prefilter. Pump primer until fuel is present at plug hole

in fuel prefilter head.

Tighten plug (1, Figure 79) in fuel prefilter head.

Continue to pump primer pump until a strong resistance is

felt.

Start engine and look for signs of leaks.

Repeat procedure if necessary.

Inspection, Maintenance and Adjustment

OP000530

4-44

Drain and Refill Transmission Fluid

The transmission fluid should be drained and refilled after

the first 500 hours of operation and at every 2,000 hours

thereafter (See page 4-58)

Drain and Refill Hub Reduction Gear Oil

The hub reduction gear oil should be drained and refilled

after the first 500 hours of operation or rebuild, and every

2,000 hours thereafter. (See page 4-59)

Drain and Refill Front Axle Case Oil

The rear axle case oil should be drained and refilled after

the first 500 hours of operation or rebuild, and every 2,000

hours thereafter. (See page 4-58)

Drain and Refill Rear Axle Case Oil

The rear axle case oil should be drained and refilled after

the first 500 hours of operation or rebuild, and every 2,000

hours thereafter. (See page 4-59)

Inspection, Maintenance and Adjustment

OP000530

4-45

1,000 HOUR / 6 MONTH SERVICE

Perform All Daily, 50, 250 and 500

Operating Hour Service Checks

Grease Swing Reduction Device

Position the machine on firm, level ground. Lower the front

attachment to the ground and shut down engine.

Remove air vent plug (1, Figure 80) from swing reduction

device.

FG006642

Figure 80

Press grease fitting and inject grease with the grease gun

on the marked point (2, Figure 81).

Install air vent plug

(1, Figure

80) in swing reduction

device.

FG006643

Figure 81

Inspection, Maintenance and Adjustment

OP000530

4-46

Replace Hydraulic Oil Return Filter

02/05 [MO] 11:30

NOTE: Change hydraulic oil return filter after first 250 hours

of operation or rebuild, and every

1,000 hours

thereafter.

NOTE: If return filter clogged warning light (Figure 82) on

instrument panel comes "ON" the return filter must be

serviced.

E/G SPEED 1700 RPM

FG000760

Figure 82

WARNING!

The hydraulic oil will be hot after normal machine

operation. Allow the system to cool before attempting to

service any of the hydraulic components.

The hydraulic tank is pressurized. Loosen the hydraulic

breather cap slightly to allow the pressurized air to vent.

After the pressure has been released, it is safe to remove

FG006645

either the breather cap or service covers or drain water

from the tank.

Figure 83

IMPORTANT

Make sure to clean any dirt or water from the top of the

hydraulic tank, especially around the fill port and filter

ports.

Position the machine on firm, level ground. Lower the front

attachment to the ground and shut down engine.

Loosen the breather cap (1, Figure 83) slightly to release

the internal pressure.

Remove bolts

(2, Figure

83) and service cover

(3).

Remove spring (4), valve

(5) O-ring

(6), and bypass

strainer (7), and then filter (8).

Remove filter and discard.

NOTE: Used filter should always be disposed of

according to local regulations.

FG000761

Figure 84

Install new filter and a new O-ring. Install bypass strainer,

valve and spring. Install service cover plate.

Tighten the breather cap (1, Figure 83).

Run engine for ten minutes at low idle to purge air from

circuit.

Check level in hydraulic oil tank (See page 4-16). Add oil if

necessary.

Inspection, Maintenance and Adjustment

OP000530

4-47

Change Pilot Filter

02/05 [MO] 11:30

NOTE: Change pilot filter after first 250 hours of operation or

rebuild, and every 1,000 hours thereafter.

NOTE: If pilot filter clogged warning light

(Figure

85) on

instrument panel comes "ON" the pilot filter must be

serviced.

E/G SPEED 1700 RPM

FG000763

Figure 85

WARNING!

The hydraulic oil will be hot after normal machine

operation.

Allow the system to cool down before changing pilot filter.

Position the machine on firm, level ground. Lower the front

attachment to the ground and shut down engine.

FG006684

Loosen the breather cap (1, Figure 83) slightly to release

Figure 86

the internal pressure.

Locate pilot system filter assembly. See Figure 86.

Unscrew canister (5, Figure 87) and remove O-ring (3) and

filter cartridge (4).

NOTE: The canister will be filled with oil. Use caution

when removing this assembly.

Insert a new filter cartridge and O-ring. Apply a small

amount of oil around the entire O-ring and install the

canister assembly onto the filter head (1, Figure 87).

NOTE: Used filter should always be disposed of

according to local regulations.

FG000323

After changing pilot filter, vent air from pump and check

Figure 87

level of hydraulic oil tank.

Inspection, Maintenance and Adjustment

OP000530

4-48

Change Brake Filter

NOTE: Change brake filter after first 250 hours of operation

or rebuild, and every 1,000 hours thereafter.

WARNING!

The hydraulic oil will be hot after normal machine

operation.

Allow the system to cool down before changing brake filter.

Position the machine on firm, level ground. Lower the front

attachment to the ground and shut down engine.

FG006773

Loosen the breather cap (1, Figure 83) slightly to release

Figure 88

the internal pressure.

Locate brake system filter assembly. See Figure 86.

Unscrew canister (5, Figure 87) and remove O-ring (3) and

filter cartridge (4).

NOTE: The canister will be filled with oil. Use caution

when removing this assembly.

Insert a new filter cartridge and O-ring. Apply a small

amount of oil around the entire O-ring and install the

canister assembly onto the filter head (1, Figure 87).

NOTE: Used filter should always be disposed of

according to local regulations.

FG003423

After changing brake filter, vent air from the breather of the

Figure 89

front & rear axle and check level of hydraulic oil tank.

Inspection, Maintenance and Adjustment

OP000530

4-49

Change Air-Conditioning Outer Filter

The unit is equipped with an air filtration system which filters out

dirt and dust particles from air being circulated into operator's

cabin. This filter should be cleaned out.

NOTE: In the event that the unit is being operated in a dusty

environment, the cleaning and replacement should

be performed more frequently. If filter is damaged,

replace damaged filter with a new one.

WARNING!

All service and inspection of air-conditioning system

should be performed with the starter switch in the "O"

(OFF) position.

NOTE: All right and left call outs are based on the operator

being seated in the operator's seat facing the front.

Open the door in the left of the machine, then remove four

wing bolts and washers, and access cover (1, Figure 90).

Donaldson.

FG000440

Figure 90

Open the cover by unscrewing the knob (1, Figure 91) in

the rear of the cabin.

FG000441

Figure 91

Inspection, Maintenance and Adjustment

OP000530

4-50

Remove filter (Figure 92) and replace with new one.

Reassemble in reverse order.

FG000342

Figure 92

Check Air Conditioner Refrigerant

WARNING!

Mixing of tobacco smoke and freon is deadly.

Do not smoke while servicing or recharging

air-conditioning system.

Run engine at about 1,800 rpm. Operate for a minimum of

FG006774

ten minutes to stabilize the system.

Figure 93

Press the "HI" fan speed switch to set maximum air flow.

Put the temperature control switch in maximum cooling

position.

Press the "Internal Air Circulation" switch.

Compare the flow of bubbles in the sight glass of receiver

dryer with the drawings in the following table.

CAUTION!

Overfilling refrigerant may cause dangerous

high-pressure and poor cooling action; and low

refrigerant level may cause compressor damage.

Always maintain refrigerant at normal level.

Inspection, Maintenance and Adjustment

OP000530

4-51

Amount of

Appearance of the Sight Glass

Solutions

Refrigerant

Almost clear.

Normal

Any bubbles disappear.

Charge or withdraw the system with

the correct amount of HFC-134a

High

No bubbles are seen.

refrigerant.

Low

A flow of bubbles is visible.

Check and Adjust Engine **

Contact your nearest DOOSAN dealer.

Engine dealer for checking and adjusting the following items:

•

Engine Compression Pressure.

•

Injection Pressure.

•

Injection Timing.

Inspection, Maintenance and Adjustment

OP000530

4-52

2,000 HOUR / YEARLY SERVICE

Perform All Daily, 50, 250, 500 and 1,000

Hour Service Checks

Change Swing Reduction Device Oil

NOTE: Change swing reduction device oil after first 250

hours of operation or rebuild and every 2,000 hours

thereafter.

WARNING!

The gear oil is very hot after the machine has been

operating. Shut all systems down and allow them to cool.

FG006599

Figure 94

Set a container under excavator.

Remove cap (3, Figure 95) and install hose (4) to drain the

swing reduction device oil.

NOTE: Dispose of drained fluids according to local

regulations.

After draining oil, remove hose and install cap.

FG006600

Figure 95

Remove breather/fill cap (2, Figure 94) and add oil to "H"

mark on dipstick (1).

FG000419

Figure 96

Inspection, Maintenance and Adjustment

OP000530

4-53

Replace Outer and Inner Air Cleaner

Elements

WARNING!

Never clean or attempt to remove the air cleaner element if

the engine is running.

NOTE: Replace outer element after cleaning 5 times or every

FG000414

2,000 hours of service.

Figure 97

NOTE: Replace inner element whenever a new outer

element is installed.

If there is clogged filter signal on the gauge panel, use the

following procedure.

Open the access door at the left of the machine.

Remove the evacuator valve (1, Figure 98) and air cleaner

cover (2).

NOTE: Inspect evacuator valve seal lips for wear or

damage. Replace valve if necessary. Install

FG000425

evacuator valve with lips parallel to the cover.

Figure 98

Remove outer filter (4, Figure 98) from the air cleaner

housing.

Clean the air cleaner cover and the inside of the air cleaner

housing.

Remove inner filter (5, Figure 99).

Clean out inside of air cleaner housing. Do not use

compressed air to blow out housing.

Install new inner filter. Do not clean and reuse inner

element.

Install new outer filter.

Install air cleaner cover and evacuator valve.

NOTE: Make sure that all gaskets and cover are

properly installed and seated.

FG000426

Figure 99

Inspection, Maintenance and Adjustment

OP000530

4-54

Change Radiator Coolant

WARNING!

Allow the engine to cool before releasing the radiator cap.

Make sure to loosen the cap slowly to release any

remaining pressure.

Radiator cleaning is performed while the engine is running.

ARO1760L

Take extreme caution when working on or near a running

Figure 100

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

personnel that service work is being performed.

Do not remove the radiator cap unless it is required.

Observe the coolant level in the coolant recovery tank.

Slowly open the radiator cap to allow any pressure to

escape.

Place a container under the radiator and open the drain

valve (2, Figure 101).

NOTE: Dispose of drained fluids according to local

regulations.

Open heater shutoff valves (3 and 4, Figure 101) to allow

coolant to drain from heater core.

FG001407

Figure 101

Remove coolant drain plug (1, Figure 103) from engine.

Install drain plug, and close drain valve after coolant has

completely drained from system.

Fill cooling system with a flushing solution.

Run engine at low idle until the coolant temperature gauge

reaches the "BLUE ZONE." Run engine for another ten

minutes.

Allow engine to cool.

ARO1760L

Drain flushing fluid and fill system with water.

Figure 102

10.

Run engine again to allow water to completely circulate.

11.

After allowing engine to cool, drain water and fill system

with proper antifreeze mixture for ambient temperature.

Refer to coolant concentration table. See

“Antifreeze

Concentration Tables” on page 4-80.

12.

Run engine without radiator cap installed, so that all air will

be purged from system. Fill radiator to fill neck.

13.

Drain and fill radiator coolant recovery tank.

FG006775

Figure 103

Inspection, Maintenance and Adjustment

OP000530

4-55

Hydraulic Oil Exchange and Suction

Strainer Cleaning

WARNING!

The hydraulic oil will be hot after normal machine

operation. Allow the system to cool before attempting to

service any of the hydraulic components.

ARO1760L

The hydraulic tank is pressurized. Loosen the breather cap

Figure 104

to allow the pressurized air to vent. After the pressure has

been released, it is safe to remove either the fill cap or

service covers.

IMPORTANT

Make sure to clean any dirt or water from the top of the

hydraulic tank, especially around the fill port and filter

ports.

Hydraulic oil change interval is 2,000 hours, only when

DOOSAN Genuine Oil is used. If another brand of oil is

used, guaranteed change interval is 1,000 hours.

NOTE: Based on the type of excavating being completed,

the working conditions (extremely hot or dusty) and

the extra front end attachments being used (hydraulic

breaker, etc.), the hydraulic fluid will need to be

changed more frequently.

Position the machine on firm, level ground. Swing upper

structure perpendicular (90°) to wheels. Lower boom and

position bucket on ground as shown in Figure 105.

Set safety lever and stand on "LOCK" position.

Shut down engine.

Release pressurized air from hydraulic tank by rotating

breather cap (1, Figure 108).

FG008608

Figure 105

Inspection, Maintenance and Adjustment

OP000530

4-56

Drain hydraulic oil from tank into a container capable of

holding 200 liters (53 U.S. gal.). After draining tank, install

drain plug.

IMPORTANT

Be careful of squirting oil when removing drain plug.

NOTE: Used filter and used oil should always be

FG008159

disposed of according to local regulations.

Figure 106

Carefully remove bolts and cover (2, Figure 108) from top

of hydraulic oil tank. There is a spring (3) under the cover

that will force the cover up.

Remove spring (3, Figure 108) and strainer (5), by pulling

on rod (4).

Clean inside and outside of strainer. Replace strainer if it is

broken.

Position strainer (5, Figure 108) on boss portion of suction

pipe (6).

HAOC411L

NOTE: Measurement "A" is 650 mm (25.59 in).

Figure 107

10.

Fill the hydraulic oil tank. Check level using sight gauge on

side of tank.

11.

Place spring (3, Figure 108) on rod (4) and assemble cover

(2).

12.

After replacing and cleaning the hydraulic oil, filter and

strainer, vent the system. See

“Venting and Priming

Hydraulic System” on page 4-91.

IMPORTANT

When the hydraulic breaker is being used, due to the

higher heat generated by this unit, use replacement

intervals recommended under the

“Hydraulic Oil

Exchange and Suction Strainer

Cleaning” on

page 4-56.

13.

Check level of hydraulic oil tank. (See page 4-16)

ARO1720L

Figure 108

Inspection, Maintenance and Adjustment

OP000530

4-57

Drain and Refill Transmission Fluid

NOTE: The transmission fluid should be drained and refilled

after first 500 hours of operation. There after every

2,000 hours of operation.

NOTE: The oil level must be checked on level ground. When

replacing fluid, only use approved grade transmission

fluid.

The gear oil drain and fill holes are located on the front

lower section of the transmission.

FG008609

Clean off any dirt, grease and other foreign materials from

Figure 109

area surrounding the drain (1, Figure 109) and fill (2) holes

of the transmission.

Place a drain pan under the drain plug and remove the

drain plug.

Clean the drain plug. Inspect the O-ring for deterioration or

damage and replace if necessary. Reinstall drain plug.

Remove the fill plug (2, Figure 109) and fill to the bottom of

the fill hole with approved transmission fluid.

NOTE: See

“Fluid Capacities” on page 4-8, for

capacity.

Clean the fill plug. Inspect the fill plug O-ring for

deterioration or damage and replace if necessary. Reinstall

the fill plug.

Drain and Refill Front Axle Case Oil

NOTE: The front axle case oil should be drained and refilled

after the first

500 hours of operation and at every

2,000 hours there after.

NOTE: The oil level must be checked on level ground. When

replacing fluid, only use approved grade axle fluid.

The oil drain (1, Figure 110) and fill (2) holes are located

the front section of the axle case.

Clean off any dirt, grease and other foreign materials from

FG008610

area surrounding the drain (1, Figure 110) and fill (2) holes

Figure 110

of the axle case.

Place a drain pan under the drain plug and remove the

drain plug.

Clean the drain plug. Inspect the O-ring for deterioration or

damage and replace if necessary. Reinstall drain plug.

Remove the fill plug (2, Figure 110) and fill to the bottom of

the fill hole with approved gear oil.

NOTE: See

“Fluid Capacities” on page 4-8, for

capacity.

Inspection, Maintenance and Adjustment

OP000530

4-58

Clean the fill plug. Inspect the fill plug O-ring for

deterioration or damage and replace if necessary. Reinstall

the fill plug.

Drain and Refill Rear Axle Case Oil

NOTE: The rear axle case oil should be drained and refilled

after the first

500 hours of operation and at every

2,000 hours there after.

NOTE: The oil level must be checked on level ground. When

replacing fluid, only use approved grade axle fluid.

The oil drain (1, Figure 111) hole is located in the lower

section of the axle case and the fill (2) hole is located in the

rear section of the rear axle case.

FG007289

Clean off any dirt, grease and other foreign materials from

Figure 111

area surrounding the drain (1, Figure 111) and fill (2) holes

of the axle case.

Place a drain pan under the drain plug and remove the

drain plug.

Clean the drain plug. Inspect the O-ring for deterioration or

damage and replace if necessary. Reinstall drain plug.

Remove the fill plug (2, Figure 111) and fill to the bottom of

the fill hole with approved gear oil.

NOTE: See

“Fluid Capacities” on page 4-8, for

capacity.

Clean the fill plug. Inspect the fill plug O-ring for

deterioration or damage and replace if necessary. Reinstall

the fill plug.

Drain and Refill Hub Reduction Gear Oil

NOTE: The hub reduction gear oil should be drained and

refilled after the first 500 hours of operation and at

every 2,000 hours there after.

NOTE: The oil level must be checked on level ground. When

replacing fluid, only use approved grade axle fluid.

Move the excavator slowly and position the drain / fill hole

to the lowest position.

Clean off any dirt, grease and other foreign materials from

FG003412

area surrounding the drain / fill (1) hole of the reduction

Figure 112

gear.

Place a drain pan under the drain plug and remove the

plug.

Move the excavator slowly and position the oil level mark

(2) on the gear housing parallel to the ground.

Fill to the bottom of the fill hole with approved gear oil.

Inspection, Maintenance and Adjustment

OP000530

4-59

NOTE: See

“Fluid Capacities” on page 4-8, for

capacity.

Clean the drain/fill plug. Inspect the plug O-ring for

deterioration or damage and replace if necessary. Reinstall

the plug.

Repeat the process for the remaining hubs.

Check Alternator and Starter**

**These checks need to be completed by an authorized

DOOSAN dealer.

Check All Rubber Antivibration Shock

Mounts

Perform and Record the Results of the

Cycle Time Tests

Inspect Machine to Check for Cracked or

Broken Welds or other Structural

Damage

Check, Adjust Valve Clearance **

Check Head Bolt Torques

Inspection, Maintenance and Adjustment

OP000530

4-60

4,000 HOUR / BIENNIAL

SERVICE

Major Parts - Periodic Replacement

To ensure safe operation and work, perform periodic

inspections. Also, to increase safety, replace the following parts.

These parts are the ones most often subjected to abrasion, heat

and fatigue. Exchange these parts with new ones at the

designated time intervals, even if the old parts look good.

Always replace all related parts such as gaskets and O-rings.

Use only original equipment manufacturers parts.

Major Component

Parts Name to be Exchanged Periodically

Time to Exchange

Engine

Fuel Hose (Tank to Fuel Prefilter)

2 years or 4,000 hours

Fuel Hose (Fuel Prefilter to Fuel Cooler)

Fuel Hose (Fuel Cooler to ECU)

Fuel Hose (Tank to CP Pump)

Heater Hose (Heater to Engine)

Heater Hose (Heater to Radiator)

Air Conditioner Hose

Hydraulic

Body

Pump Suction Hose

System

Pump Discharge Hoses

Pump Side Branch Hoses

Swing Motor Hoses

Travel Motor Hoses

Work

Boom Cylinder Line Hoses

Device

Arm Cylinder Line Hoses

Bucket Cylinder Line Hoses

Option Cylinder Line Hoses

Inspection, Maintenance and Adjustment

OP000530

4-61

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 can not be stored

more than 2 years before being discarded or installed

on a machine.

•

In-service lifetime of hoses fitted on a machine can

never exceed 6 years, but replace hoses described in

“Major Parts - Periodic Replacement” on page 4-61,

every

2 years. Always replace hoses having

exceeded the allowed in-service lifetime irrespective

of the external appearance/wear.

•

Always store hoses in a dark place at a maximum of

65% relative humidity, between 0°C (32°F) and 35°C

(95°F) but as close as possible to 15°C (59°F) and

away from copper, manganese or tube generating

Ozone.

Inspection, Maintenance and Adjustment

OP000530

4-62

AIR-CONDITIONING SYSTEM

NOTE: See

“Clean Air-Conditioning Outer Filter” on

page 4-37.

Check Control Panel

When a function switch is pushed, the last setting has to be

displayed on the LCD display.

When the light switch is turned to "I" position, the LED for

illumination in the control panel has to turn "ON."

Check Air Conditioner Hoses

Check the hose for cracking and damage.

CAUTION!

When a leak occurs, dirt will accumulate in the area where

the leak is. Consult a DOOSAN distributor or sales agency.

Check Condenser

Inspect the condenser for dust and debris. Clean if necessary.

NOTE: See “Clean Radiator, Oil Cooler, Intercooler, Fuel

Cooler and Air Conditioner Condenser Core” on

page 4-39.

Check Magnetic Clutch

Check the magnetic clutch for dirt and interference.

Push the "A/C" switch in order to energize magnetic clutch and

check the magnetic clutch.

Check Belt Tension

10mm/10kg

FAN

NOTE: See “Check Engine Fan Belt for Cracks, Wear and

Correct Tension” on page 4-31.

COMPRESSOR

ALTERNATOR

CRANKSHAFT

FG000353

Figure 113

Inspection, Maintenance and Adjustment

OP000530

4-63

INSPECTION OF BOLT AND NUT

TIGHTENING ELEMENTS

Inspect ALL fasteners after the first 50 hours of operation and

every 250 hours thereafter. If any are loose or are missing

tighten them or install new hardware. Always use a calibrated

torque wrench.

IMPORTANT

Always clean fasteners before tightening.

If counterweight is loose, contact a DOOSAN distributor or

sales agent.

Bolt

Torque

Bolt

No.

Point to be Inspected

Qty.

Head

Dia. mm

kg•m

N•m

ft lb

Size

Joint Bolt with Engine Mounting

Pump Side

264

195

Bracket and Engine

Fan Side

6.5

Joint Bolt & Nut Between Engine

Pump Side

451

333

Mounting Bracket and Frame

Fan Side

451

333

Radiator Mounting Bolt

264

195

Tightening Bolt for Hydraulic Oil Tank

264

195

Tightening Bolt for Fuel Tank

264

195

Tightening Bolt for Pump

6.5

Tightening Bolt for Control Valve

108

Tightening Bolt for Swing Reduction Device

539

398

Tightening Bolt for Swing Motor

14.4

141

104

Tightening Bolt for Battery

6.5

Joint Bolt with Cab Mounting Rubber and

6.5

Frame

Joint Bolt with Cab Mounting Rubber and Cab

206

152

Joint Bolt with Swing Bearing and Upper

539

398

Frame

Joint Bolt with Swing Bearing and Bottom

539

398

Frame

Tightening Bolt for Rear Axle

929

686

Tightening Bolt for Propeller Shaft

Tightening Bolt for Travel Motor

265

195

Tightening Bolt for Ram Cylinder

929

686

Tightening Bolt for Center Joint

108

Tire Wheel Nut

55~60

539~588

400~434

Front Pin Mounting Bolt

265

195

Breaker Filter (Optional)

108

Tightening Bolt for Lower

Front

929

686

Attachment

Rear

929

686

Inspection, Maintenance and Adjustment

OP000530

4-64

Joint Bolt with Engine Mounting Bracket and Engine

1) Pump Side

•

Tool : 24 mm (

)

•

Torque : 27 kg•m

FG006787

Figure 114

2) Fan Side

•

Tool : 17 mm (

)

•

Torque : 6.5 kg•m

FG006788

Figure 115

Joint Bolt & Nut Between Engine Mounting Bracket and

Frame

1) Pump Side

•

Tool : 30 mm (

)

•

Torque : 46 kg•m

FG006789

Figure 116

2) Fan Side

•

Tool : 30 mm (

)

•

Torque : 46 kg•m

FG006790

Figure 117

Inspection, Maintenance and Adjustment

OP000530

4-65

Radiator Mounting Bolt

•

Tool : 24 mm (

)

•

Torque : 27 kg•m

FG006791

Figure 118

Tightening Bolt for Hydraulic Oil Tank

•

Tool : 24 mm (

)

•

Torque : 27 kg•m

FG006792

Figure 119

Tightening Bolt for Fuel Tank

•

Tool : 24 mm (

)

•

Torque : 27 kg•m

FG006793

Figure

120

Tightening Bolt for Pump

•

Tool : 17 mm (

)

•

Torque : 6.5 kg•m

FG006795

Figure 121

Inspection, Maintenance and Adjustment

OP000530

4-66

Tightening Bolt for Control Valve

•

Tool : 19 mm (

)

•

Torque : 11 kg•m

FG006796

Figure 122

Tightening Bolt for Swing Reduction Device

•

Tool : 30 mm (

)

•

Torque : 35 kg•m

FG006797

Figure 123

Tightening Bolt for Swing Motor

•

Tool : 10 mm (

)

•

Torque : 14.4 kg•m

FG006798

Figure 124

10. Tightening Bolt for Battery

•

Tool : 17 mm (

)

•

Torque : 6.5 kg•m

FG003449

Figure 125

Inspection, Maintenance and Adjustment

OP000530

4-67

11. Joint Bolt with Cab Mounting Rubber and Frame

•

Tool : 17 mm (

)

•

Torque : 6.5 kg•m

FG000454

Figure 126

Joint Bolt with Cab Mounting Rubber and Cab

•

Tool : 24 mm (

)

•

Torque : 21 kg•m

FG000455

Figure 127

12. Joint Bolt with Swing Bearing and Upper Frame

•

Tool : 30 mm (

)

•

Torque : 55 kg•m

FG003450

Figure 128

Joint Bolt with Swing Bearing and Bottom Frame

•

Tool : 30 mm (

)

•

Torque : 55 kg•m

FG003451

Figure 129

Inspection, Maintenance and Adjustment

OP000530

4-68

13. Tightening Bolt for Rear Axle

•

Tool : 36 mm (

)

•

Torque : 95 kg•m

FG003452

Figure 130

14. Tightening Bolt for Propeller Shaft

•

Tool : 14 mm (

)

•

Torque : 7 kg•m

FG008167

Figure 131

15. Tightening Bolt for Travel Motor

•

Tool : 14 mm (

)

•

Torque : 27 kg•m

FG003454

Figure 132

16. Tightening Bolt for Ram Cylinder

•

Tool : 20 mm (

)

•

Torque : 95 kg•m

FG006799

Figure 133

Inspection, Maintenance and Adjustment

OP000530

4-69

17. Tightening Bolt for Center Joint

•

Tool : 19 mm (

)

•

Torque : 11 kg•m

FG003456

Figure 134

18. Tire Wheel Nut

•

Tool : 32 mm (

)

•

Torque : 55 ~ 60 kg•m

FG003457

Figure 135

19. Front Pin Mounting Bolt

•

Tool : 24 mm (

)

•

Torque : 27 kg•m

FG003458

Figure 136

20. Breaker Filter (Optional)

•

Tool : 19 mm (

)

•

Torque : 11 kg•m

FG006800

Figure 137

Inspection, Maintenance and Adjustment

OP000530

4-70

BUCKET

Bucket Tooth Replacement

WARNING!

Due to the possibility of flying metal objects, always wear

safety helmet, protective gloves and eye protection when

changing bucket teeth.

Curl the bucket upwards and place the round rear surface

of the bucket firmly on the ground. Shut the engine off and

lock out the hydraulic controls before working on the

bucket.

NOTE: These instructions are only for DOOSAN OEM

buckets. If you are using other manufacturers

buckets, refer to their specific instructions.

HAOC680L

Figure 140

On a routine basis, inspect bucket teeth to make sure that

tooth wear or breakage has not developed. Do not allow

replaceable bucket teeth to wear down to a point that

bucket adapter is exposed. See Figure 140.

To replace a tooth (1, Figure 141), use a hammer and

punch to drive locking pin (2) and lock washer (3) out of

tooth adapter (4).

Once worn tooth has been removed, use a putty knife to

scrape adapter as clean as possible.

Slide new tooth into position and insert lock washer.

FG000346

Figure 141

Insert locking pin into tooth and with a hammer, drive pin in

until lock washer seats in locking groove.

Inspection, Maintenance and Adjustment

OP000530

4-72

Bucket O-ring Replacement

WARNING!

Due to possibility of flying metal objects, always wear

safety helmet, protective gloves and eye protection when

changing pins.

Inspect bucket O-rings on a routine basis. If worn or

damaged, replacement is necessary.

FG006427

Figure 142

Roll old O-ring (1, Figure 143) onto boss (2) around bucket

pin (3). Remove bucket pin and move arm or bucket link

(4) out of way.

FG006428

Figure 143

Remove old O-ring and temporarily install new O-ring (1,

Figure 144) onto bucket boss (2). Make sure that O-ring

groove on both bucket link

(4) and boss have been

cleaned.

Realign arm or link with bucket pin hole and insert bucket

pin (3, Figure 143).

FG006429

Figure 144

Inspection, Maintenance and Adjustment

OP000530

4-73

ELECTRICAL SYSTEM

NOTE: Never disassemble electrical or electronic parts.

Consult with a DOOSAN distributor or sales agency

before servicing.

Battery

WARNING!

Battery electrolyte contains sulfuric acid and can quickly

burn the skin and eat holes in clothing. If you spill acid on

yourself, immediately flush the area with water.

Battery acid could cause blindness if splashed into the

eyes. If acid gets into the eyes, flush them immediately with

large quantities of water and see a doctor at once.

If you accidentally drink acid, drink a large quantity of water

or milk, beaten egg or vegetable oil. Call a doctor or poison

prevention center immediately.

When working with batteries, always wear safety glasses or

goggles.

Battery generates hydrogen gas, so there is danger of an

explosion. Do not bring lighted cigarettes near the battery,

or do anything that will cause sparks.

Before working with batteries, shut down engine and turn

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

Avoid short circuiting the battery terminals through

accidental contact with metallic objects, such as tool.

When removing or installing, check which is the positive (+)

terminal and negative (-) terminal.

When removing the battery, first disconnect the negative (-)

terminal. When installing the battery, first connect the

positive (+) terminal.

If the terminals are loose, there is danger that the defective

contact may generate sparks that will cause an explosion.

When installing the terminals, install them tightly.

Batteries in Cold Weather

In colder weather a greater drain is placed on the batteries when

they are used for the preheat cycle and when starting a cold

engine. Battery performance decreases as the temperature gets

lower.

In extremely cold weather, remove the batteries at night and

move them to a warm location. This will help to keep them at a

higher power level.

Inspection, Maintenance and Adjustment

OP000530

4-75

Inspection of Battery Electrolyte Level

This machine has two maintenance free batteries. They never

require the addition to water.

When the charge indicator becomes transparency, it means low

electrolyte state because of the leakage or charging system

error. Determine the cause of problem and replace the batteries

immediately.

Check Charging State

FG000347

Check charging state through the charging indicator.

Figure 146

•

GREEN: Sufficiently charged.

•

BLACK: Insufficient charged.

•

TRANSPARENT: Replace battery.

Check the Battery Terminals

Be certain that the battery is held securely in its compartment.

Clean the battery terminals and the battery cable connectors. A

solution of baking soda and water will neutralize acid on the

battery surface, terminals, and cable connectors. Petroleum jelly

or grease can be applied to the connectors to help prevent

corrosion.

Battery Replacement

HAOU790L

When the charging indicator indicates transparency state,

replace the battery. The batteries should always be replaced in

Figure 147

pairs.

Using an old battery with a new one will shorten the life span of

the new battery.

Fuses

The fuses in the fuse box are used to protect the various

electrical circuits and their components from being

damaged. See Figure 148. The fuses used are standard

automotive type fuses.

The section on “Fuse Identification” on page 4-78, lists the

circuits and the fuse amperage required for each circuit. If

a fuse blows, determine the cause and repair any faults or

failures.

HAOC670L

Do not insert a higher amperage fuse into a lower

Figure 148

amperage slot. Serious damage to the electrical

components or fire can result.

Inspection, Maintenance and Adjustment

OP000530

4-76

CAUTION!

Before replacing a fuse, be sure to turn starter switch to "O"

(OFF) position.

Fuse Boxes

There are two fuse boxes (Figure 149) on the left side of the

heater box. The fuses prevent electrical devices from

overloading or shorting.

A decal attached to the inside of the fuse box's cover indicates

the function and amperage of each fuse.

Spare fuses are mounted on the inside of fuse box's cover. (One

each of a 10A, 15A, 20A and 30A.)

Change a fuse if the element separates. If the element of a new

FG000110

fuse separates, check the circuit and repair the circuit.

Figure 149

CAUTION!

Always replace fuses with the same type and capacity fuse

that was removed. Otherwise, electrical damage could

result.

Inspection, Maintenance and Adjustment

OP000530

4-77

Fuse Identification

Fuse Box (1)

Fuse Box (2)

FG009158

Figure 146

Fuse Box (1)

Fuse Box (2)

No.

Name

Capacity

Name

Capacity

Transmission Lever

10A

Gauge Panel/Press. Sensor

10A

Aux. Mode Switch/Check

Reverse Solenoid

10A

Connector

Forward/Cruise Solenoid

10A

Working Lamp

10A

Pilot Cut Off/Ram Lock/

10A

Stop Lamp

10A

Inching/Hi/Low Solenoid

Forward/Reverse/Cruise

Quick Clamp (Option)/

10A

Switch

Breaker (Option)

Beacon (Option) 12v Power

10A

Horn

10A

Socket

Room Lamp/Hazard/Position

10A

Position Lamp (LH)

10A

Lamp/Turn Signal Lamp

Starter Switch/Hour Meter

10A

Position Lamp (RH)

10A

Head Lamp

30A

Cabin Lamp (Option)

30A

Airconditioner/Heater

20A

Spare

20A

Fuel Heater

20A

e-EPOS Controller

20A

Seat Heater (Option)/

15A

Swing Priority Sol./Outrigger

15A

Air Suspension (Option)

Window Washer/Low Wiper

15A

Power Max/Cigar Lighter

15A

(Option)

Fuel Pump/Stereo/Memory

15A

ECU

15A

Backup

Inspection, Maintenance and Adjustment

OP000530

4-78

ENGINE COOLING SYSTEM

General

Keeping an engine's cooling system in peak operating condition,

can have many benefits to keeping a machine in good operating

condition. A properly functioning cooling system will; improve

fuel efficiency, reduce engine wear, and extend component life.

Always use distilled water in the radiator. Contaminants in tap

water neutralize the corrosion inhibitor components. If tap water

must be used, it should not exceed 300 ppm hardness, or

contain more than 100 ppm of either chloride or sulfate. Water

that has been treated with a water softener also contains salt

that will cause corrosion of components. Water from creeks and

stagnant pools usually contains dirt, minerals and/or organic

material that are deposited in the cooling system and impair

cooling efficiency. Distilled water is the best.

Engine overheating is often caused by bent or clogged radiator

fins. The spaces between the fins can be cleaned by use of air

or water under pressure. When straightening bent fins, use care

not to damage the tubes or break the bond between the fins and

the tubes.

WARNING!

Pressure at air nozzle must not exceed 30 PSI (2.1 kg/cm²).

Always wear goggles when using compressed air.

Do not pour cold water into radiator when engine is very hot

and water level is below the top of the tubes. Such action

could result in damage to engine cylinder heads.

Heavy duty diesel engines require a balanced mixture of water

and antifreeze. Drain and replace the mixture every year or

2,000 hours of operation, which ever comes first. This will

eliminate buildup of harmful chemicals.

Antifreeze is essential in any climate. It broadens the operating

temperature range by lowering the coolant's freezing point and

by raising its boiling point. Do not use more than 50% antifreeze

in the mixture unless additional freeze protection is required.

Never use more than 68% antifreeze under any condition.

Inspection, Maintenance and Adjustment

OP000530

4-79

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

OP000530

4-80

FUEL TRANSFER PUMP

(OPTION)

WARNING!

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

•

Cooling and lubrication of pump is achieved by

fuel passing through pump. If pump is dry

operated, heat generated by moving parts will

cause damage to pump rotors, vanes and seals.

To prevent unnecessary wear and/or damage to

pump do not dry operate fuel pump for more than

fifteen seconds.

Do not operate pump for more than fifteen minutes at a

time.

•

Continuous usage of pump over recommended

time interval will cause overheating of motor and

will result in causing motor damage.

Do not use refueling pump for other types of fuel or fluids.

(Use only for diesel fuel.)

•

Do not use refueling pump for other types of fuel

which have a low flash point.

•

Do not use refueling pump for fuel contaminated

with water or high humidity. Moisture in pump

mechanism can cause rust and can create pump

failure.

Always operate pump using strainer installed on inlet hose.

This will prevent any foreign materials from being

introduced into pump. Always maintain pump and all of its

components in a clean condition.

•

If dirt or other foreign materials enter pump, it can

become lodged between the rotor and/or vanes

and generate heat which can cause pump

damage.

•

Do not remove strainer or use a strainer with

larger mesh to increase flow of fuel.

Be careful not to overfill or spill fuel.

Make sure direction of check valve is in line with flow

direction of fuel.

If any pump parts or components become lost, damaged or

inoperable, immediately replace it with a new ones.

Inspection, Maintenance and Adjustment

OP000530

4-81

IMPORTANT

If there are any sign of leakage while operating transfer

pump, inspect the following components to prevent any

fires or hazardous fuel spills.

•

Check all hoses leading to and from the transfer

pump.

•

Check all hose clamps.

•

Check transfer pump inlet port.

The transfer pump is used to transfer fuel from a refueling

source to the fuel tank. A check valve is installed in the inlet

hose to prevent fuel from flowing back from fuel tank to source.

A strainer is installed in inlet hose to prevent any foreign material

from being introduced into transfer pump or fuel tank.

A thermal limiter, built into the motor, will automatically shut off

power if motor is overheating to protect it from being damaged.

FUEL

FUEL TANK

FG000161

Figure 151

Reference

Description

Number

Body

Strainer Cap

Check Valve

Inlet Hose

Strainer

Inspection, Maintenance and Adjustment

OP000530

4-82

Remove strainer cap (4, Figure 151) from strainer (3) on

end of inlet hose (5).

NOTE: Keep strainer cap (4, Figure 151) in a safe

location to reseal strainer (3) after refueling is

complete.

Insert inlet hose (5, Figure 151) into refueling tank.

Turn fuel pump switch (Figure 152) inside of battery box on

front side to "I" (ON) position.

NOTE: Transfer pump rate of flow is approximately 35

FG006783

liters/minute (9.24 U.S. gpm). Use extra care

Figure 152

not to overfill fuel tank so that fuel does not over

flow.

Once fuel transfer is completed, immediately turn switch to

"O" (OFF) position to stop pump.

Lift inlet hose (5, Figure 151) from fueling source and turn

switch to "I" (ON) position for two - three seconds to drain

remaining fuel from hose to fuel tank.

Install strainer cap (4, Figure 151) on inlet strainer (3) and

return hose (5) to storage position.

Inspection, Maintenance and Adjustment

OP000530

4-83

HANDLING OF ACCUMULATOR

WARNING!

Even though the engine or pump is stopped, the hydraulic

accumulators for the pilot and brake system are still

charged. Do not disconnect any pilot and brake system

hoses until accumulator pressure has been released from

the circuit. To release pressure, turn the starter switch to

the "I" (ON) position and operate all hydraulic control levers

and press the service brake pedal. Even though the engine

is shutdown hydraulic actuated components may move

while releasing pilot pressure and emergency brake is

applied during pressing service brake pedal. Keep all

personnel away from excavator while performing this

operation.

•

Set safety lever and stand on "LOCK" position

after stopping engine.

•

DO NOT mishandle accumulator(s). They are very

dangerous because they contain high-pressure

nitrogen gas.

•

DO NOT punch a hole or apply heat or fire to an

accumulator.

•

DO NOT weld on accumulator, or try attaching

anything to it.

•

When replacing an accumulator, contact a

DOOSAN distributor or sales agency so the gas

can be properly released.

•

Wear safety goggles and protective gloves when

working on an accumulator. Hydraulic oil under

pressure can penetrate the skin and cause

serious injuries.

Pilot Accumulator

Release pilot accumulator pressure using the following

procedure;

Position the machine on firm, level ground. Lower the front

attachment to the ground and shut down engine.

Set safety lever and stand on "RELEASED" position.

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

Fully stroke work in all directions.

FG006781

Set safety lever and stand on "LOCK" position.

Figure 153

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

switch.

Remove accumulator by unscrewing it slowly.

Inspection, Maintenance and Adjustment

OP000530

4-84

Doosan DX190W. Operation and Maintenance Manual (2006) - page 4