Doosan DX255LC. Operation and Maintenance Manual (2006)

DX255LC

Operation and Maintenance Manual

K1016584E

Serial Number 5001 and Up

September 2006

DOOSAN reserves the right to improve our products in a continuing process to provide the best possible product

to the market place. These improvements can be implemented at any time with no obligation to change materials

on previously sold products. It is recommended that consumers periodically contact their distributors for recent

documentation on purchased equipment.

This documentation may include attachments and optional equipment that is not available in your machine's

package. Please call your distributor for additional items that you may require.

Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and

may vary from the actual item.

K1016584E Operation and Maintenance Manual

Table of Contents

Safety

1-1

To the Operator of a DOOSAN Daewoo Excavator

1-1

Location of Safety Labels

1-5

Summary of Safety Precautions for Lifting in Digging Mode

1-15

Unauthorized Modifications

1-16

General Hazard Information

1-16

Before Starting Engine

1-25

Machine Operation

1-29

Maintenance

1-36

Battery

1-45

Towing

1-47

Shipping and Transportation

1-48

Excavator Rated Lift Capacity Tables

1-49

Operating Controls

2-1

Component Locations

2-4

Operator's Area

2-6

Operational Controls and Panels

2-8

Instrument Panel

2-22

Multifunction Gauge and Graphic Information

2-29

Mode Selector Buttons

2-34

Setting Main Menu

2-36

Flow Control

2-45

Operation Selection Display

2-47

Heater and Air Conditioner Control Panel

2-49

Stereo

2-55

Miscellaneous Electrical Devices

2-57

Seat Adjustment

2-59

K1016584E

Table of Contents

Ceiling Cover

2-63

Front Windows

2-64

Door Side Latch

2-66

Cabin Storage Compartments

2-67

Ashtray

2-67

Sun Visor

2-68

Hanger

2-68

Cup Holder

2-69

Door Window Holder

2-69

Emergency Glass Breaking Tool

2-69

Miscellaneous Access Covers and Doors

2-70

Operation

3-1

To Handle a New Excavator

3-1

Starting and Stopping the Engine

3-2

Safety Lever

3-13

Travel

3-14

Operating Instructions

3-20

Operating Precautions

3-26

Parking Excavator

3-31

Towing Procedure

3-32

Hydraulic Breaker

3-33

Adjusting the Pump Flow

3-38

Operating Techniques

3-41

Operation Under Unusual Conditions

3-43

Inspection, Maintenance and Adjustment

4-1

Preventive Maintenance

4-1

Preliminary Work Machine Setup for Maintenance

4-4

Table of Recommended Lubricants

4-6

Fluid Capacities

4-8

Lubrication and Service Chart

4-8

Maintenance Intervals

4-12

K1016584E

Table of Contents

10 Hour / Daily Service

4-14

50 Hour / Weekly Service

4-25

250 Hour / Monthly Service

4-28

500 Hour / 3 Month Service

4-35

1,000 Hour / 6 Month Service

4-44

2,000 Hour / Yearly Service

4-51

4,000 Hour / Biennial Service

4-57

12,000 Hour / Six Year Service

4-58

Air-Conditioning System

4-59

Bolt and Nut Inspection

4-60

Bucket

4-68

Electrical System

4-71

Engine Cooling System

4-75

Fuel Transfer Pump (Option)

4-77

Handling of Accumulator

4-80

Track Tension

4-81

Venting and Priming Hydraulic System

4-83

Long Term Storage

4-85

Maintenance in Special Conditions

4-86

Transportation

5-1

Loading and Unloading

5-1

Lifting With Sling

5-5

Troubleshooting

6-1

Electrical System

6-1

Engine

6-2

Hydraulic System

6-3

Swing System

6-4

Travel System

6-5

Specification

7-1

Standard Specification

7-1

K1016584E

Table of Contents

III

OP000481

1Safety

TO THE OPERATOR OF A

DOOSAN DAEWOO

EXCAVATOR

DANGER!

Unsafe use of the excavator could lead to serious injury

or death. Operating procedures, maintenance and

equipment practices or traveling or shipping methods

that do not follow the safety guidelines on the following

pages could cause serious, potentially fatal injuries or

extensive damage to the machine or nearby property.

Please respect the importance of taking responsibility for

your own safety, and that of other people who may be

affected by your actions.

The safety information on the following pages is organized

into the following sections:

“Location of Safety Labels” on page 1-5

“Summary of Safety Precautions for Lifting in Digging

Mode” on page 1-15

“Unauthorized Modifications” on page 1-16

“General Hazard Information” on page 1-16

“Before Starting Engine” on page 1-25

“Machine Operation” on page 1-29

“Maintenance” on page 1-36

“Battery” on page 1-45

“Towing” on page 1-47

10. “Shipping and Transportation” on page 1-48

11. “Excavator Rated Lift Capacity Tables” on page 1-49

OP000481

Safety

1-1

WARNING!

Improper operation and maintenance of this machine

can be hazardous and could result in serious injury or

death.

Operator and maintenance personnel should read this

manual thoroughly before beginning operation or

maintenance.

Keep this manual in the storage compartment to the

rear of the operator's seat, and have all personnel

involved in working on the machine read the manual

periodically.

Some actions involved in operation and maintenance of

the machine can cause a serious accident, if they are

not done in a manner described in this manual.

The procedures and precautions given in this manual

apply only to intended uses of the machine.

If you use your machine for any unintended uses that

are not specifically prohibited, you must be sure that it

is safe for any others. In no event should you or others

engage in prohibited uses or actions as described in

this manual.

DOOSAN delivers machines that comply with all

applicable regulations and standards of the country to

which it has been shipped. If this machine has been

purchased in another country or purchased from

someone in another country, it may lack certain safety

devices and specifications that are necessary for use in

your country. If there is any question about whether

your product complies with the applicable standards and

regulations of your country, consult DOOSAN or your

DOOSAN distributor before operating the machine.

Safety

OP000481

1-2

SAFETY ALERT SYMBOL

Be Prepared - Get to Know All Operating and Safety

Instructions.

This is the Safety Alert Symbol. Wherever it appears in

this manual or on safety signs on the machine you

should be alert to the potential for personal injury or

accidents. Always observe safety precautions and follow

recommended procedures.

Learn the Signal Words Used with the

Safety Alert Symbol

The words "CAUTION," "WARNING," and "DANGER" used

throughout this manual and on decals on the machine

indicate degree of risk of hazards or unsafe practices. All

three degrees of risk indicate that safety is involved.

Observe precautions indicated whenever you see the Safety

Alert "Triangle," no matter which signal word appears next to

the "Exclamation Point" symbol.

CAUTION!

This word is used on safety messages and safety labels

and indicates potential of a hazardous situation that, if

not avoided, could result in minor or moderate injury. It

may also be used to alert against a generally unsafe

practice.

WARNING!

This word is used on safety messages and safety labels

and indicates potential of a hazardous situation that, if

not avoided, could result in serious injury or death. It

may also be used to alert against a highly unsafe

practice.

DANGER!

This word is used on safety messages and safety labels

and indicates an imminent hazard of a situation that, if

not avoided, is very likely to cause death or extremely

serious injury. It may also be used to alert against

equipment that may explode or detonate if handled or

treated carelessly.

Safety

OP000481

1-3

Safety precautions are described in SAFETY from page 1-5

on.

DOOSAN cannot predict every circumstance that might

involve a potential hazard in operation and maintenance.

Therefore the safety messages in this manual and on the

machine may not include all possible safety precautions. If

any procedures or actions not specifically recommended or

allowed in this manual are used, you must be sure that you

and others can do such procedures and actions safely and

without damaging the machine. If you are unsure about the

safety of some procedures, contact a DOOSAN distributor.

Safety

OP000481

1-4

LOCATION OF SAFETY

LABELS

FG006900

Figure 1

There are several specific warning signs on this machine.

The exact location of hazards and the description of the

hazards are reviewed in this section.

Please become familiarized with all warning signs.

Make sure that all of the warning signs are legible. Clean

the warning signs or replace the warning signs if you cannot

read the words. Replace the illustrations if the illustrations

are not visible. When you clean the warning signs, use a

cloth, water and soap. Do not use solvent, gasoline, or other

harsh chemicals to clean the safety signs. Solvents,

gasoline, or other harsh chemicals could loosen the

adhesive that secures the warning sign. Loose adhesive will

allow the warning sign to fall off.

OP000481

Safety

1-5

1. Warnings for Operation, Inspection

and Maintenance (190-00688,

190-00092)

AVOID DEATH OR SERIOUS INJURY. - READ AND UNDERSTAND

OPERATION MANUAL AND SAFETY LABELS prior to operating

this machine.

Never get in under the machine while it is being jacked up

with boom and arm.

Sound the horn to alert the people nearby before operating,

and make sure that all persons are clear of area.

190-00092

Controls may be changed for attachments or operator

preference. Try control pattern before operating.

190-00688

ARO1080L

2. Warnings for High Voltage

(190-00689, 190-00096)

DANGER

SERIOUS INJURY OR DEATH BY

ELECTROCTION can occur if

machine or attachments are

not a safe distance from electrical

power lines.

Line voltage

Safe Distance

6.6 kv

At least 3m(10ft)

66.6 kv

At least 5m(16ft)

190-00096

275.0 kv

At least 10m(33ft)

190-00689

ARO1090L

OP000481

Safety

1-7

5. Warnings When Adjusting Track

Tension (2190-3386A, 190-00521)

The track adjuster adjustment and handling

The spring in the track adjuster is loaded with great force

and the pressure in the cylinder is very high. For this

reason there is a possibility of an accident which

may involve injury to personnel. It is very dangerous

to make mistakes when performing such an adjustment

or disassembly.

Be sure to read the procedures described in the Operation

and Maintenance Manual carefully before adjusting the

track tension.

2190-3386A

190-00521

ARO1120L

6. Warnings for Leaving Operator's

Seat (190-00693, 190-00094)

Sudden and unwanted machine

movement can cause serious

injury or death.

Always make sure when leaving

operator's seat to :

Lower equipment to the ground.

Move safety lever to LOCK position.

Turn key switch OFF. Remove key

from switch.

190-00693

190-00094

ARO1140L

OP000481

Safety

1-9

7. Warnings for Batteries Maintenance

(2190-2533A, 190-00100)

Battery fumes can explode. Keep sparks and flames away

from batteries.

Always avoid storing metals like tools or flammable

materials around or on the batteries. Explosion or fire

can be caused by shortcircuiting batteries.

Surfuric acid in battery is poisonous. It is strong enough

burn skin, eat holes in clothing, and cause blindness

if splashed eyes.

If you spill acid on yourself;

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 10-15 minutes.

Get medical attention immediately.

2190-2533A

190-00100

ARO1150L

8. Warnings for High Temperature

Hydraulic Oil (190-00691, 190-00097)

HOT OIL CAN CAUSE INJURY OR

BLINDNESS.

To prevent hot oil from spurting out:

Turn engine off

Allow oil to cool

190-00097

Slowly loosen cap to relieve

pressure

190-00691

ARO1160L

Safety

OP000481

1-10

9. Warnings for Hot Coolant (190-00692,

190-00097)

HOT COOLANT CAN CAUSE INJURY

OR BLINDNESS.

Never loosen or open radiator cap

when coolant is hot and under

pressure.

To open cap, stop engine, wait until

radiator is cool. Then loosen cap

190-00097

slowly to relieve the pressure.

190-00692

ARO1170L

10. Warnings for Handling an

Accumulator (190-00703, 190-00099)

Keep away from flame.

Do not weld on, or drill

into the accumulator.

EXPLOSION HAZARD

190-00703

190-00099

ARO1180L

OP000481

Safety

1-11

SUMMARY OF SAFETY

PRECAUTIONS FOR LIFTING IN

DIGGING MODE

DANGER!

Unsafe use of the excavator while making rated lifts

could cause serious, potentially fatal injuries or

extensive damage to the machine or nearby property.

Do not let anyone operate the machine unless they've

been properly trained and understand the information in

the Operation and Maintenance Manual.

To lift safely while in Digging Mode, the following items must

be evaluated by the operator and the work site crew.

•

Condition of ground support.

•

Excavator configuration and attachments.

•

Weight, lifting height and lifting radius.

•

Safe rigging of the load.

•

Proper handling of the suspended load.

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

in keeping a suspended load secure, if they are anchored

safely to control points on the ground.

WARNING!

NEVER wrap a tag line around your hands or body.

NEVER rely on tag lines or make rated lifts when wind

gusts are more than 48.3 km/h (30 MPH). Be prepared

for any type of wind gust when working with loads that

have a large surface area.

Always engage the "Digging Mode" control on the Instrument

Panel before using the excavator for lifting work.

WARNING!

If you need more information or have any questions or

concerns about safe operating procedures or working

the excavator correctly in a particular application or in

the specific conditions of your individual operating

environment, please consult your local DOOSAN

representative.

OP000481

Safety

1-15

UNAUTHORIZED

MODIFICATIONS

Any modification made without authorization or written

approval from DOOSAN can create a safety hazard, for

which the machine owner must be held responsible.

For safety's sake, replace all OEM parts with the correct

authorized or genuine DOOSAN part. For example, not

taking the time to replace fasteners, bolts or nuts with the

correct replacement parts could lead to a condition in which

the safety of critical assemblies is dangerously compromised.

GENERAL HAZARD

INFORMATION

Safety Rules

Only trained and authorized personnel can operate and

maintain the machine.

Follow all safety rules, precautions and instructions when

operating or performing maintenance on the machine.

Do not operate the machine if you are not feeling well, if

you are taking medication that makes you feel sleepy, if you

have been drinking, or if you are suffering from emotional

problems. These problems will interfere with your sense of

judgement in emergencies and may cause accidents.

When working with another operator or with a person on

work site traffic duty, be sure that all personnel know the

nature of the work and understand all hand signals that are

to be used.

Always observe strictly any other rules related to safety.

Safety Features

Be sure that all guards and covers are installed in their

proper position. Have guards and covers repaired

immediately if damaged.

Be sure that you understand the method of use of safety

features such as safety lock lever and the seat belt, and

use them properly.

Never remove any safety features. Always keep them in

good operating condition.

Failure to use safety features according to the instructions in

the Operation and Maintenance Manual could result in

serious bodily injury.

Safety

OP000481

1-16

Inside Operator's Compartment

When entering the operator's compartment, always remove

all mud and oil from the soles of your shoes. If you operate

the travel pedal with mud or oil stuck to your shoes, your

foot may slip and this may cause a serious accident.

After using the ashtray, make sure that any matches or

cigarettes are properly extinguished, and be sure to close

the ashtray. If the ashtray is left open, there is danger of

fire.

Do not stick suction pads to the window glass. Suction pads

act as a lens and may cause fire.

Do not leave lighters laying around the operator's

compartment. If the temperature inside the operator's

compartment becomes high, there is danger that the lighter

may explode.

Do not use cellular telephones inside the operator's

compartment when driving or operating the machine.

There is danger that this may lead to an unexpected

accident.

Never bring any dangerous objects such as flammable or

explosive items into the operator's cabin.

To ensure safety, do not use the radio or music

headphones when operating the machine. There is danger

that this may lead to a serious accident.

When operating the machine, do not put your hands or

head out of the window.

When standing up from the operator's seat, always place

safety lock lever securely in the "LOCK" position. If you

accidentally touch the work equipment levers when they are

not locked, the machine may suddenly move and cause

serous injury or damage.

When leaving the machine, lower the work equipment

completely to the ground, set safety lock lever to the

"LOCK" position and shut down engine. Use the key to lock

all the equipment. Always remove the key and take it with

you.

Clothing and Personal Protective Items

Contain long hair, and avoid loose clothing and jewelry.

They can catch on controls or in protruding parts and cause

serious injury or death.

Do not wear oily clothes. They are highly flammable.

Full eye protection, a hard hat, safety shoes and gloves

may be required at the work site.

While working on the machine, never use inadequate tools.

They could break or slip, causing injury, or they may not

HAOA020L

adequately perform intended functions.

Figure 2

OP000481

Safety

1-17

Breathing Masks, Ear Protection May Be

Required

Do not forget that some risks to your health may not be

immediately apparent. Exhaust gases and noise pollution

may not be visible, but these hazards can cause disabling

or permanent injuries.

NOTE:

The equivalent continuous A-weighted sound

pressure level at the workstation for this machine is

71 dB(A).

Measurement is obtained on a dynamic machine

following the procedures and cabin conditions as

described in ISO 6396.

NOTE:

The guaranteed sound power level emitted by the

machinery for this machine is 103 dB(A).

Measurement is obtained on a dynamic machine with

the procedures as described in 2000/14/EC.

Vibration Level Information

Hands/Arms: The weighted root mean square acceleration to

which the hands/arms are subjected, is less than 2.5 m/s².

Whole body: The weighted root mean square acceleration to

which the whole body is subjected, is less than 0.5 m/s².

Measurements are obtained on a representative machine,

using measuring procedures as described in the following

standard: ISO 2631/1. ISO 5349, and SAE J1166.

Recommendations for Limiting

Vibrations

Select the right machine, equipment and attachments

for a particular application.

Replace any damaged seat by a DOOSAN genuine

part. Keep the seat maintained and adjusted.

•

Adjust the seat and suspension for the weight

and size of the operator.

•

Inspect and maintain the suspension and

adjustment mechanisms of the seat regularly.

Check that the machine is properly maintained.

•

Tire pressure, brakes, steering, linkages, etc.

Steer, brake, accelerate, shift gears, move the

attachments and load the attachments smoothly.

Adjust the machine speed and travel path to reduce

the vibration level.

Safety

OP000481

1-18

•

Slow down if it is necessary when passing rough

terrain.

•

Drive around obstacles and excessive rough

terrain conditions.

Keep the terrain on work sites where the machine is

working and traveling in good condition.

•

Remove any large rocks or obstacles.

•

Fill any ditches and holes.

•

Provide machines for and schedule time to

maintain the terrain conditions.

Travel over longer distance (e.g. on public roads) at

adjusted (medium) speed.

•

Always adjust the speed for preventing bouncing.

Mounting and Dismounting

Before getting on or off the machine, if there is any oil,

grease, or mud on the handrails, steps, or track shoes, wipe

it off immediately. Always keep these parts clean. Repair

any damage and tighten any loose bolts.

Never jump on or off the machine. In particular, never get

on or off a moving machine. These actions may lead to

serious injury.

When getting on or off the machine, always face the

machine, and maintain three-point contact (both feet and

one hand or one foot and both hands) with the handrails,

steps, and track shoes to ensure that you support yourself

securely.

Never hold any control levers when getting on or off the

machine.

Apply the door lock securely. If you grip the handrail inside

the door when moving on top of the track shoes, and the

door lock is not applied securely, the door may move and

cause you to fall.

Use the points marked by arrows in the diagram when

getting on or off the machine.

FG006901

Figure 3

OP000481

Safety

1-19

Fuel, Oil and Hydraulic Fluid Fire

Hazards

Fuel, oil and antifreeze will catch fire if it is brought close to

a flame. Fuel is particularly flammable and can be

hazardous.

Always strictly observe the following.

Add fuel, oil, antifreeze and hydraulic fluid to the machine

only in a well ventilated area. The machine must be parked

with controls, lights and switches turned "OFF." The engine

must be "OFF" and any flames, glowing embers, auxiliary

heating units or spark causing equipment must be doused,

turned "OFF" and/or kept well clear of the machine.

Static electricity can produce dangerous sparks at the fuel

filling nozzle. In very cold, dry weather or other conditions

Figure 4

that could produce a static discharge, keep the tip of the

fuel nozzle in constant contact with the neck of the fuel

filling nozzle, to provide a ground.

Keep fuel and other fluid reservoir caps tight and do not

start the engine until caps have been secured.

Precautions When Handling Fluids at

High Temperature

Immediately after operations are stopped, the coolant,

engine oil, and hydraulic oil are at high temperature and the

radiator and hydraulic tank are still under pressure.

Attempting to remove the cap, drain the oil or coolant, or

replace the filters may lead to serious burns. Always wait for

the temperature to go down, and follow the specified

procedures when carrying out these operations.

HAOA050L

Figure 5

To prevent hot coolant from spurting out, shut down engine,

wait for the coolant to cool, then loosen the cap slowly to

relieve the pressure.

To prevent hot oil from spurting out, shut down engine, wait

for the oil to cool, then loosen the cap slowly to relieve the

pressure.

HAOA060L

Figure 6

Safety

OP000481

1-20

Asbestos Dust Hazard Prevention

Asbestos dust can be HAZARDOUS to your health if it is

inhaled. Materials containing asbestos fiber can be present on

work site. Breathing air that contains asbestos fiber can

ultimately cause serious or fatal lung damage. To prevent lung

damage from asbestos fiber, observe following precautions;

•

Use a respirator that is approved for use in an

asbestos-laden atmosphere.

•

Never use compressed air for cleaning.

ARO1770L

•

Use water for cleaning to keep down the dust.

Figure 7

•

Work on the machine or component with the wind

at your back whenever possible.

•

Always observe any rules and regulations related

to the work site and working environment.

Injury from Work Equipment

Do not enter or put your hand, arm or any other part of

your body between movable parts, such as between the

work equipment and cylinders, or between the machine and

work equipment.

If the control levers are operated, the clearance between the

machine and the work equipment will change and this may

lead to serious damage or personal injury.

If going between movable parts is necessary, always position

HDO1010L

and secure the work equipment so that it cannot move.

Figure 8

Fire Extinguisher and First Aid Kit

As a precaution if any injury or fire should occur, always do

the following.

•

Be sure that fire extinguishers have been provided

and read the labels to ensure that you know now

to use them. It is recommended that an

appropriately sized

(2.27 kg

[5 lb] or larger)

multipurpose "A/B/C" fire extinguisher be mounted

in the cabin. Check and service the fire extinguisher

at regular intervals and make sure that all work site

HDO1009L

crew members are adequately trained in its use.

Figure 9

•

Provide a first aid kit in the storage compartment

and keep another at the work site. Check the kit

periodically and make any additions if necessary.

•

Know what to do in case of injury from fire.

•

Keep emergency numbers for doctor, ambulance

service, hospital and fire department near your

telephone.

OP000481

Safety

1-21

If the machine catches fire, it may lead to serious personal

injury or death. If a fire occurs during operation, escape

from the machine as follows;

•

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

and shut down engine.

•

If there is time, use the fire extinguisher to

extinguish as much of the fire as possible.

•

Use the handrails and steps to escape from the

machine.

The above is the basic method for escaping from the

machine, but changing the method may be necessary

according to the conditions, so carry out practice drills at the

work site.

Protection from Falling or Flying Objects

On work sites where there is danger that falling objects or

flying objects may hit the operator's cabin select a guard to

match the operating conditions to protect the operator.

Working in mines, tunnels, deep pits or on loose or wet

surfaces could produce danger of falling rock or hazardous

flying objects. Additional protection for the operator's cabin

could be required in the form of a FOPS (Falling Object

Protective Structure) or window guards.

HAOA110L

Figure 10

Never attempt to alter or modify any type of protective

structure reinforcement system, by drilling holes, welding,

remounting or relocating fasteners. Any serious impact or

damage to the system requires a complete integrity

reevaluation. Reinstallation, recertification and/or replacement

of the system may be necessary.

Contact your DOOSAN distributor for available safety guards

and/or recommendations if there is any danger of getting hit

by objects that could strike the operator's cabin. Make sure

that all other work site crew members are kept well away

from the excavator and safe from possible hazards.

HAOA100L

Figure 11

For breaker operation, install a front guard and apply a

laminated coating sheet to the front glass. Contact your

DOOSAN distributor for recommendations.

When carrying out demolition or cutting operation, install a

front guard and top guard, and apply a laminated coating

sheet to the front glass.

When working in mines or quarries where there is danger of

falling rock, install FOPS (Falling Objects Protective

Structure) and apply a laminated coating sheet to the front

glass.

If any glass on the machine is broken, replace it with new

glass immediately.

Safety

OP000481

1-22

Attachment Precautions

Option kits are available through your dealer. Contact

DOOSAN for information on available one-way (single-acting)

and two-way (double-acting) piping

/ valving

/ auxiliary

control kits. Because DOOSAN cannot anticipate, identify or

test all of the attachments that owners may wish to install

on their machines, please contact DOOSAN for authorization

and approval of attachments, and their compatibility with

options kits.

Accumulator

The pilot control system is equipped with an accumulator.

For a brief period of time after the engine has been shut

down, the accumulator will store a pressure charge that may

enable hydraulic controls to be activated. Activation of any

controls may enable the selected function to operate under

force of gravity.

When performing maintenance on the pilot control system,

the hydraulic pressure in the system must be released as

describe in “Handling of Accumulator” on page 4-80.

The accumulator is charged with high-pressure nitrogen gas,

so it is extremely dangerous if it is handled in the wrong

way. Always observe the following precautions;

•

Do not drill or make any holes in the accumulator

or expose it any flame, fire or heat source.

•

Do not weld on the accumulator, or try attaching

anything to it.

•

When carrying out disassembly or maintenance of

the accumulator, or when disposing of the

accumulator, the charged gas must be properly

released. Contact your DOOSAN distributor.

•

Wear safety goggles and protective gloves when

working on an accumulator. Hydraulic oil under

pressure can penetrate the skin and cause

serious injuries.

Indoor Ventilation

Engine exhaust gases can cause fatal accidents, and

unconsciousness, loss of alertness, judgement and motor

control and serious injury.

Make sure there is adequate ventilation before starting the

engine in any enclosed area.

You should also be aware of open windows, doors or

ductwork into which exhaust may be carried, or blown by

the wind, exposing others to danger.

ARO1770L

Figure 12

OP000481

Safety

1-23

BEFORE STARTING ENGINE

Work Site Precautions

Before starting operations, thoroughly check the area for any

unusual conditions that could be dangerous.

Check the terrain and condition of the ground at the work

site, and determine the best and safest method of operation.

Make the ground surface as hard and horizontal as possible

before carrying out operations. If there is a lot of dust and

sand on the work site, spray water before starting operations.

If you need to operate on a street, protect pedestrians and

cars by designating a person for work site traffic duty or by

erecting fences and posting "No Entry" signs around the

work site.

Erect fences, post "No Entry" signs, and take other steps to

prevent people from coming close to or entering the work

site. If people come close to a moving machine, they may

be hit or caught by the machine, and this may lead to

serious personal injury or death.

DANGER

No Entry

Water lines, gas lines, phone lines and high voltage

FG000400

electrical lines may be buried under the work site. Contact

Figure 14

each utility and identify their locations. Be careful not to

damage or cut any of these lines.

Check the condition of the river bed, and the depth and flow

of the water before operating in water or crossing a river.

NEVER be in water that is in excess of the permissible

water depth.

Any type of object in the vicinity of the boom could

represent a potential hazard, or cause the operator to react

suddenly and cause an accident. Use a spotter or signal

person working near bridges, phone lines, work site

scaffolds, or other obstructions.

FG000363

Figure 15

Minimum levels of insurance coverage, work permits or

certification, physical barriers around the work site or

restricted hours of operation may be mandated by governing

authorities. There may also be regulations, guidelines,

standards or restrictions on equipment that may have to be

followed for local requirements. There may also be

regulations related to performing certain kinds of work. If

there is any question about whether your machine and work

site complies with the applicable standards and regulations

contact your local authorities and agencies.

Avoid entering soft ground. It will be difficult for the machine

FG000372

to escape.

Figure 16

OP000481

Safety

1-25

Avoid operating your machine to close to the edge of cliffs,

overhangs, and deep ditches. The ground may be weak in

such areas. If the ground should collapse, the machine

could fall or tip over and this could result in serious injury or

death.

Remember that the soil after heavy rain, blasting or after

earthquakes, is weakened in these areas.

Earth laid on the ground and the soil near ditches is loose.

It can collapse under the weight of vibration of your machine

and cause your machine to tip over.

Install the head guard (FOPS) if working in areas where

there is danger of falling rocks.

Checks Before Starting Engine

Every day before starting the engine for the first time, carry

out the following checks. If these checks are not carried out

properly, there is danger of serious injury.

Completely remove all wood chips, leaves, grass, paper and

other flammable materials accumulated in the engine

compartment and around the battery. They could cause a

fire. Remove any dirt from the window glass, mirrors,

handrails, and steps.

Do not leave tools or spare parts laying around in the

operator's compartment. The vibration of the machine when

traveling or during operations may cause them to fall and

damage or break the control levers or switches. They may

also get caught in the gap of the control levers and cause

the work equipment to malfunction or move dangerously.

This may lead to unexpected accidents.

Check the coolant level, fuel level, and hydraulic tank oil

level, and check for clogged air cleaner and damage to the

electrical wiring.

Adjust the operator's seat to a position where it is easy to

operate the machine, and check the seat belt and mounts

for damage and wear.

Check the operation of the gauges and the angle of the

mirrors, and check that the safety lever is in "LOCKED"

position.

If any abnormalities are found in the above checks, carry

out repairs immediately.

Engine Starting

Walk around your machine before getting in the operator's

cabin. Look for evidence of leaking fluid, loose fasteners,

misaligned assemblies or any other indications of possible

equipment hazard.

Safety

OP000481

1-26

All equipment covers and machinery safety guards must be

in place, to protect against injury while the machine is being

operated.

Look around the work site area for potential hazards, people

or properly that could be at risk while operation is in

progress.

NEVER start the engine if there is any indication that

maintenance or service work is in progress, or if a warning

tag is attached to controls in the cabin.

A machine that has not been used recently, or is being

operated in extremely cold temperatures, could require a

warm-up or maintenance service before start-up.

Check gauges and monitor displays for normal operation

before starting the engine. Listen for unusual noises and

remain alert for other potentially hazardous conditions at the

start of the work cycle.

Do not short circuit the starting motor to start the engine. This

is not only dangerous, but may also damage the machine.

When starting the engine, sound the horn as an alert.

Start and operate the machine only while seated.

Before Operating Machine

If checks are not carried out properly after starting the

engine, it may result in a delay in discovering abnormalities

in the machine, and this may lead to personal injury or

damage to the machine.

Carry out the checks in an open area where there are no

obstructions. Do not let anyone near the machine when

carrying out the checks.

•

Check the operating condition of the equipment,

and the actuation of the bucket, arm, boom,

travel, and swing systems.

•

Check the machine for any abnormal noise,

vibration, heat, smell, or abnormality with the

gauges. Check also for leakage of air, oil, and fuel.

•

If any abnormality is found, repair the problem

immediately. If the machine is used without

repairing the problems, it may lead to unexpected

injury or failure.

•

Clear all personnel from directly around machine

and from the area.

•

Clear all obstacles from the machine's path.

Beware of hazards.

•

Be sure that all windows are clean. Secure the

doors and the windows in the open position or in

the shut position.

OP000481

Safety

1-27

•

Adjust the rear view mirrors for best visibility close

to the machine. Make sure that the horn, the

travel alarm (if equipped), and all other warning

devices are working properly.

•

Fasten the seat belt securely.

•

Warm up the engine and hydraulic oil before

operating machine.

•

Before moving the machine, check the position of

undercarriage. The normal travel position is with

idler wheels to the front under the cabin and the

drive sprockets to the rear. When the

undercarriage is in the reversed position, the travel

controls must be operated in opposite directions.

Safety

OP000481

1-28

MACHINE OPERATION

When Swinging or Changing Direction

of Travel

Before operating the machine or the work equipment, always

observe the following precautions to prevent serious injury or

death.

•

Start and operate the machine only while seated.

•

When changing the direction of travel from

forward to reverse or from reverse to forward,

reduce speed early and stop the machine before

HAOA190L

changing the direction of travel.

Figure 17

•

Sound the horn to warn people in the area.

•

Check that there is no one in the area around the

machine. There are blind spots behind the

machine, so if necessary, swing the upper

structure to check that there is no one behind the

machine before traveling in reverse.

•

When operating in areas that may be hazardous

or have poor visibility, designate a person to

direct work site traffic.

•

Ensure that no unauthorized person can come

within the turning radius or direction of travel.

Be sure to observe the above precautions even if a travel

alarm or mirrors are installed.

OP000481

Safety

1-29

Travel Precautions

TRAVEL POSTURE

Never turn the starting switch to the "O" (OFF) position

when traveling. It is dangerous if the engine stops when the

machine is traveling. It will be impossible to operate the

steering.

Attachment control levers should not be operated while

traveling.

Do not change selected travel mode (FAST/SLOW) while

traveling.

40~50cm (16~20 in)

Fold in work equipment so that the outer end of the boom

is as close to the machine as possible, and is 40 - 50 cm

INCORRECT

(16 - 20 in) above ground.

Never travel over obstacles or slopes that will cause the

machine to tilt severely. Travel around any slope or obstacle

that causes the machine to tilt 10 degrees or more to the

right or left, or 30 degrees or more from front to rear.

Do not operate the steering suddenly. The work equipment

may hit the ground and cause the machine to lose its

balance, and this may damage the machine or structures in

FG006902

the area.

Figure 18

When traveling on rough ground, travel at low speed, and

avoid sudden changes in direction.

Always keep to the permissible water depth. Permissible

water depth is to the center line of the upper track rollers.

When traveling over bridges or structures on private land,

check first that the bridge or structure can withstand the

weight of the machine. When traveling on public roads,

check with the local authorities and follow their instructions.

Safety

OP000481

1-30

Traveling on Slopes

Never jump onto a machine that is running away to stop it.

There is danger of serious injury.

Traveling on slopes could result in the machine tipping over

or slipping.

On hills, banks or slopes, carry the bucket approximately 20

30 cm

12 in) above the ground. In case of an

emergency, quickly lower the bucket to the ground to help

stop the machine.

Do not travel on grass, fallen leaves, or wet steel plates.

Even slight slopes may cause the machine to slip to the

side, so travel at low speed and make sure that the

machine is always traveling directly up or down the slope.

Avoid changing the direction of travel on a slope. This could

result in tipping or side slipping of the machine.

When possible, operate the machine up slopes and down

slopes. Avoid operating the machine across the slope, when

possible.

FG006903

Figure 19

Prohibited Operations

Do not dig the work face under an overhang. This may

cause the overhang to collapse and fall on top of the

machine.

FG006904

Figure 20

OP000481

Safety

1-31

Do not carry out deep digging under the front of the

machine. The ground under the machine may collapse and

cause the machine to fall.

Working heavy loads over loose, soft ground or uneven,

broken terrain can cause dangerous side load conditions

and possible tipover and injury. Travel without a load or a

balanced load may also be hazardous.

Never relay on lift jacks or other inadequate supports when

work is being done. Block tracks fore and aft to prevent any

movement.

FG006905

Figure 21

When using the machine, to prevent accidents caused by

damage to the work equipment and overturning because of

an excessive load, do not use the machine in excess of its

ability (in terms of the maximum load and stability

determined by the structure of the machine).

When working at the edge of an excavation or on a road

shoulder, the machine could tip over, possibly resulting in

serious injury or death. Investigate the configuration and

ground conditions of the work site beforehand to prevent the

machine from falling and to prevent the ground, stockpiles,

or banks from collapsing.

FG006906

Figure 22

Precautions for Operation

Be careful not to go close to the edge of a cliff by mistake.

Use the machine only for its main purpose. Using it for

other purposes will cause failures.

To ensure an ample view, do as follows:

•

When working in dark areas, attach working lights

and front lights to the machine. If necessary, set

up lighting at the work site.

•

Stop operations when the visibility is poor, such

as in fog, mist, snow, and rain. Wait for the

visibility to improve to a level which causes no

problems for the operation.

To avoid hitting the work equipment, always do the following;

•

When working in tunnels, on bridges, under

electric wires, or when parking the machine or

carrying out other operations in places with limited

height, be extremely careful not to hit the bucket

or other parts.

•

To prevent collisions, operate the machine at a

safe speed when working in confined spaces,

indoors, or in crowded areas.

•

Do not pass the bucket over the heads of workers

FG000430

or over the operator's compartment of dump truck.

Figure 23

Safety

OP000481

1-32

Avoid High Voltage Cables

Serious injury or death can result from contact or proximity to

high voltage electric lines. The bucket does not have to make

physical contact with power lines for current to be transmitted.

Use a spotter and hand signals to stay away from power

lines not clearly visible to the operator.

Voltage

Minimum Safe Distance

6.6 kV

3 m (9' 10")

FG006907

33.0 kV

4 m (13' 1")

Figure 24

66.0 kV

5 m (16' 5")

154.0 kV

8 m (26' 3")

275.0 kV

10 m (32' 10")

Use these minimum distances as a guideline only.

Depending upon the voltage in the line and atmospheric

conditions, strong current shocks can occur with the boom

or bucket as far away as 4 - 6 m (13 - 20 ft.) from the

power line. Very high voltage and rainy weather could

further decrease that safety margin.

NOTE:

Before starting any type of operation near power lines

(either above ground or buried cable type), you

should always contact the power utility directly and

work out a safety plan with them.

Protecting Cabin from Falling Object

(Optional)

In a work site where falling objects or flying objects are

expected, be sure to install adequate protective devices for

covering the cabin.

When using a breaker, be sure to install the front window

protection guard (Figure 25).

FG000112

Figure 25

OP000481

Safety

1-33

In a work site where falling rocks can cause damage and

possibly crush personnel, or in a mining operation, be sure

to install the falling object protective structure (Figure 26).

Be sure to install any other additional protective structures

required for work site conditions.

When the falling object protective structure is installed, and

the front window needs to be cleaned, loosen the bolts

marked with an arrow. Be sure to tighten bolts when done.

Operate Carefully on Snow, Ice and in

Very Cold Temperatures

In icy cold weather avoid sudden travel movements and stay

away from even slight slopes. The machine could skid off to

one side very easily.

Snow accumulation could hide or obscure potential hazards.

Use care while operating or while using the machine to

FG000113

clear snow.

Figure 26

Warming up the engine for a short period may be

necessary, to avoid operating with sluggish or reduced

working capacity. The jolting shocks and impact loads

caused by bumping or bottoming the boom or attachment

are more likely to cause severe stress in very cold

temperatures. Reducing work cycle rate and work load may

be necessary.

When the temperature rises, frozen road surfaces become

soft, so the machine travel becomes unstable.

In cold weather, do not touch metal surfaces with your bare

hands. If you touch a metal surface in extremely cold

weather, your skin may freeze to the metal surface.

Operations on Slopes

When working on slopes. there is danger that the machine

may lose its balance and turn over, when swinging, or when

work equipment is operated. Always carry out these

operations carefully.

Do not swing the work equipment from the uphill side to the

downhill side when the bucket is loaded. This operation is

dangerous.

If the machine has to be used on a slope, pile the soil to

FG006908

make a platform that will keep the machine as horizontal as

Figure 27

possible.

In addition, lower the bucket as far as possible, keep it

pulled into the front, and keep the swing speed as low as

possible.

Safety

OP000481

1-34

Parking Machine

Avoid making sudden stops, or parking the machine

wherever it happens to be at the end of the work day. Plan

120

ahead so that the excavator will be on firm, level ground

away from traffic and away from high walls, cliff edges and

any area of potential water accumulation or runoff. If parking

Block

on inclines is unavoidable, block the crawler tracks to

prevent movement. Lower the bucket or other working

attachment completely to the ground, or to an overnight

support saddle. There should be no possibility of unintended

or accidental movement.

Unlock

When parking on public roads, provide fences, signs, flags,

or lights, and put up any other necessary signs to ensure

that passing traffic can see the machine clearly, and park

the machine so that the machine, flags, and fences do not

obstruct traffic.

Lock

FG006909

After the front attachment has been lowered to an overnight

Figure 28

storage position and all switches and operating controls are

in the "OFF" position, the safety lock lever must be set to

the "LOCKED" position. This will disable all pilot circuit

control functions.

Always close the door of the operator's compartment.

Never Let Anyone Ride on Attachment

Never let anyone ride on any work attachment, such as the

bucket, crusher, grapple, or clamshell (grab bucket). There is

a danger of the person falling and suffering serious injury.

ARO1310L

Figure 29

OP000481

Safety

1-35

MAINTENANCE

Warning Tag

Alert others that service or maintenance is being performed

and tag operator's cabin controls - and other machine areas

if required - with a warning notice. OSHA mandated control

WARNING

lever lockout can be made with any OSHA certified lockout

DO NOT OPERATE

device and a length of chain or cable to keep the safety

lever in the fully lowered, nonactive position.

when performing inspection

or maintenance

Warning tags, for controls are available from DOOSAN

190-00695

distributors.

ARO1320L

Figure 30

Clean Before Inspection or Maintenance

Clean the machine before carrying out inspection and

maintenance. This prevents dirt from getting into the

machine and also ensures safety during maintenance.

If inspection and maintenance are carried out when the

machine is dirty, it will become more difficult to locate the

problems, and also there is danger that you may get dirt or

mud in your eyes or that you may slip and injure yourself.

When washing the machine, do the following;

•

Wear shoes with nonslip soles to prevent yourself

from slipping and falling on wet places.

•

Wear safety glasses and protective clothing when

washing the machine with high-pressure steam.

•

Take action to prevent touching high-pressure

water and cutting your skin or having mud fly into

your eyes.

ARO1330L

Figure 31

•

Do not spray water directly on electrical

components (sensors, connector). If water gets

into the electrical system, there is danger that it

will cause defective operation and malfunction.

Pick up any tools or hammers that are laying in the work

place, wipe up any grease or oil or any other slippery

substances, and clean the area to make it possible to carry

out the operation in safety. If the work place is left untidy,

you may trip or slip and suffer injury.

Safety

OP000481

1-36

Proper Tools

Use only tools suited to the task. Using damaged, low

qualify, faulty, or makeshift tools could cause personal injury.

There is danger that pieces from, chisels with crushed

heads, or hammers, may get into your eyes and cause

blindness.

HDO1037L

Figure 32

Use of Lighting

When checking fuel, oil, battery electrolyte, or window

washing fluid, always use lighting with antiexplosion

specifications. If such lighting equipment is not used, there

is danger of an explosion.

If work is carried out in dark places without using lighting, it

may lead to injury, so always use proper lighting.

Even if the place is dark, never use a lighter or flame

instead of lighting. There is danger of fire. There is also

HDO1040L

danger that the battery gas may catch fire and cause and

Figure 33

explosion.

Fire Prevention and Explosion

Prevention

All fuels, most lubricants and some coolant mixtures are

flammable. Leaking fuel or fuel that is spilled onto hot

surfaces or onto electrical components can cause a fire.

Store all fuels and all lubricants in properly marked

containers and away from all unauthorized persons.

Store oily rags and other flammable material in a protective

container.

HDO1015I

Figure 34

Do not smoke while you refuel the machine or while you are

in a refueling area.

Do not smoke in battery charging areas or in areas the

contain flammable material.

Clean all electrical connections and tighten all electrical

connections. Check the electrical wires daily for wires that

are loose of frayed. Tighten all lose electrical wires before

you operate the machine. Repair all frayed electrical wires

before you operate the machine.

Remove all flammable materials before they accumulate on

the machine.

OP000481

Safety

1-37

Do not weld on pipes or on tubes that contain flammable

fluids. Do not flame cut on pipes or on tubes that contain

flammable fluids. Before you weld on pipes or on tubes or

before you flame cut on pipes or on tubes, clean the pipes

or tubes thoroughly with a nonflammable solvent.

Burn Prevention

When checking the radiator coolant level, shut down engine,

let the engine and radiator cool down, then check the

coolant recovery tank. If the coolant level in the coolant

recovery tank is near the upper limit, there is enough

coolant in the radiator.

Loosen the radiator cap gradually to release the internal

pressure before removing the radiator cap.

If the coolant level in the coolant recovery tank is below the

lower limit, add coolant.

Cooling system conditioner contains alkali. Alkali can cause

personal injury. Do not allow alkali to contact the skin, the

eyes, or the mouth.

Allow cooling system components to cool before you drain

the cooling system.

Hot oil and hot components can cause personal injury. Do

not allow hot oil or hot components to contact the skin.

Remove the hydraulic tank filter plug only after the engine

has been stopped. Make sure that the hydraulic tank filter

plug is cool before you remove it with your bare hand.

Remove the hydraulic tank filter plug slowly to relieve

pressure.

Relieve all pressure in the hydraulic oil system, in the fuel

system, or in the cooling system before you disconnect any

HAAE1980

lines, fittings, or related items.

Figure 35

Batteries give off flammable fumes that can explode.

Do not smoke while you are checking the battery electrolyte

levels.

Electrolyte is an acid. Electrolyte can cause personal injury.

Do not allow electrolyte to contact the skin or the eyes.

Always wear protective glasses when you work on batteries.

Safety

OP000481

1-38

Welding Repairs

CAUTION!

When you connect or disconnect connectors between

ECU and Engine or connector between ECU and the

machine, always disconnect the source power to protect

damage of the ECU.

If you don't observe this procedure, the ECU would be

damaged or the engine would operate abnormally.

When carrying out welding repairs, carry out the welding in

a properly equipped place. The welding should be performed

by a qualified worker. During welding operations, there is the

danger of, generation of gas, fire, or electric shock, so never

let an unqualified worker do welding.

The qualified welder must do the following;

•

To prevent explosion of the battery, disconnect

the battery terminals and remove batteries.

•

To prevent generation of gas, remove the paint

from the location of the weld.

•

If hydraulic equipment, piping or places close to

them are heated, a flammable gas or mist will be

generated and there is danger of it catching fire.

To avoid this, never subject these places to heat.

•

Do not weld on pipes or on tubes that contain

flammable fluids. Do not flame cut on pipes or on

tubes that contain flammable fluids. Before you

weld on pipes or on tubes or before you flame

cut on pipes or on tubes, clean the pipes or

tubes thoroughly with a nonflammable solvent.

•

If heat is applied directly to rubber hoses or

piping under pressure, they may suddenly break

so cover them with a fireproof covering.

•

Wear protective clothing.

•

Make sure there is good ventilation.

•

Remove all flammable objects and provide a fire

extinguisher.

OP000481

Safety

1-39

Treatment for Electrical Welding to the Body Structure

To prevent damage to ECU by electrical welding, please

observe the following procedures:

Open the door of the battery cover.

Detach the cover after loosening the bolts on the

battery.

Detach the positive and negative terminal cables from

the battery.

FG000312

Detach the undercover, and after that detach the

connector (1) from the ECU that are installed at the

Figure 36

engine.

Proceed with welding.

After welding, carefully reassemble the connector.

Connect the battery terminal cables.

Reassemble the undercover under the engine.

Reassemble the cover over the battery.

10. Close the cover of the battery.

FG000335

Figure 37

Warning for Counterweight and Front

Attachment Removal

DANGER!

DOOSAN warns any user, that the removal of the

counterweight from the machine, front attachment or

any other part, may affect the stability of the machine.

This could cause unexpected movement, resulting in

death or serious injuries. DOOSAN is not liable for any

misuse.

Never remove the counterweight or front attachment

unless the upper structure is in-line with the lower

FG006910

structure.

Figure 38

Never rotate the upper structure once the counterweight

or front attachment has been removed.

Safety

OP000481

1-40

Precautions for Removal, Installation,

and Storage of Attachments

Before starting removal and installation of attachments,

decide the team leader.

Do not allow anyone except the authorized workers close to

the machine or attachment.

Place attachments that have been removed from the

machine in a safe place so that they do not fall. Put up a

fence around the attachments and take other measures to

HDO1041L

prevent unauthorized persons from entering.

Figure 39

Precautions When Working on Machine

When carrying out maintenance operations on the machine,

keep the area around your feet clean and tidy to prevent

you from falling. Always do the following;

•

Do not spill oil or grease.

•

Do not leave tools laying about.

•

Watch your step when walking.

Never jump down from the machine. When getting on or off

ARO1380L

the machine, use the steps and handrails, and maintain a

Figure 40

three-point contact (both feet and one hand or both hands

and one foot) to support yourself securely.

If the job requires it, wear protective clothing.

To prevent injury from slipping or falling, when working on

the hood or covers, never use any part except the

inspection passage fitted with nonslip pads.

Lock Inspection Covers

When carrying out maintenance with the inspection cover

open, lock the cover securely in position with the lock bar.

If maintenance work is carried out with the inspection cover

open but not locked, there is danger that it may suddenly

close and cause injury if there is a gust of wind.

Crushing Prevention and Cutting

Prevention

You should always have at least two people working

together if the engine must be run during service. One

person needs to remain in the operator's seat, ready to work

the controls or stop the machine and shut off the engine.

OP000481

Safety

1-41

Unless you are instructed otherwise, never attempt

adjustments while the machine is moving or while the

engine is running.

Stay clear of all rotating parts and moving parts.

Keep objects away from moving fan blades. The fan blades

will throw objects and the fan blades can cut objects.

Do not use a wire rope cable that is kinked or flayed. Wear

gloves when you handle a wire rope cable.

When you strike a retainer pin, the retainer pin might fly out.

The loose retainer pin can injure personnel. Make sure that

the area is clear of people when you strike a retainer pin.

To avoid injury to your eyes, wear protective glasses when

you strike a retainer pin.

Track Tension Adjustments Require

Caution

Never turn out the track tension grease fitting nut. To

release pressure from the crawler frame track tension

assembly, you should NEVER attempt to disassemble the

track adjuster or attempt to remove the grease fitting or

valve assembly.

Keep your face and body away from the valve. Refer to the

track adjustment procedure in the Operator and Maintenance

HAOA110L

Manual or Shop Manual.

Figure 41

Supports and Blocking for Work

Equipment

Do not allow weight or equipment loads to remain

suspended.

Lower everything to the ground before leaving the operator's

seat.

Do not use hollow, cracked or unsteady wobbling supports.

Do not work under any equipment supported only by a lifting

HDO1042L

jack.

Figure 42

Action When Abnormality Is Found

During Inspection

If any abnormality is found during inspection, always carry

out repairs. In particular, if the machine is used when there

are still problems with the brake or work equipment systems,

it may lead to serious injury.

If necessary depending on the type of failure, please contact

your DOOSAN distributor for repairs.

Safety

OP000481

1-42

Precautions with High-pressure Lines,

Tubes and Hoses

When inspecting or replacing high-pressure piping or hoses,

check that the pressure has been released from the circuit.

Failure to release the pressure may lead to serious injury.

Always do the following;

•

Wear protective glasses and leather gloves.

•

Fluid leaks from hydraulic hoses or pressurized

components can be difficult to see but pressurized

oil has enough force to pierce the skin and cause

serious injury. Always use a piece of wood or

cardboard to check for suspected hydraulic leaks.

Never use your hands or expose your fingers.

•

Do not bend high-pressure lines. Do not strike

high-pressure lines. Do not install lines, tubes or

hoses that are bent or damaged.

•

Make sure that all clamps, guards and heat

shields are installed correctly to prevent vibration,

rubbing against other parts, and excessive heat

during operation.

HDO1045I

If any of the following conditions are found,

Figure 43

replace the part.

Damage or leakage from hose end.

–

Wear, damage, cutting of covering, or

exposure of strengthening wire layer.

Cover portion is swollen in places.

–

There is twisting or crushing at movable

parts of hose.

Foreign material is embedded in the

covering.

Hose end is deformed.

NOTE:

Refer to “Hose In-service Lifetime Limit

(European

Standard

ISO 8331

and

EN982 CEN)”

on page 4-58, for additional

European regulations.

OP000481

Safety

1-43

Waste Materials

Physical contact with used motor oil may pose a health risk.

Wipe oil from your hands promptly and wash off any

remaining residue.

Used motor oil is an environmental contaminant and may

only be disposed of at approved collection facilities. To

prevent pollution of the environment, always do the

following;

•

Never dump waste oil in a sewer system, rivers,

HAOA470L

etc.

Figure 44

•

Always put oil drained from your machine in

containers. Never drain oil directly onto the

ground.

•

Obey appropriate laws and regulations when

disposing of harmful materials such as oil, fuel,

solvent, filters, and batteries.

Safety

OP000481

1-44

BATTERY

Battery Hazard Prevention

Battery electrolyte contains diluted sulfuric acid and batteries

generate hydrogen gas. Hydrogen gas is highly explosive,

and mistakes in handling them can cause serious injury or

fire. To prevent problems, always do the following;

•

Do not smoke or bring any flame near the battery.

•

When working with batteries, ALWAYS wear

safety glasses and rubber gloves.

•

If you spill battery electrolyte on yourself or your

clothes, immediately flush the area with water.

•

If battery electrolyte gets into your eyes, flush

them immediately with large quantities of water

and see a doctor at once.

•

If you accidentally drink battery electrolyte, drink a

large quantity of water or milk, raw egg or

vegetable oil. Call a doctor or poison prevention

center immediately.

•

When cleaning the top surface of the battery,

wipe it with a clean, damp cloth. Never use

gasoline, thinner, or any other organic solvent or

detergent.

•

Tighten the battery caps securely.

•

If the battery electrolyte is frozen, do not charge

the battery or start the engine with power from

another source. There is danger that the battery

may catch fire.

Figure 45

•

When charging the battery or starting with power

from another source, let the battery electrolyte

melt and check that there is no leakage of battery

electrolyte before starting the operation.

•

Always remove the battery from the machine

before charging.

OP000481

Safety

1-45

Boost Starting or Charging Engine

Batteries

If any mistake is made in the method of connecting the

booster cables, it may cause an explosion or fire. Always do

the following;

•

Turn off all electrical equipment before connecting

leads to the battery. This includes electrical

switches on the battery charger or boost starting

equipment.

HAOA310L

•

When boost starting from another machine or

Figure 46

vehicle do not allow the two machines to touch.

Wear safety glasses or goggles while required

battery connections are made.

•

24 volt battery units consisting of two series

connected twelve volt batteries have a cable

connecting one positive terminal on one of the 12

volt batteries to a negative terminal on the other

battery. Booster or charger cable connections

must be made between the nonseries connected

positive terminals and between the negative

terminal of the booster battery and the metal

frame of the machine being boosted or charged.

Refer to the procedure and illustration in “Starting

Engine With a Booster Cable” on page 3-7 of this

manual.

•

Connect positive cable first when installing cables

and disconnect the negative cable first when

removing them. The final cable connection, at the

metal frame of the machine being charged or

boost started, should be as far away from the

batteries as possible.

Safety

OP000481

1-46

TOWING

Precautions When Towing

Cloth

If any mistake is made in the method of selecting or

inspecting the towing wire or in the method of towing, it may

lead to serious personal injury. Always do the following;

•

Always use the method of towing given in this

Operation and Maintenance Manual. Do not use

any other method.

Towing Wire

•

Use leather gloves when handling the wire rope.

•

When carrying out the preparation work for towing

with two or more workers, determine the signals

to use and follow these signals correctly.

•

Always fit the towing rope to the left and right

hooks and secure in position.

Shackle

•

If the engine on the problem machine will not

start or there is a failure in the brake system.

always contact your DOOSAN distributor.

Towing Wire_FG000669

•

Never go between the towing machine and the

towed machine during the towing operation.

Figure 47

•

It is dangerous to carry out towing on slopes, so

select a place where the slope is gradual. If there

is no place where the slope is gradual, carry out

operations to reduce the angle of the slope before

starting the towing operation.

•

When towing a problem machine, always use a

wire rope with a sufficient towing capacity.

•

Do not use a frayed, kinked rope or a rope with

any loss of diameter.

•

Do not use the lightweight towing hook for towing

another machine.

OP000481

Safety

1-47

SHIPPING AND

TRANSPORTATION

Obey State and Local Over-the-Road

Regulations

Check state and local restrictions regarding weight, width

and length of a load before making any other preparation for

transport.

The hauling vehicle, trailer and load must all be in

compliance with local regulations governing the intended

shipping route.

Partial disassembly or teardown of the excavator may be

necessary to meet travel restrictions or particular conditions

at the work site. See the Shop Manual for information on

partial disassembly.

Refer to the Transportation and Shipping section of this

Operation and Maintenance Manual for information on

loading, unloading and towing.

Safety

OP000481

1-48

EXCAVATOR RATED LIFT

CAPACITY TABLES

WARNING!

Let everybody be away from the boom cylinder. While

lifting operation, boom, arm, bucket hoses might burst

and then high-pressure oil will be ejected at high speed.

If that failure mode takes place, handling weight or front

structure might fall by its gravity to the ground to cause

fatal injury to the person.

When changing the hoses record the part numbers of

the hoses to factory log book.

Figure 48

Do the service job under the company's serviceman.

WARNING!

All rated lift capacities are based on the machine and

the load both remaining level at all times. DO NOT

EXCEED THE RATED LIFT CAPACITY. Lifting loads

greater than those shown in the rated capacity tables

can cause catastrophic equipment failure and/or

structural collapse of the machine.

To operate safely the excavator should be on a firm, level

and uniformly supporting surface. The operator is expected

to make due allowance for all specific work site and lift

related conditions, and respond to changes in those

conditions that could pose a hazard. The following could all

cause hazardous conditions and accidents or injuries:

•

Soft or uneven ground.

•

Unlevel terrain.

•

Side loads.

•

Modifications or poor maintenance of the excavator.

•

Failure to lift squarely over the end or over the

side of the machine.

When a load is in the air, the operator must remain alert.

•

Avoid side loads that may be caused by uneven

slings, traveling with the load or swinging too

quickly.

•

The load can become unbalanced if the hook line

is twisted and starts to rotate. If the surface area

of the load is large enough, wind gusts can

create side loads.

OP000481

Safety

1-49

•

Keep the bucket hook point directly over the load.

Tag lines on opposite sides of the load can help

maintain greater stability against side loads and

wind gusts.

Avoid traveling with a suspended load. Before swinging (or if

required, traveling), bring the load into an arm position

(radius and height) that has a safer weight capacity rating

and adequate movement clearance. The operator and all

work site personnel should be thoroughly familiar with safety

instructions and procedures within this Operation and

Maintenance Manual.

The following weight loads are in compliance with SAE

(J1097) and ISO applicable, recommended standards for

hydraulic excavators performing lifting operation on a firm

supporting surface. An asterisk

(*) next to the lift rating

indicates rated load does not exceed

87% of hydraulic

capacity. All other ratings have been determined not to

exceed 75% of tipping capacity.

Do not attempt to lift or hold any load that exceeds rated

load capacity at the specified distances (from the machine's

rotation center line and height - see "lift radius" and "lift

height" in the reference drawing, Figure 49).

Lifting Radius

Centerline

of Rotation

Lifting

Point

Lifting

Point

Height

Ground Line (Machine Supporting Surface)

FG006911

Figure 49

The weight of slings and any auxiliary lifting device (and/or

the weight difference of any attachment heavier than

standard configuration) must be deducted from the rated lift

capacity to determine allowable net lifting load. The lift point

should be on the back of the bucket, as shown in Figure 49.

Safety

OP000481

1-50

TRACK WIDTH

3.2 m (10' 6") STD TRACK

BOOM

5.9 m (19' 5")

ARM

3 m (9' 10")

BUCKET

SAE 1.1 m³ (CECE 0.95 m³)

SHOE

600mm (24'')

RATING OVER FRONT

RATING OVER SIDE OR 360 degree

UNIT

1,000 kg (1,000 lb)

METRIC

A(m)

MAX. REACH

A(m)

B(m)

3.86

6.46

4.50

3.78

7.29

5.10

5.03

3.79

7.90

5.56

5.36

4.96

4.97

3.95

3.87

3.66

8.35

6.91

6.22

.77

4.86

5.48

3.90

4.01

3.40

8.66

14.39

10.14

8.13

8.02

6.98

6.04

6.25

4.74

5.78

3.83

4.21

3.23

8.85

6.79

12.12

10.93

9.33

7.73

7.75

5.86

6.76

4.63

5.71

3.75

4.48

3.15

8.91

5.90

13.53

10.55

10.32

7.48

8.42

5.70

.95

4.52

5.64

3.69

4.81

3.14

8.87

0 (GROUND)

3.58

7.22

14.27

10.35

10.98

7.32

8.73

5.58

6.86

4.44

5.58

3.64

4.91

3.20

8.70

-1

6.23

9.35

14.46

10.27

11.29

7.23

8.65

5.51

6.80

4.39

5.55

3.61

5.15

3.35

8.42

-2

8.80

12.04

14.20

10.27

11.25

7.21

8.62

5.48

.78

4.37

5.56

3.61

8.00

-3

11.63

15.40

13.51

10.33

10.83

7.24

8.64

5.50

6.81

4.40

6.25

4.05

7.42

-4

14.97

15.66

12.31

10.46

9.94

7.32

8.10

5.57

7.04

4.83

6.63

-5

13.01

10.36

8.30

7.48

7.22

6.39

5.56

FEET

10'

15'

20'

25'

MAX. REACH

A (ft)

B (ft)

A (ft)

8.42

22' 4"

9.84

9.57

8.35

25' 9"

12.76

11.89

9.41

8.65

7.79

27' 11"

30.61

19.33

15.12

13.01

13.04

9.14

9.25

7.14

29' 0"

13.94

24.06

19.20

17.55

12.43

13.51

8.85

10.25

6.91

29' 3"

0 (GROUND)

16.48

26.88

18.50

18.78

12.02

13.26

8.63

10.83

7.05

28' 7"

-5

24.06

27.50

18.26

18.55

11.82

13.15

8.53

11.76

7.65

26' 11"

-10

34.96

26.08

18.35

18.59

11.85

13.88

9.00

24' 3"

-15

31.09

22.04

18.74

15.79

12.27

19' 11"

1. LOAD POINT IS THE HOOK ON THE BACK OF THE BUCKET.

* RATED LOADS ARE BASED ON HYDRAULIC CAPACITY.

3. RATED LOADS DO NOT EXCEED 87 % OF HYD. CAPACITY OR 75 % OF TIPPING CAPACITY.

FG006912

Safety

OP000481

1-52

Doosan DX255LC. Operation and Maintenance Manual (2006) - page 1