Doosan DX255LC. Operation and Maintenance Manual (2006)

OPERATION UNDER UNUSUAL

CONDITIONS

NOTE:

See “Maintenance in Special Conditions” on

page 4-86 for other recommendations.

Operation In Extreme Cold

If machine is to be operated in extreme cold weather

temperatures, certain precautions must be taken to assure

continued normal operation. The following paragraphs detail

checks to be made to be certain the machine is capable of

operating at these temperatures.

Check the cooling system for correct antifreeze solution

for lowest temperature expected. Carefully inspect

cooling system and correct or report any leaks.

Keep batteries fully charged to prevent freezing. If

water is added to batteries, run engine at least one

hour to mix electrolyte solution.

Keep engine in best possible mechanical condition to

assure easy starting and good performance during

adverse weather conditions.

Use engine oil of the proper specifications for the

expected temperatures. Refer to the "Lubrication

Specifications" of the engine manual for details.

Keep fuel tank full at all times. Drain condensation

from tank before and after operation. Drain and service

fuel filter. To eliminate clogging of fuel filters due to

wax crystal formation in the fuel, be sure that the fuel

used has a cloud point specification below the lowest

expected temperature.

Lubricate entire machine according to "Periodic Service

Table and Chart" Section

4, in this manual or

lubrication chart on machine.

Start engine and allow it to reach normal operating

temperature before applying load.

If mud and ice collects and freezes on any of the

moving parts while machine is idle, apply heat to

thaw the frozen material before attempting to

operate machine.

Operate hydraulic units with care until they have

reached a temperature to enable them to operate

normally.

Check all machine controls and/or functions to be

sure they are operating correctly.

An extra outer air filter should be kept in the operator's

cabin to replace element that could become iced and

cause restricted air flow to engine.

OP000483

Operation

3-43

If cold weather starting aid must be used, see "Engine

Starting" COLD WEATHER START portion of this manual.

10. Clean off all mud, snow and ice to prevent freezing.

Cover machine with tarpaulin if possible, keep ends of

tarpaulin from freezing to ground.

Operation in Extreme Heat

Continuous operation of the machine in high temperatures

may cause the machine to overheat. Monitor engine and

transmission temperatures and stop machine for a cooling-off

period whenever necessary.

Make frequent inspections and services of the fan and

radiator. Check coolant level in radiator. Check grills

and radiator fins for accumulation of dust, sand and

insects which could block the cooling passages.

Formation of scale and rust in cooling system

occurs

more rapidly in extremely

high

temperatures. Change antifreeze each year to

keep corrosion inhibitor at full strength.

If necessary, flush cooling system periodically to

keep passage clear. Avoid use of water with a

high alkali content which increases scale and rust

formation.

Check level of battery electrolyte daily. Keep electrolyte

above plates preventing damage to batteries. Use a

slightly weaker electrolyte solution in hot climates.

Dilute 1.28 specific gravity electrolyte as issued to 1.20

- 1.24 specific gravity readings at full charge. Recharge

batteries whenever they reach a 1.16 specific gravity

reading. Batteries self-discharge at a higher rate if left

standing for long periods at high temperatures. If

machine is to stand for several days, remove batteries

and store in a cool place.

WARNING!

Do not store acid type storage batteries near stacks of

tires; the acid fumes have a harmful affect on rubber.

Service fuel system as directed in "Engine Fuel

System" Section

5, of this manual. Check for water

content before filling fuel tank. High temperatures and

cooling off cause condensation in storage drums.

Lubricate as specified in "Periodic Service Chart and

Table" Section 4, in this manual or Lubrication Decal

on the machine.

Do not park machine in sun for long periods of time.

When practical park machine under cover to protect it

from sun, dirt and dust.

Operation

OP000483

3-44

Cover inactive machine with tarpaulin if no suitable

shelter is available. Protect engine compartment,

transmission and hydraulics from entrance of dust.

In hot, damp, climates corrosive action will occur

on all parts of the machine and will be accelerated

during the rainy season. Rust and paint blisters will

appear on metal surfaces and fungus growth on

other surfaces.

Protect all unfinished, exposed surfaces with a

film of preservative lubricating oil. Protect cables

and terminals with ignition insulation compound.

Apply paint or suitable rust preventive to damaged

surfaces to protect them from rust and corrosion.

Operation in Dusty or Sandy Areas

Operation of the machine can cause dust in almost any

area. However, when in predominantly dusty or sandy areas,

additional precautions must be taken.

Keep cooling system fins and cooling areas clean. Blow

out with compressed air, if possible, as often as necessary.

WARNING!

Wear goggles when using compressed air.

Use care when servicing fuel system to prevent dust

and sand from entering the tank.

Service the air cleaner at frequent intervals, check air

restriction indicator daily and keep dust cup and dust

valve clean. Prevent dust and sand from entering

engine parts and compartments as much as possible.

Lubricate and perform services outlined on current

lubrication chart on machine and "Lubrication Chart and

Table" Section

4. Clean all lubrication fittings before

applying lubricant. Sand mixed with lubricant becomes

very abrasive and speeds wear on parts.

Protect machine from dust and sand as much as

possible. Park machine under cover or protect with

tarpaulin to keep dust and sand from damaging unit.

Operation in Rainy or Humid Conditions

Operation under rainy conditions is similar to that as in

extreme heat procedures listed previously.

Keep all exposed surfaces coated with preservative

lubricating oil. Pay particular attention to damaged or

unpainted surfaces. Cover all paint cracks and chip

marks as soon as possible to prevent corrosive effects.

OP000483

Operation

3-45

Operation in Salt Water Areas

The corrosive effect of salt water and salt water spray is

very extensive. When operating in salt water areas, observe

the following precautions.

When exposed to salt water, dry machine thoroughly

and rinse with fresh water as soon as possible.

Keep all exposed surfaces coated with preservative

lubricating oil. Pay particular attention to damaged paint

surfaces.

Keep all painted surfaces in good repair.

Lubricate machine as prescribed on lubrication chart on

machine or "Periodic Service Table and Chart" Section

4, in this manual. Shorten lubricating intervals for parts

subject to exposure to salt water, if found necessary.

Operation at High Altitudes

Normally, operation of machine at high altitudes will be as

outlined in extreme cold. Before operating at high altitudes,

engine fuel and air mixture may have to be adjusted

according to appropriate engine manual.

Check engine operating temperature for evidence of

overheating. The pressure cap on radiator must make

a perfect seal to maintain coolant pressure in the

system.

Operation

OP000483

3-46

OP000484

4Inspection, Maintenance

and Adjustment

PREVENTIVE MAINTENANCE

Routine maintenance and inspections are required to keep

your machine in the correct operating condition. The

following pages list the inspection intervals, the system or

component checks, and location references.

NOTE:

The following pages list the service checks and their

required intervals. The service cycles may need to be

shortened depending on the working conditions.

Extremely hot or dusty conditions will require more

frequent service. Operational hours are determined

by the amount of time accumulated on the engine

hour meter on the control console in the cabin.

HAOA601L

Figure 1

NOTE:

Besides the normal hour meter, the multifunction

gauge can be used to keep track of the hours on

CHECK

individual filters. See “Filter / Oil Info” on page 2-40.

02/05 [MO] 11:30

E/G SPEED

1700

RPM

POWER

AUTO

ESC

FG000037

Figure 2

OP000484

Inspection, Maintenance and Adjustment

4-1

Product Identification Number (P. I. N.)

Location

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

boom foot (Figure

3). It is also stamped on the product

identification plate (Figure

4) on outside of the cabin on

right.

NOTE:

Please make note of these numbers and their

locations. These will be required whenever warranty

or service work is requested. Keep this number on

FG001447

file, incase the machine is stolen.

Figure 3

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

Incheon, Korea

K1011647A

FG000764

Figure 4

Component Serial Numbers

There are many serial numbers on each traceable

components of the machine. For example, the engine serial

number is stamped on the rear left side of the engine block,

above the starter. Additional engine information is described

on a label (Figure 5) on the rocker cover.

Please make note of these numbers and their locations.

These will be required whenever warranty service work is

requested.

FG000664

Figure 5

Inspection, Maintenance and Adjustment

OP000484

4-2

Safety Precautions

Make sure to lock out the hydraulic controls and post a

notice (Warning Tag) that the machine is being

serviced to prevent any unauthorized operation.

Make sure to clean up any fluid spills, especially

around the engine.

Inspect all fuel lines to make sure that fittings, lines,

filters and O-rings, etc., are tight and are not showing

signs of wear or damage.

If the inspection or test procedure requires that the

engine be running, make sure to keep all unauthorized

personnel away from the machine, and that all industry

standard safety precautions are followed.

OP000484

Inspection, Maintenance and Adjustment

4-3

PRELIMINARY WORK MACHINE

SETUP FOR MAINTENANCE

When performing maintenance specified in this manual,

always park the excavator as follows.

NOTE:

Certain types of maintenance may require the

machine to be positioned differently. Always return

machine to this position.

Park on firm, level ground.

Lower bucket to ground.

FG006932

Figure 6

Set safety lever on "LOCK" position.

Unlock

lock

FG001091

Figure 7

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

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

heat surge may occur.

HAOB290L

Figure 8

Inspection, Maintenance and Adjustment

OP000484

4-4

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

Remove key from starter switch.

O I

WARNING!

engine must be run while performing

maintenance, use extreme care. Always have one

person in the cabin at all times. Never leave the

cabin with the engine running.

FG000175

Figure 9

Before starting maintenance work, hang up a tag, "Do

Not Touch When Performing Inspection or

Maintenance" on cabin door or work lever.

FG000401

Figure 10

OP000484

Inspection, Maintenance and Adjustment

4-5

TABLE OF RECOMMENDED

LUBRICANTS

NOTE:

Refer to the Maintenance Intervals Table for

application points.

Ambient Temperature

Kind of

Reservoir

-22

-4

104

122 °F

Fluid

-30

-20

-10

50 °C

SAE 10W-30

Engine Oil

* SAE 10W-40

Pan

Engine Oil

SAE 15W-40

Swing Drive

SAE 90 and API GL5

Case

Gear Oil

* SAE 80W-90 and API GL5

Final Drive

Case

SAE 140 and API GL5

ISO VG 32

***

Hydraulic

* ISO VG 46

Oil Tank

Oil

ISO VG 68

* ASTM D975 No. 2

Diesel

Fuel Tank

Fuel

ASTM D975 No. 1

Grease

* Multipurpose Lithium Grease NLGI No. 2

Fitting

Cooling

Add Antifreeze

Coolant

System

* (50% antifreeze - 50% distilled water)

Installed at factory.

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

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

brands of oil is used, guaranteed change interval is 1,000 hours.

API: American Petroleum Institute.

Inspection, Maintenance and Adjustment

OP000484

4-6

ACEA: Association des Constructeurs Europens d’Automobiles.

ASTM: American Society of Testing and Material.

ISO: International Standardization Organization.

NLGI: National Lubricating Grease Institute.

SAE: Society of Automotive Engineers.

IMPORTANT

Do not mix oils from different manufacturers. DOOSAN

does not endorse specific brands but does suggest that

owners select quality oils whose suppliers provide

assurance that required standards will always be met or

exceeded.

Fluctuating daily or weekly extremes of temperature, or

operation in subzero freezing weather may make it

impractical to use straight weight lubricants. Use good

judgement in selecting lubricant types that are

appropriate for climate conditions.

OP000484

Inspection, Maintenance and Adjustment

4-7

FLUID CAPACITIES

Component

Capacity

Engine

Oil Pan with Filter

27 liters

(7.1 U.S. gal.)

Cooling System

24 liters

(6.3 U.S. gal.)

Fuel Tank

410 liters

(108 U.S. gal.)

Hydraulic Oil

Tank Level

150 liters

(40 U.S. gal.)

System

240 liters

(63 U.S. gal.)

Travel Reduction Device (Each)

3.3 liters

(0.87 U.S. gal.)

Swing Device

7.3 liters

(1.93 U.S. gal.)

LUBRICATION AND SERVICE

CHART

Lubrication and service chart is on the inside of battery box

cover. The symbols shown here are used in the lubrication

and service chart on the next page.

Symbol

Description

Symbol

Description

Lubrication

Coolant

Gear Oil (Swing Device, Travel Device)

Air Cleaner Element

Engine Oil

Fuel Filter

Engine Oil Filter

Air Conditioner Filter

Hydraulic Oil

Drain Water

Hydraulic Oil Return Filter

Inspection, Maintenance and Adjustment

OP000484

4-8

SERVICE DATA

DX255LC

No.

Items to Check

Service

Qty.

Service Interval

250

500

1000

2000

Front Joint Pin (1)

Grease

F100

W10

Front Joint Pin (2)

Grease

F100

W10

Swing Bearing

Grease

W10

Swing Gear

Grease

Swing Reduction

Grease

W10

Gear

Gear Oil

Swing Device

5 L

(80W90)

Track Spring

Grease

W10

Travel Reduction

Gear Oil

2X3.3 L

F, V

Device

(80W90)

Engine Oil

27 L

(10W40)

Hydraulic Oil Tank

Hydraulic Oil

240 L

Fuel Tank

Diesel

410 L

Fuel Prefilter

Cartridge

Coolant

Radiator

30 L

(Antifreeze)

Hydraulic Oil

Element

Return Filter

Pilot Filter

Element

Hydraulic Oil

Strainer

Suction Strainer

Engine Oil Filter

Cartridge

Fuel Filter

Cartridge

Air Cleaner

Element

(Outer)

Air Cleaner

Element

(Inner)

Air Conditioner

Cartridge

Filter (Outer)

Air Conditioner

Cartridge

Filter (Inner)

V: Maintenance and Refill.

C: Cleaning.

F: First Time Exchange Only.

F100: Every 10 Hours For First 100 Hours.

W10: Every 10 Hours If Operating In Water.

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

“Engine Cooling System” on page 4-75, for further explanation.

: Replacement On Every Interval.

NOTE:

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

OP000484

Inspection, Maintenance and Adjustment

4-11

MAINTENANCE INTERVALS

SERVICE ITEM

PAGE

10 Hour / Daily Service

Grease Boom, Arm and Front Attachment Pins (for first 100 hours)

4-14

Check Engine Oil Level

4-14

Check Level of Hydraulic Oil Tank

4-15

Check for Leaks in Hydraulic System

4-16

Check Fuel Level

4-16

Check for Leaks in Fuel System

4-17

Check Fuel Prefilter and Drain Water As Required

4-18

Check Oil Level of Swing Reduction Device

4-19

Clean Dust Net in Front of Oil Cooler and Intercooler

4-20

Check Cooling System and Refill As Required

4-20

Check Level of Window Washer Liquid

4-21

Inspect the Bucket Teeth and Side Cutters for Signs of Wear

4-21

Inspect Cooling Fan Blade

4-22

Check Air Intake System

4-22

Inspect Seat Belt for Proper Operation

4-22

Inspect the Structure for Cracks and Faulty Welds

4-23

Check the Operation of All Switches

4-23

Check the Operation of All Exterior Lights, Horn and Control Console Indicator and

4-23

Monitor Lights

Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at

4-23

Normal Operating Temperature. Listen for Any Abnormal Sounds

Check Operation of All Controls

4-24

50 Hour / Weekly Service

Perform All Daily Service Checks

4-25

Grease Arm and Front Attachment Pins

4-25

Grease Swing Bearing

4-26

Drain Water and Sediment from Fuel Tank

4-27

Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)

4-27

Change Engine Oil and Filter (After First 50 Hours)

4-27

Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts

4-27

(Links, Shoes, Rollers, Idlers)

250 Hour / Monthly Service

Perform All Daily and 50 Hour Service Checks

4-28

Change Swing Reduction Device Oil (Drain and Refill After First 250 Hours)

4-28

Grease Arm and Front Attachment Pins

4-29

Check Engine Fan Belt Tension

4-31

Check Engine Fan Belt Wear

4-31

Check Oil Level in Travel Reduction Device (One on Each Side of Unit)

4-32

Change Breaker Filter Element (Optional)

4-33

Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 250 Hours)

4-33

Change Hydraulic Oil Return Filter (After First 250 Hours)

4-33

Change Pilot Filter (After First 250 Hours)

4-33

Inspection, Maintenance and Adjustment

OP000484

4-12

SERVICE ITEM

PAGE

Inspect Pins and Bushings of the Front End Attachments for Signs of Wear

4-34

Check Fluid Levels in Batteries and Battery Charge Levels

4-34

Inspect for Any Loose or Missing Nuts and Bolts

4-34

Inspect Fuel System Hose Clamps

4-34

500 Hour / 3 Month Service

Perform All Daily, 50 and 250 Hour Service Checks

4-35

Grease Swing Gear and Pinion

4-35

Change Engine Oil and Filter

4-36

Clean Air-Conditioning Outer Filter

4-37

Check and Clean Air-Conditioning Inner Filter

4-38

Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Core

4-39

Clean Outer Filter of Air Cleaner

4-40

Change of Fuel Prefilter

4-41

Change Fuel Filter

4-42

1,000 Hour / 6 Month service

Perform All Daily, 50, 250 and 500 Hour Service Checks

4-44

Grease Swing Reduction Device

4-44

Change Hydraulic Oil Return Filter

4-45

Change Pilot Filter

4-46

Change Oil in Travel Reduction Device (One on Each Side of Unit)

4-47

Change Air-Conditioning Outer Filter

4-48

Check Air Conditioner Refrigerant

4-49

Check and Adjust Engine **

4-50

2,000 Hour / Yearly Service

Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks

4-51

Change Swing Reduction Device Oil

4-51

Change Outer and Inner Air Cleaner Elements

4-52

Change Radiator Coolant

4-53

Hydraulic Oil Exchange and Suction Strainer Cleaning

4-54

Check Alternator and Starter**

4-56

Check All Rubber Antivibration Shock Mounts

4-56

Perform and Record the Results of the Cycle Time Tests

4-56

Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage

4-56

Check, Adjust Valve Clearance **

4-56

Check Head Bolt Torques

4-56

4,000 Hour / Biennial Service

Major Parts - Periodic Replacement

4-57

12,000 HOUR / SIX YEAR SERVICE

Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN)

4-58

** These checks need to be completed by an authorized DOOSAN dealer.

OP000484

Inspection, Maintenance and Adjustment

4-13

10 HOUR / DAILY SERVICE

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.

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.

Shut down engine and wait for fifteen minutes. This will

allow all oil to drain back to oil pan.

FG007006

Remove dipstick

(1, Figure

13) and wipe the oil off

Figure 13

with a clean cloth.

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

out again.

Inspection, Maintenance and Adjustment

OP000484

4-14

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.

FG000616

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

slowly to allow the pressurized air to vent. After the

ARO1760L

pressure has been released, it is safe to remove either

Figure 15

the fill cap or service covers.

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."

FG006941

Figure 16

Set safety lever to "LOCK" position.

Check level gauge by opening right access door. Oil

level must be between marks on sight gauge.

FG000118

Figure 17

OP000484

Inspection, Maintenance and Adjustment

4-15

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

Shut down engine.

The hydraulic tank is pressurized. Turn the

breather cap slowly to allow the pressurized air to

vent.

Remove the upper cover of the hydraulic tank and

add oil.

IMPORTANT

FG006942

Figure 18

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

Overfilling 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.

Shut down engine and wait for the hydraulic oil to

cool down.

Drain the excess oil from drain valve (Figure 19)

at the bottom of the tank into a suitable container,

using a hose connected to the valve.

NOTE:

Dispose of drained fluids according to local

regulations.

FG006943

Figure 19

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.

FG000130

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

Figure 20

through fuel fill tube (1, Figure 20). When working at a

temperature of 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.

Inspection, Maintenance and Adjustment

OP000484

4-16

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).

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

in the hydraulic pump compartment. Put the suction

hose of the pump into the fuel resupply tank. Turn the

switch in the pump compartment "ON," and the fuel will

be pumped into the excavator fuel tank.

NOTE:

See “Fuel Transfer Pump (Option)” on

page 4-77, for further information.

Do not overfill the tank.

Securely tighten cap after fueling.

NOTE:

If breather holes (3, Figure 21) 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

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.

OP000484

Inspection, Maintenance and Adjustment

4-17

Check Fuel Prefilter and Drain Water As

Required

A fuel prefilter is inside the left rear side access door.

Open the access door on left rear side of the machine.

FG006944

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

Inspection, Maintenance and Adjustment

OP000484

4-18

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.

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

the dipstick with a cloth.

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

FG006969

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.

FG006945

Figure 26

OP000484

Inspection, Maintenance and Adjustment

4-19

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.

FG006946

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 bolt(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.

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.

Inspection, Maintenance and Adjustment

OP000484

4-20

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 4-76)

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

FG006947

between "FULL" and "LOW" marks on tank.

Figure 28

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

this tank.

Check Level of Window Washer Liquid

Open left front access door and check fluid level in

windshield washer tank.

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.

FG008040

Figure 29

Inspect the 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'

buckets, refer to their specific instructions.

Figure 30

1. POINT, 2. ADAPTER and

3. PIN

OP000484

Inspection, Maintenance and Adjustment

4-21

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,

Figure 31

and for contact 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.

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 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

FG000421

found on air intake system.

Figure 33

Inspect Seat Belt for Proper Operation

Inspection, Maintenance and Adjustment

OP000484

4-22

Inspect the 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 the Operation of All Switches

Verify the working condition of all switches before

starting the engine.

Check the 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

OP000484

Inspection, Maintenance and Adjustment

4-23

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

OP000484

4-24

50 HOUR / WEEKLY SERVICE

Perform All Daily Service Checks

Grease Arm and Front Attachment Pins

Grease every

10 hours for first 100 hours and every

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,E

FG006949

Figure 34

Reference

Description

Number

Arm Link Joint Pin (1 Points)

Bucket Link Joint Pin (1 Point)

Link Joint Pin (2 Points)

Bucket Cylinder Rod Pin (1 Point)

Arm Bucket Joint Pin (1 Points)

OP000484

Inspection, Maintenance and Adjustment

4-25

Arm link joint pin (1 point)

Link joint pin (2 points)

Arm bucket joint pin (1 point)

Bucket link joint pin (1 point)

FG001438

Figure 35

Bucket cylinder rod pin (1 point)

FG001439

Figure 36

Grease Swing Bearing

Position the machine on firm, level ground. Lower the

front attachment to the ground and shut down engine.

There are three grease fittings for the swing bearing.

Do not over lubricate. Purge old grease with new.

Remove all purged grease.

FG006950

Figure 37

Inspection, Maintenance and Adjustment

OP000484

4-26

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

on the inside walls of the tank.

FG000296

Figure 38

Check Engine Fan Belt for Cracks, Wear

and Correct Tension (After First 50

Hours)

Inspect after first 50 hours of operation and every 250

hours thereafter. For details, See “Check Engine Fan

Belt Tension” on page 4-31.

Change Engine Oil and Filter (After First

50 Hours)

Change engine oil and filter after first

50 hours of

operation or rebuild, then every

500 thereafter. For

details, See “Change Engine Oil and Filter” on

page 4-36.

Inspect the Track Assemblies for Proper

Tension and Loose, Worn or Damaged

Parts (Links, Shoes, Rollers, Idlers)

Do a daily walk-around inspection of all components

including the track assemblies. Look for missing,

damaged or excessively worn parts. See “Track

Tension” on page 4-81.

Jack up each track and perform the two speed travel

motor test.

OP000484

Inspection, Maintenance and Adjustment

4-27

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

FG006951

Figure 39

Reference

Description

Number

Boom Cylinder Head Pin

Arm Cylinder Head Pin (1 Point)

(2 Points)

Boom Arm Joint Pin (2 Points)

Boom Foot Pin (2 Points)

Arm Cylinder Rod Pin (1 Point)

Boom Cylinder Rod Pin

Bucket Cylinder Head Pin

(2 Points)

(1 Point)

OP000484

Inspection, Maintenance and Adjustment

4-29

Check Engine Fan Belt Tension

FAN

10mm/10kg

COMPRESSOR

IMPORTANT

A loose fan belt can cause engine overheating, poor

ALTERNATOR

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

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

Figure 43

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

43. To adjust the belt, loosen the alternator adjustment

plate bolts, adjust the belt tension and retighten the

bolts.

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.

Figure 44

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.

OP000484

Inspection, Maintenance and Adjustment

4-31

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.

Check Oil Level in Travel Reduction

Device (One on Each Side of Unit)

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

FG006955

pressurized air to escape.

Figure 45

Make sure that the machine is on firm, level ground.

Rotate the track until ports (1 thru 3, Figure 45) are in

their proper positions as shown.

Loosen fill plug

(3, Figure

45) slightly to allow

pressurized air to escape.

Remove oil level plug (1, Figure 45).

Check oil level. The oil should be near the bottom of

the level plug opening.

Add oil through the fill plug (3, Figure 45) opening, if

necessary.

Clean and install oil level and fill plugs

(1 and

Figure 45).

Repeat this procedure on the other travel reduction

device.

Inspection, Maintenance and Adjustment

OP000484

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. Lower the

FG006956

front attachment to the ground and shut down engine.

Figure 46

Loosen the hydraulic oil tank breather cap to release

pressure.

Locate breaker filter assembly (Figure 46).

Position a container under the filter assembly. Remove

the drain plug and completely drain the assembly.

Using a 30 mm spanner, 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 Nm, 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 Oil in Travel Reduction Device

(One on Each Side of Unit) (After

First 250 Hours)

NOTE:

Drain and refill oil after first 250 hours of operation or

rebuild, and every 1,000 hours thereafter (See page

4-47).

Change Hydraulic Oil Return Filter (After

First 250 Hours)

NOTE:

Change hydraulic oil return filter after first 250 hours

of operation or rebuild, then every

1,000 hours

thereafter (See page 4-45).

Change Pilot Filter (After First 250 Hours)

NOTE:

Change pilot filter after first 250 hours and every

1,000 hours thereafter (See page 4-46).

OP000484

Inspection, Maintenance and Adjustment

4-33

500 HOUR / 3 MONTH SERVICE

Perform All Daily, 50 and 250 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.

FG006957

Figure 47

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.

FG000148

Figure 48

OP000484

Inspection, Maintenance and Adjustment

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

49) 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.

FG000144

Figure 49

Replace engine oil filter by using filter wrench. The

engine oil filter is a spin-on type. See Figure

50.

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.

FG006958

Figure 50

Refill the engine with the correct oil through the oil fill

port (Figure 51). 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.

FG006314

Figure 51

Inspection, Maintenance and Adjustment

OP000484

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 front of the machine, then

remove the cover (1, Figure 52) by loosening the four

wing bolts.

Donaldson.

FG000440

Figure 52

Open the cover by turning the knob (1, Figure 53) in

the rear of the cabin.

FG000441

Figure 53

OP000484

Inspection, Maintenance and Adjustment

4-37

Remove filter (Figure 54) 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 54

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 55

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

OP000484

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

FG006960

glasses, mask and safety shoes during the cleaning

Figure 56

precess. Make sure that all extra personnel are clear of

the work area.

Open the rear 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

FG006946

radiator, oil cooler, intercooler and fuel cooler.

Figure 57

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.

FG006960

Figure 58

OP000484

Inspection, Maintenance and Adjustment

4-39

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 59)

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 59

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 59) on instrument panel comes

"ON" the air cleaner must be serviced.

NOTE:

Change outer filter after cleaning 5 times or

every 2,000 hours / 1 year of service.

Remove and clean rubber evacuator valve (1, Figure 60)

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 60

cover.

Remove the access cover (2, Figure 61) by loosening the

latches (3).

Remove the outer filter (4, Figure 61) from the housing. Do

not remove inner filter (5).

FG000702

Figure 61

Inspection, Maintenance and Adjustment

OP000484

4-40

Clean the outer filter

(4, Figure

61) 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 62

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 63

outer and inner filters. Do not clean inner filter.

Change of Fuel Prefilter

Open the left rear 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.

FG006961

Figure 64

Remove the bowl using supplied tool.

Remove the cartridge.

FG006962

Figure 65

OP000484

Inspection, Maintenance and Adjustment

4-41

Coat surface of packing (2, Figure 66) 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

66) with fuel, and

tighten the bowl with tool.

FG000428

Figure 66

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.

Position a small container under fuel filter.

FG006315

Figure 67

Unscrew fuel filter from head assembly. Discard fuel

filter.

NOTE:

Dispose of drained fluids according to local

regulations.

After cleaning filter head, install new fuel filter. Screw

filter on head until gasket contacts head, and turn filter

1/2 turn more with a filter wrench.

NOTE:

Coat fuel filter gasket with fuel.

NOTE:

Fill fuel filter with clean fuel. This will help

FG000478

reduce fuel system priming.

Figure 68

Inspection, Maintenance and Adjustment

OP000484

4-42

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 69) on the fuel prefilter head.

Figure 69

Pump the hand operated primer pump (2, Figure 69)

on the fuel prefilter. Pump primer until fuel is present

at plug hole in fuel prefilter head.

Tighten plug (1, Figure 69) 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.

OP000484

Inspection, Maintenance and Adjustment

4-43

1,000 HOUR / 6 MONTH

SERVICE

Perform All Daily, 50, 250 and 500 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

70) from swing

reduction device.

FG006963

Figure 70

Press grease fitting and inject grease with the grease

gun on the marked point (2, Figure 71).

Install air vent plug (1, Figure 70) in swing reduction

device.

FG006964

Figure 71

Inspection, Maintenance and Adjustment

OP000484

4-44

Change 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 72) on

instrument panel comes "ON" the return filter must be

serviced.

E/G SPEED 1700 RPM

FG000760

Figure 72

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

FG006965

remove either the fill cap or service covers or drain

water from the tank.

Figure 73

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

73) slightly to

release the internal pressure.

Remove bolts

(2, Figure

73) 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

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

Figure 74

strainer, valve and spring. Install service cover plate.

Tighten the breather cap (1, Figure 73).

Run engine for ten minutes at low idle to purge air

from circuit.

Check level in hydraulic oil tank (See page 4-15). Add

oil if necessary.

OP000484

Inspection, Maintenance and Adjustment

4-45

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 75) on

instrument panel comes "ON" the pilot filter must be

serviced.

E/G SPEED 1700 RPM

FG000763

Figure 75

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

FG006966

front attachment to the ground and shut down engine.

Figure 76

Loosen the breather cap

(1, Figure

73) slightly to

release the internal pressure.

Locate pilot system filter assembly. See Figure 76.

Unscrew canister (5, Figure 77) 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 77).

NOTE:

Used filter should always be disposed of

according to local regulations.

FG000323

After changing pilot filter, vent air from pump and

Figure 77

check level of hydraulic oil tank.

Inspection, Maintenance and Adjustment

OP000484

4-46

Change Oil in Travel Reduction Device

(One on Each Side of Unit)

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

FG006955

pressurized air to escape.

Figure 78

NOTE:

Drain oil after first 250 hours of operation or rebuild,

and every 1,000 hours thereafter.

Make sure that the machine is on firm, level ground.

Rotate the track until ports (1 thru 3, Figure 78) are in

their proper positions as shown.

Place a container under drain plug (2, Figure 78) and

remove plugs (1 thru 3) to drain the travel reduction

gear oil.

NOTE:

Dispose of drained fluids according to local

regulations.

Install drain plug

(2, Figure

78). Refill the travel

reduction gear case with fluid through fill port (3) until

the fluid level is at port (1). Install level plug (1) and fill

plug (3).

NOTE:

See “Fluid Capacities” on page 4-8. for

capacity.

Repeat this procedure on the other travel reduction

device.

OP000484

Inspection, Maintenance and Adjustment

4-47

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 front of the machine, then

remove four wing bolts and washers, and access cover

(1, Figure 79).

Donaldson.

FG000440

Figure 79

Open the cover by unscrewing the knob (1, Figure 80)

in the rear of the cabin.

FG000441

Figure 80

Inspection, Maintenance and Adjustment

OP000484

4-48

Remove filter (Figure 81) and replace with new one.

Reassemble in reverse order.

FG000342

Figure 81

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 1800 rpm. Operate for a minimum

FG006968

of ten minutes to stabilize the system.

Figure 82

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.

OP000484

Inspection, Maintenance and Adjustment

4-49

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

High

No bubbles are seen.

HFC-134a 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

OP000484

4-50

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

FG006969

operating. Shut all systems down and allow them to

cool.

Figure 83

Set a container under excavator.

Remove cap (3, Figure 84) 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.

FG006970

Figure 84

Remove breather/fill cap (2, Figure 83) and add oil to

"H" mark on dipstick (1).

FG000419

Figure 85

OP000484

Inspection, Maintenance and Adjustment

4-51

Change Outer and Inner Air Cleaner

Elements

WARNING!

Never clean or attempt to remove the air cleaner

element if the engine is running.

NOTE:

Change outer element after cleaning 5 times or every

FG000414

2,000 hours of service.

Figure 86

NOTE:

Change 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 rear of the cabin.

Remove the evacuator valve

(1, Figure

87) 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 87

Remove outer filter (4, Figure 87) from the air cleaner

housing.

Clean the air cleaner cover and the inside of the air

cleaner housing.

Remove inner filter (5, Figure 88).

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 88

Inspection, Maintenance and Adjustment

OP000484

4-52

Change Radiator Coolant

WARNING!

Allow the engine to cool before releasing the radiator

cap. Make sure to loosen the cap slowly to release any

remaining pressure.

Radiator cleaning is performed while the engine is

running. Take extreme caution when working on or near

ARO1760L

a running engine. Make sure to lock out and tag the

Figure 89

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 90).

NOTE:

Dispose of drained fluids according to local

regulations.

FG006319

Figure 90

Open heater shutoff valves

(3 and

4, Figure

91) to

allow coolant to drain from heater core.

FG006320

Figure 91

OP000484

Inspection, Maintenance and Adjustment

4-53

Doosan DX255LC. Operation and Maintenance Manual (2006) - page 4