Doosan DX255LC. Operation and Maintenance Manual (2006) - page 5
4.
Remove coolant drain plug (1, Figure 92) from engine.
5.
Install drain plug, and close drain valve after coolant
has completely drained from system.
1
6.
Fill cooling system with a flushing solution.
7.
Run engine at low idle until the coolant temperature
gauge reaches the "BLUE ZONE." Run engine for
another ten minutes.
8.
Allow engine to cool.
9.
Drain flushing fluid and fill system with water.
10. Run engine again to allow water to completely circulate.
11. After allowing engine to cool, drain water and fill
FG006444
system with proper antifreeze mixture for ambient
Figure 92
temperature. Refer to coolant concentration table. See
“Antifreeze Concentration Tables” on page 4-76.
12. Run engine without radiator cap installed, so that all air
will be purged from system. Fill radiator to fill neck.
13. Drain and fill radiator coolant recovery tank.
Hydraulic Oil Exchange and Suction
Strainer Cleaning
WARNING!
The hydraulic oil will be hot after normal machine
operation. Allow the system to cool before attempting to
service any of the hydraulic components.
ARO1760L
The hydraulic tank is pressurized. Loosen the breather
Figure 93
cap to allow the pressurized air to vent. After the
pressure has been released, it is safe to remove either
the fill cap or service covers.
IMPORTANT
Make sure to clean any dirt or water from the top of the
hydraulic tank, especially around the fill port and filter
ports.
Hydraulic oil change interval is 2,000 hours, only when
DOOSAN Genuine Oil is used. If another brand of oil is
used, guaranteed change interval is 1,000 hours.
NOTE:
Based on the type of excavating being completed,
the working conditions (extremely hot or dusty) and
the extra front end attachments being used (hydraulic
breaker, etc.), the hydraulic fluid will need to be
changed more frequently.
Inspection, Maintenance and Adjustment
OP000484
4-54
1.
Position the machine on firm, level ground. Swing
upper structure perpendicular
(90°) to tracks. Lower
boom and position bucket on ground as shown in
Figure 94.
2.
Set safety lever on "LOCK" position.
3.
Shut down engine.
4.
Release pressurized air from hydraulic tank by rotating
breather cap (1, Figure 97).
FG006974
Figure 94
5.
Drain hydraulic oil from tank into a container capable of
holding 280 liters (74 U.S. gal.). After draining tank,
install drain plug.
IMPORTANT
Be careful of squirting oil when removing drain
plug.
FG006975
NOTE:
Used filter and used oil should always be
disposed of according to local regulations.
Figure95
6.
Carefully remove bolts and cover (2, Figure 97) from
top of hydraulic oil tank. There is a spring (3) under
the cover that will force the cover up.
7.
Remove spring
(3, Figure
97) and strainer
(5), by
pulling on rod (4).
A
8.
Clean inside and outside of strainer. Replace strainer if
it is broken.
9.
Position strainer
(5, Figure
97) on boss portion of
suction pipe (6).
NOTE:
Measurement "A" is 650 mm (25.59 in).
HAOC411L
Figure 96
OP000484
Inspection, Maintenance and Adjustment
4-55
10. Fill the hydraulic oil tank. Check level using sight
gauge on side of tank.
1
2
11. Place spring (3, Figure 97) on rod (4) and assemble
cover (2).
12. After replacing and cleaning the hydraulic oil, filter and
strainer, vent the system. See “Venting and Priming
3
Hydraulic System” on page 4-83.
IMPORTANT
4
When the hydraulic breaker is being used, due to
the higher heat generated by this unit, use
replacement intervals recommended under the
5
“Hydraulic Oil and Filter Service Intervals” on
page 3-37.
6
13. Check level of hydraulic oil tank. (See page 4-15)
ARO1720L
Figure 97
Check Alternator and Starter**
**These checks need to be completed by an authorized
DOOSAN dealer.
Check All Rubber Antivibration Shock
Mounts
Perform and Record the Results of the
Cycle Time Tests
Inspect Machine to Check for Cracked
or Broken Welds or other Structural
Damage
Check, Adjust Valve Clearance **
Check Head Bolt Torques
Inspection, Maintenance and Adjustment
OP000484
4-56
4,000 HOUR / BIENNIAL
SERVICE
Major Parts - Periodic Replacement
To ensure safe operation and work, perform periodic
inspections. Also, to increase safety, replace the following
parts. These parts are the ones most often subjected to
abrasion, heat and fatigue. Exchange these parts with new
ones at the designated time intervals, even if the old parts
look good.
Always replace all related parts such as gaskets and
O-rings. Use only original equipment manufacturers parts.
Major Component
Parts Name to be Exchanged Periodically
Time to Exchange
Engine
Fuel hose (Tank to fuel prefilter)
2 years or 4,000 hours
Fuel hose (Fuel prefilter to fuel cooler)
Fuel hose (Fuel cooler to ECU)
Fuel hose (Tank to CP pump)
Heater hose (Heater to engine)
Heater hose (Heater to radiator)
Air Conditioner hose
Hydraulic
Body
Pump suction hose
System
Pump discharge hoses
Pump side branch hoses
Swing motor hoses
Travel motor hoses
Work
Boom cylinder line hoses
Device
Arm cylinder line hoses
Bucket cylinder line hoses
OP000484
Inspection, Maintenance and Adjustment
4-57
12,000 HOUR / SIX YEAR
SERVICE
Hose In-service Lifetime Limit (European
Standard ISO 8331 and EN982 CEN)
European regulations state that the in-service life of any
hydraulic hose may not exceed six years. DOOSAN
recommends the following;
•
Hoses at the customer premises cannot be stored
more than 2 years before being discarded or installed
on a machine.
•
In-service lifetime of hoses fitted on a machine can
never exceed 6 years, but replace hoses described in
“Major Parts - Periodic Replacement” on page 4-57,
every
2 years. Always replace hoses having
exceeded the allowed in-service lifetime irrespective
of the external appearance/wear.
•
Always store hoses in a dark place at a maximum of
65% relative humidity, between 0˚C (32˚F) and 35˚C
(95˚F) but as close as possible to 15˚C (59˚F) and
away from copper, manganese or tube generating
Ozone.
Inspection, Maintenance and Adjustment
OP000484
4-58
AIR-CONDITIONING SYSTEM
NOTE:
See “Clean Air-Conditioning Outer Filter” on
page 4-37.
Check Control Panel
When a function switch is pushed, the last setting has to be
displayed on the LCD display.
When the light switch is turned to "I" position, the LED for
illumination in the control panel has to turn "ON."
Check Air Conditioner Hoses
Check the hose for cracking and damage.
CAUTION!
When a leak occurs, dirt will accumulate in the area
where the leak is. Consult a DOOSAN distributor or
sales agency.
Check Condenser
Inspect the condenser for dust and debris. Clean if
necessary.
NOTE:
See “Clean Radiator, Oil Cooler, Intercooler, Fuel
Cooler and Air Conditioner Condenser Core” on
page 4-39.
Check Magnetic Clutch
Check the magnetic clutch for dirt and interference.
Push the "A/C" switch in order to energize magnetic clutch
and check the magnetic clutch.
Check Belt Tension
NOTE:
See “Check Engine Fan Belt Tension” on page 4-31.
OP000484
Inspection, Maintenance and Adjustment
4-59
BOLT AND NUT INSPECTION
Inspect ALL fasteners after the first 50 hours of operation
and every
250 hours thereafter. If any are loose or are
missing tighten them or install new hardware. Always use a
calibrated torque wrench.
IMPORTANT
Always clean fasteners before tightening.
If counterweight is loose, contact a DOOSAN distributor
or sales agent.
NO.
POINT TO BE INSPECTED
BOLT
QTY.
BOLT
TORQUE
DIA.
HEAD
kg•m
Nm
ft lb
MM
SIZE
Joint bolt with engine
pump side
16
8
24
24.5
240
177
1
mounting bracket and
fan side
10
8
17
5
49
36
engine
Joint bolt and nut
pump side
20
2
30
46
451
333
2
between engine mount-
fan side
20
2
30
46
451
333
ing bracket and frame
3
Radiator mounting bolt
16
4
24
27
265
195
4
Tightening bolt for hydraulic oil tank
16
6
24
27
265
195
5
Tightening bolt for fuel tank
16
6
24
27
265
195
6
Tightening bolt for pump
20
4
17 (S)
49
480
354
7
Tightening bolt for control valve
16
4
24
27
265
195
Tightening bolt for swing reduction
8
24
12
36
95
931
687
device
9
Tightening bolt for swing motor
12
12
10 (S)
14.4
141
105
10
Tightening bolt for battery
10
2
17
5
49
36
Joint bolt with cabin mounting rubber
24
35
36
95
931
687
and frame
11
Joint bolt with cabin mounting rubber
24
35
36
95
931
687
and cabin
Joint bolt with swing bearing and upper
20
36
30
55
539
398
frame
12
Joint bolt with swing bearing and bot-
20
36
30
55
539
398
tom frame
Tightening bolt for travel device
20
40
30
49
480
354
13
Tightening bolt for sprocket
18
52
27
45
441
325
14
Tightening bolt for upper roller
20
4
30
55
539
398
15
Tightening bolt for bottom roller
16
80
24
27
265
195
16
Tightening bolt for track guard
16
16
24
27
265
195
17
Bolt for track shoes
20
408
27
78
765
564
18
Fixing bolt for front pin
16
10
24
27
265
195
19
Breaker Filter (Optional)
1
30
27
265
195
20
Grease valve for track adjuster
PF 1/2
2
27
14
137
101
Inspection, Maintenance and Adjustment
OP000484
4-60
1.
Joint bolt with engine mounting bracket and engine
1) Pump side
•
Tool: 24 mm (
)
•
Torque: 24.5 kg•m (240 Nm, 177 ft lb)
FG006971
Figure 98
2) Fan side
•
Tool: 19 mm (
)
•
Torque: 11.2 kg•m (110 Nm, 81 ft lb)
FG006972
Figure 99
2.
Joint bolt and nut between engine mounting bracket
and frame
1) Pump side
•
Tool: 30 mm (
)
•
Torque: 46 kg•m (451 Nm, 333 ft lb)
FG006981
Figure 100
2) Fan side
•
Tool: 30 mm (
)
•
Torque: 46 kg•m (451 Nm, 333 ft lb)
FG006982
Figure 101
OP000484
Inspection, Maintenance and Adjustment
4-61
3.
Radiator mounting bolt
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (265 Nm, 195 ft lb)
FG006983
Figure 102
4.
Tightening bolt for hydraulic oil tank
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (265 Nm, 195 ft lb)
FG006984
Figure 103
5.
Tightening bolt for fuel tank
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (265 Nm, 195 ft lb)
FG006985
Figure 104
6.
Tightening bolt for pump
•
Tool: 17 mm (
)
•
Torque: 49 kg•m (480 Nm, 354 ft lb)
FG006986
Figure 105
Inspection, Maintenance and Adjustment
OP000484
4-62
7.
Tightening bolt for control valve
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (265 Nm, 195 ft lb)
FG006987
Figure 106
8.
Tightening bolt for swing reduction device
•
Tool: 36 mm (
)
•
Torque: 95 kg•m (931 Nm, 687 ft lb)
FG006988
Figure 107
9.
Tightening bolt for swing motor
•
Tool: 10 mm (
)
•
Torque: 11 kg•m (108 Nm, 80 ft lb)
FG008041
Figure 108
10. Tightening bolt for battery
•
Tool: 17 mm (
)
•
Torque: 5 kg•m (49 Nm, 36 ft lb)
FG001428
Figure 109
OP000484
Inspection, Maintenance and Adjustment
4-63
11. Joint bolt with cabin mounting rubber and frame
•
Tool: 17 mm (
)
•
Torque: 6.5 kg•m (64 Nm, 47 ft lb)
FG000454
Figure 110
Joint bolt with cabin mounting rubber and cabin
•
Tool: 24 mm (
)
•
Torque: 21 kg•m (206 Nm, 152 ft lb)
FG000455
Figure 111
12. Joint bolt with swing bearing and upper frame
•
Tool: 36 mm (
)
•
Torque: 95 kg•m (931 Nm, 687 ft lb)
FG006989
Figure 112
Joint bolt with swing bearing and bottom frame
•
Tool: 36 mm (
)
•
Torque: 95 kg•m (931 Nm, 687 ft lb)
FG006990
Figure 113
Inspection, Maintenance and Adjustment
OP000484
4-64
13. Tightening bolt for travel device
•
Tool: 30 mm (
)
•
Torque: 49 kg•m (480 Nm, 354 ft lb)
FG006991
Figure 114
Tightening bolt for sprocket
•
Tool: 27 mm (
)
•
Torque: 45 kg•m (441 Nm, 325 ft lb)
FG006996
Figure 115
14. Tightening bolt for upper roller
•
Tool: 30 mm (
)
•
Torque: 55 kg•m (539 Nm, 398 ft lb)
FG000460
Figure 116
15. Tightening bolt for bottom roller
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (265 Nm, 195 ft lb)
FG000461
Figure 117
OP000484
Inspection, Maintenance and Adjustment
4-65
16. Tightening bolt for track guard
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (265 Nm, 195 ft lb)
FG000462
Figure 118
17. Bolt for track shoes
•
Tool: 27 mm (
)
•
Torque: 78 kg•m (765 Nm, 564 ft lb)
FG000463
Figure 119
18. Fixing bolt for front pin
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (265 Nm, 195 ft lb)
FG000464
Figure 120
Inspection, Maintenance and Adjustment
OP000484
4-66
19. Fixing breaker filter (Optional)
•
Tool: 30 mm (
)
•
Torque: 27 kg•m (265 Nm, 195 ft lb)
FG006992
Figure 121
20. Grease valve for track adjuster
•
Tool: 27 mm (
)
2
•
Torque: 14 kg•m (137 Nm, 101 ft lb)
1
3
FG000163
Figure 122
OP000484
Inspection, Maintenance and Adjustment
4-67
BUCKET
Bucket Tooth Replacement
WARNING!
Due to the possibility of flying metal objects, always
wear safety helmet, protective gloves and eye protection
when changing bucket teeth.
Curl the bucket upwards and place the round rear
surface of the bucket firmly on the ground. Shut the
engine off and lock out the hydraulic controls before
working on the bucket.
NOTE:
These instructions are only for DOOSAN OEM
buckets. If you are using other manufacturers
buckets, refer to their specific instructions.
HAOC680L
Figure 123
1.
On a routine basis, inspect bucket teeth to make sure
that tooth wear or breakage has not developed. Do not
allow replaceable bucket teeth to wear down to a point
that bucket adapter is exposed. See Figure 123.
2.
To replace a tooth (1, Figure 124), use a hammer and
punch to drive locking pin (2) and lock washer (3) out
4
of tooth adapter (4).
3.
Once worn tooth has been removed, use a putty knife
3
to scrape adapter as clean as possible.
2
4.
Slide new tooth into position and insert lock washer.
1
FG000346
Figure 124
5.
Insert locking pin into tooth and with a hammer, drive
pin in until lock washer seats in locking groove.
Inspection, Maintenance and Adjustment
OP000484
4-68
Bucket O-ring Replacement
WARNING!
Due to possibility of flying metal objects, always wear
safety helmet, protective gloves and eye protection
when changing pins.
1.
Inspect bucket O-rings on a routine basis. If worn or
damaged, replacement is necessary.
FG006993
Figure 125
2.
Roll old O-ring (1, Figure 126) onto boss (2) around
bucket pin (3). Remove bucket pin and move arm or
1
4
bucket link (4) out of way.
2
3
ARO1390L
Figure 126
3.
Remove old O-ring and temporarily install new O-ring
(1, Figure 127) onto bucket boss (2). Make sure that
1
4
O-ring groove on both bucket link (4) and boss have
2
been cleaned.
4.
Realign arm or link with bucket pin hole and insert
bucket pin (3, Figure 126).
ARO1391L
Figure 127
OP000484
Inspection, Maintenance and Adjustment
4-69
5.
Roll new O-ring (1, Figure 128) into O-ring groove.
1
ARO1392L
Figure 128
Inspection, Maintenance and Adjustment
OP000484
4-70
ELECTRICAL SYSTEM
NOTE:
Never disassemble electrical or electronic parts.
Consult with a DOOSAN distributor or sales agency
before servicing.
Battery
WARNING!
Battery electrolyte contains sulfuric acid and can quickly
burn the skin and eat holes in clothing. If you spill acid
on yourself, immediately flush the area with water.
Battery acid could cause blindness if splashed into the
eyes. If acid gets into the eyes, flush them immediately
with large quantities of water and see a doctor at once.
If you accidentally drink acid, drink a large quantity of
water or milk, beaten egg or vegetable oil. Call a doctor
or poison prevention center immediately.
When working with batteries, always wear safety glasses
or goggles.
Battery generates hydrogen gas, so there is danger of
an explosion. Do not bring lighted cigarettes near the
battery, or do anything that will cause sparks.
Before working with batteries, shut down engine and
turn the starter switch to the "O" (OFF) position.
Avoid short circuiting the battery terminals through
accidental contact with metallic objects, such as tool.
When removing or installing, check which is the positive
(+) terminal and negative (-) terminal.
When removing the battery, first disconnect the negative
(-) terminal. When installing the battery, first connect the
positive (+) terminal.
If the terminals are loose, there is danger that the
defective contact may generate sparks that will cause an
explosion. When installing the terminals, install them
tightly.
Batteries in Cold Weather
In colder weather a greater drain is placed on the batteries
when they are used for the preheat cycle and when starting
a cold engine. Battery performance decreases as the
temperature gets lower.
In extremely cold weather, remove the batteries at night and
move them to a warm location. This will help to keep them
at a higher power level.
OP000484
Inspection, Maintenance and Adjustment
4-71
Inspection of Battery Electrolyte Level
This machine has two maintenance free batteries. They
never require the addition to water.
When the charge indicator becomes transparency, it means
low electrolyte state because of the leakage or charging
system error. Determine the cause of problem and replace
the batteries immediately.
Check Charging State
FG000347
Check charging state through the charging indicator.
Figure 129
•
GREEN: Sufficiently charged.
•
BLACK: Insufficient charged.
•
TRANSPARENT: Replace battery.
Check the Battery Terminals
Be certain that the battery is held securely in its
compartment. Clean the battery terminals and the battery
cable connectors. A solution of baking soda and water will
neutralize acid on the battery surface, terminals, and cable
connectors. Petroleum jelly or grease can be applied to the
connectors to help prevent corrosion.
Battery Replacement
HAOU790L
When the charging indicator indicates transparency state,
replace the battery. The batteries should always be replaced
Figure 130
in pairs.
Using an old battery with a new one will shorten the life
span of the new battery.
Fuses
1.
The fuses in the fuse box are used to protect the
O
X
various electrical circuits and their components from
being damaged. See Figure 131. The fuses used are
standard automotive type fuses.
2.
The section on “Fuse Identification” on page 4-74, lists
the circuits and the fuse amperage required for each
circuit. If a fuse blows, determine the cause and repair
any faults or failures.
HAOC670L
3.
Do not insert a higher amperage fuse into a lower
Figure 131
amperage slot. Serious damage to the electrical
components or fire can result.
Inspection, Maintenance and Adjustment
OP000484
4-72
CAUTION!
Before replacing a fuse, be sure to turn starter switch to
"O" (OFF) position.
Fuse Boxes
There are two fuse boxes (Figure 132) on the left side of
the heater box. The fuses prevent electrical devices from
overloading or shorting.
A decal attached to the inside of the fuse box's cover
indicates the function and amperage of each fuse.
Spare fuses are mounted on the inside of fuse box's cover.
(One each of a 10A, 15A, 20A and 30A.)
Change a fuse if the element separates. If the element of a
FG000110
new fuse separates, check the circuit and repair the circuit.
Figure 132
CAUTION!
Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage
could result.
OP000484
Inspection, Maintenance and Adjustment
4-73
Fuse Identification
Fuse Box (1)
Fuse Box (2)
FG000542
Figure 133
Fuse Box One
Fuse Box Two
No.
No.
Name
Capacity
Name
Capacity
1
Warning Light (Optional)
10A
1
Horn
10A
2
2-pump (Optional)
10A
2
Quick Clamp (Optional)
10A
3
Cigar Lighter
10A
3
Travel Alarm (Optional)
10A
4
12V Power
10A
4
Auxiliary Mode
10A
5
Wiper, Washer
10A
5
Check Connector
10A
6
Lower Wiper (Optional)
10A
6
Pilot Cutoff
10A
7
Stereo
10A
7
Memory Backup
10A
Starter Switch, Hour
8
10A
8
Room Light
10A
Meter
9
Spare
30A
9
Cabin Light (Optional)
30A
10
Air Conditioner, Heater
20A
10
Work Light
20A
11
Shear, Breaker (Optional)
15A
11
Fuel Heater
20A
Instrument Panel, Pressure
12
Seat Heater (Optional)
15A
12
15A
Sensor
e-EPOS, Booster, Travel
13
15A
13
Headlight
15A
speed changer, Booster
14
ECU
15A
14
Fuel Pump (Optional), Wiper
15A
Inspection, Maintenance and Adjustment
OP000484
4-74
ENGINE COOLING SYSTEM
GENERAL
Keeping an engine's cooling system in peak operating
condition, can have many benefits to keeping a machine in
good operating condition. A properly functioning cooling
system will; improve fuel efficiency, reduce engine wear, and
extend component life.
Always use distilled water in the radiator. Contaminants in
tap water neutralize the corrosion inhibitor components. If
tap water must be used, it should not exceed
300 ppm
hardness, or contain more than 100 ppm of either chloride
or sulfate. Water that has been treated with a water softener
also contains salt that will cause corrosion of components.
Water from creeks and stagnant pools usually contains dirt,
minerals and/or organic material that are deposited in the
cooling system and impair cooling efficiency. Distilled water
is the best.
Engine overheating is often caused by bent or clogged
radiator fins. The spaces between the fins can be cleaned
by use of air or water under pressure. When straightening
bent fins, use care not to damage the tubes or break the
bond between the fins and the tubes.
WARNING!
Pressure at air nozzle must not exceed 30 PSI (2.1
kg/cm2). Always wear goggles when using
compressed air.
Do not pour cold water into radiator when engine is
very hot and water level is below the top of the
tubes. Such action could result in damage to engine
cylinder heads.
Heavy duty diesel engines require a balanced mixture of
water and antifreeze. Drain and replace the mixture every
year or 2,000 hours of operation, which ever comes first.
This will eliminate buildup of harmful chemicals.
Antifreeze is essential in any climate. It broadens the
operating temperature range by lowering the coolant's
freezing point and by raising its boiling point. Do not use
more than 50% antifreeze in the mixture unless additional
freeze protection is required. Never use more than
68%
antifreeze under any condition.
OP000484
Inspection, Maintenance and Adjustment
4-75
Types of Antifreeze
There are two main classifications of antifreeze available on
the market today.
1.
Ethylene Glycol - Standard Life Antifreeze
2.
Propylene Glycol - Extended Life Antifreeze
Ethylene glycol (standard life antifreeze) has been on the
market for many years. Its chemical properties do not
provide the improved corrosion resistance that propylene
glycol (extended life antifreeze) does. Ethylene glycol is also
very hazardous to the environment, people and animals.
DOOSAN recommends that ethylene glycol be replaced with
propylene glycol.
The newer propylene glycol antifreeze comes in many
different colors. Some of the colors are pink, red, orange
and yellow. There are even some that come in a blue-green
color. The blue-green color makes it very difficult to tell the
difference of what type of antifreeze is in a cooling system.
The colors are only a dye added to the clear antifreeze. Do
not rely on color. Keep careful machine records of what
brand and type of antifreeze is used in the unit. If you are
unsure of what type of antifreeze is in the system, drain and
flush the system.
NOTE:
Do not mix ethylene glycol and propylene glycol
antifreeze together. If the two are mixed, the
protection level will be reduced to the level of the
ethylene glycol.
ANTIFREEZE CONCENTRATION TABLES
Ethylene Glycol - Standard Life Antifreeze
(1,000 Hour / 6 Months)
Ambient Temperature
Cooling Water
Antifreeze
-10°C (14°F)
80%
20%
-15°C (5°F)
73%
27%
-20°C (-4°F)
67%
33%
-25°C (-13°F)
60%
40%
-30°C (-22°F)
56%
44%
-40°C (-40°F)
50%
50%
Propylene Glycol - Extended Life Antifreeze
(2,000 Hour / Yearly)
Ambient Temperature
Cooling Water
Antifreeze
-10°C (14°F)
78%
22%
-15°C (5°F)
71%
29%
-20°C (-4°F)
65%
35%
-25°C (-13°F)
59%
41%
-30°C (-22°F)
55%
45%
-40°C (-40°F)
48%
52%
Inspection, Maintenance and Adjustment
OP000484
4-76
FUEL TRANSFER PUMP
(OPTION)
WARNING!
Do not dry operate fuel pump for more than fifteen
seconds.
•
Cooling and lubrication of pump is achieved
by fuel passing through pump. If pump is dry
operated, heat generated by moving parts will
cause damage to pump rotors, vanes and
seals. To prevent unnecessary wear and/or
damage to pump do not dry operate fuel pump
for more than fifteen seconds.
Do not operate pump for more than fifteen minutes at a
time.
•
Continuous usage of pump over recommended
time interval will cause overheating of motor
and will result in causing motor damage.
Do not use refueling pump for other types of fuel or
fluids. (Use only for diesel fuel.)
•
Do not use refueling pump for other types of
fuel which have a low flash point.
•
Do not use refueling pump for fuel
contaminated with water or high humidity.
Moisture in pump mechanism can cause rust
and can create pump failure.
Always operate pump using strainer installed on inlet
hose. This will prevent any foreign materials from being
introduced into pump. Always maintain pump and all of
its components in a clean condition.
•
If dirt or other foreign materials enter pump, it
can become lodged between the rotor and/or
vanes and generate heat which can cause
pump damage.
•
Do not remove strainer or use a strainer with
larger mesh to increase flow of fuel.
Be careful not to overfill or spill fuel.
Make sure direction of check valve is in line with flow
direction of fuel.
If any pump parts or components become lost, damaged
or inoperable, immediately replace it with a new ones.
OP000484
Inspection, Maintenance and Adjustment
4-77
IMPORTANT
If there are any sign of leakage while operating transfer
pump, inspect the following components to prevent any
fires or hazardous fuel spills.
•
Check all hoses leading to and from the
transfer pump.
•
Check all hose clamps.
•
Check transfer pump inlet port.
The transfer pump is used to transfer fuel from a refueling
source to the fuel tank. A check valve is installed in the
inlet hose to prevent fuel from flowing back from fuel tank to
source. A strainer is installed in inlet hose to prevent any
foreign material from being introduced into transfer pump or
fuel tank.
A thermal limiter, built into the motor, will automatically shut off
power if motor is overheating to protect it from being damaged.
FUEL
1
4
3
2
5
FUEL TANK
IN
OUT
FG000161
Figure 134
Reference
Reference
Description
Description
Number
Number
1
Body
4
Strainer Cap
2
Check Valve
5
Inlet Hose
3
Strainer
Inspection, Maintenance and Adjustment
OP000484
4-78
1.
Remove strainer cap (4, Figure 134) from strainer
(3)
on end of inlet hose (5).
NOTE:
Keep strainer cap (4, Figure
134) in a safe
location to reseal strainer (3) after refueling is
complete.
I
O
2.
Insert inlet hose (5, Figure 134) into refueling tank.
3.
Turn fuel pump switch (Figure 135) inside of battery
box on front side to "I" (ON) position.
NOTE:
Transfer pump rate of flow is approximately 35
FG003379
liters/minute (9.24 U.S. gpm). Use extra care
Figure 135
not to overfill fuel tank so that fuel does not over
flow.
4.
Once fuel transfer is completed, immediately turn
switch to "O" (OFF) position to stop pump.
5.
Lift inlet hose (5, Figure 134) from fueling source and
turn switch to "I" (ON) position for two - three seconds
to drain remaining fuel from hose to fuel tank.
6.
Install strainer cap (4, Figure 134) on inlet strainer
(3)
and return hose (5) to storage position.
OP000484
Inspection, Maintenance and Adjustment
4-79
HANDLING OF ACCUMULATOR
WARNING!
Even though the engine is stopped, the hydraulic
accumulators for the pilot system are still charged. Do
not disconnect any pilot system hoses until accumulator
pressure has been released from the circuit. To release
pressure, turn the starter switch to the "I" (ON) position
and operate all hydraulic control levers and forward/
reverse travel levers. Even though the engine is
shutdown hydraulic actuated components may move
while releasing pilot pressure. Keep all personnel away
from excavator while performing this operation.
•
Set safety lever on "LOCK" position after
stopping engine.
•
DO NOT mishandle accumulator(s). They are
very dangerous because they contain
high-pressure nitrogen gas.
•
DO NOT punch a hole or apply heat or fire to
an accumulator.
•
DO NOT weld on accumulator, or try attaching
anything to it.
•
When replacing an accumulator, contact a
DOOSAN distributor or sales agency so the
gas can be properly released.
•
Wear safety goggles and protective gloves
when working on an accumulator. Hydraulic oil
under pressure can penetrate the skin and
cause serious injuries.
Release pilot accumulator pressure using the following
procedure;
1.
Position the machine on firm, level ground. Lower the
front attachment to the ground and shut down engine.
2.
Set safety lever on "RELEASED" position.
3.
Turn starter switch to the "I" (ON) position.
4.
Fully stroke work and travel levers in all directions.
5.
Set safety lever on "LOCK" position.
FG001443
6.
Turn key to "O" (OFF) position and remove from starter
Figure 136
switch.
7.
Remove accumulator by unscrewing it slowly.
Inspection, Maintenance and Adjustment
OP000484
4-80
TRACK TENSION
WARNING!
Safely measuring track tension requires two people. One
person must be in the operator's seat, running the
controls to keep one side frame in the air, while the
other person makes dimensional checks. Take all
necessary precautions to make sure the machine won't
move or shift position during service. Warm up the
engine to prevent stalls, travel the excavator to an area
that provides level, uniform ground support and/or use
support blocks when necessary.
The track adjusting mechanism is under very
high-pressure. NEVER release pressure too suddenly.
The grease cylinder valve should never be backed off
more than one complete turn from the fully snugged
down position. Bleed off pressure slowly and keep your
body away from the valve at all times.
Track shoe link pins and bushings wear with normal usage,
reducing track tension. Periodic adjustment is necessary to
compensate for wear and it may also be required by
working conditions.
1.
Track tension is checked by jacking up one side of the
excavator. See Figure 137. Place blocking under frame
while taking measurement.
90 ~ 110
FG006994
Figure 137
2.
Measuring the distance (A, Figure
138) between the
bottom of the side frame and the top of the lowest
crawler shoe. Recommended tension for operation over
most types of terrain is
320
-
340 mm
(12.60
-
13.39 in)
NOTE:
This measurement can be thrown off if there is
too much mud or dirt or other material in the
A
track assembly. Clean off the tracks before
checking clearance.
3.
Too little sag in the crawler track (less than 320 mm
FG000162
(12.60 in) clearance) can cause excessive component
Figure 138
wear. The recommended adjustment can also be too
tight causing accelerated stress and wear if ground
OP000484
Inspection, Maintenance and Adjustment
4-81
conditions are wet, marshy or muddy, or if the ground
is hard and full of rocks or gravel.
4.
The increased clearance recommended for muddy
ground conditions is between 340 - 370 mm (13.39 -
14.57 in). The clearance should be approximately
370 mm
(14.57 in) for operation over gravel, rocky
terrain, or over sand or snow.
WARNING!
The track adjusting mechanism is under very
high-pressure. NEVER release pressure too
suddenly. The grease cylinder valve should never
be backed off more than 1 complete turn from the
fully snugged down position. Bleed off pressure
slowly and keep your body away from the valve at
all times. If there is problem in the fitting thread,
the valve or fitting might be ejected at high speed
to cause fatal wound.
5.
Track tension adjustments are made through the
grease fitting (1, Figure 139) in the middle of each side
2
frame. Adding grease increases the length of an
adjustment cylinder
(2). The longer the adjustment
cylinder, the greater the pressure on the tension spring
pushing the track idler wheel outward.
6.
If there is not enough slack or clearance in the tracks
and the adjustment is too tight, the idler wheel and
adjusting cylinder can be retracted by bleeding off
1
grease through hole in valve
(3, Figure
139) by
3
loosening valve slowly (3, Figure 139).
FG000163
Figure 139
NOTE:
After track tension is adjusted by loosening
valve, be sure to tighten valve (3, Figure 139)
with 14 kg•m (137 Nm, 101 ft lb).
WARNING!
Do not loosen or remove the grease fitting
(1,
Figure 139) until the pressure is entirely bleed off
by loosening valve (3, Figure 139) slowly.
Inspection, Maintenance and Adjustment
OP000484
4-82
VENTING AND PRIMING
HYDRAULIC SYSTEM
Main System Pump
NOTE:
If pump is run without sufficient oil in the main
hydraulic pump, damage can occur. Always vent
pump of air after draining hydraulic system.
1.
With the engine stopped, remove vent plug (Figure
140) to see if any oil is present.
2.
If oil is not present, fill pump with oil through port
(Figure 140).
3.
Install vent plug (Figure 140) first.
FG000158
Figure 140
4.
Start engine and run it for several minutes at low idle
engine speed. This will pressurize the hydraulic oil tank
and system.
5.
Slowly loosen vent plug (Figure 140) several turns, until
hydraulic oil flows out of plug. This shows that air has
been released.
6.
Tighten the plug (Figure 140).
Hydraulic Cylinders
IMPORTANT
If cylinders are operated in high idle after the hydraulic
system has been drained or the cylinder has been
rebuilt, damage to piston packing and seals may occur.
Always vent air from cylinders at low idle and at a slow
speed.
1.
Run engine at low idle. Extend and retract each
cylinder to within 100 mm (4 in) of fully stroking it 4 -
5 times.
2.
Operate fully extend and retract each cylinder
3-
4
times.
3.
Repeat procedure until cylinders extend and retract
smoothly.
OP000484
Inspection, Maintenance and Adjustment
4-83
Swing Motor
IMPORTANT
If the air is not vented from the system, it will cause
damage to the swing motor and bearings.
NOTE:
Perform this only when oil has been drained from
swing motor.
FG006995
1.
Shut down engine.
Figure 141
2.
Disconnect drain hose and fill swing motor case with
hydraulic oil.
3.
Connect the drain hose.
4.
Start engine and set throttle at "LOW IDLE" and swing
upper structure slowly two full revolutions to the left
and right.
Travel Motor
NOTE:
Perform this only when oil is drained from travel
motor
1.
Shut down engine
2.
Disconnect drain hose (Figure 142) and fill motor case
with hydraulic oil.
3.
Connect drain hose.
4.
Start engine and set engine speed control dial to "LOW
FG006998
IDLE." Run the engine for one minute and slowly drive
Figure 142
excavator forwards and backwards.
General Venting
1.
After venting air from all components, shut the engine
down and check the hydraulic oil level. Fill hydraulic oil
tank to "H" mark on sight gauge.
2.
Start engine and operate all controls again, run engine
for five minutes to ensure all systems have been vent
and purged of air. Set engine speed to "LOW IDLE,"
and check hydraulic oil level again. Add oil as
necessary.
3.
Check for oil leaks and clean all fill and venting
locations.
Inspection, Maintenance and Adjustment
OP000484
4-84
LONG TERM STORAGE
Perform the following if storing the excavator for more than
one month.
Conditions
Maintenance Required
Cleaning
Pressure wash the undercarriage and track assemblies.
Inspect for damage or loose or missing parts.
Lubrication
Perform all daily lubrication procedures.
Apply a coating of light oil to the exposed plated metal
surfaces, such as hydraulic cylinder rods, etc.
Apply a coating of light oil to all of the control linkages and
control cylinders (control valve spools, etc.).
Battery
Remove the battery from the excavator or remove the
battery leads from the battery to fully charge and store.
Cooling System
Inspect the coolant recovery tank to make sure that the
antifreeze level in the system is at the correct level.
Every 90 days, use a hydrometer to measure the protection
level of the coolant. Refer to the antifreeze/coolant
protection chart to determine the amount of protection the
cooling system requires. Add coolant as required.
Hydraulic System
Once a month, start the engine and follow the "Hydraulic
Oil Warm-up" procedures listed in this manual.
OP000484
Inspection, Maintenance and Adjustment
4-85
MAINTENANCE IN SPECIAL
CONDITIONS
NOTE:
See “Operation Under Unusual Conditions” on
page 3-43 for other recommendations.
Conditions
Maintenance Required
Operating in mud, water or rain.
Perform a walk around inspection to check for any loose
fittings, obvious damage to the machine or any fluid
leakage.
After completing operations, clean mud, rocks or debris
from the machine. Inspect for damage, cracked welds or
loosened parts.
Perform all daily lubrication and service.
If the operations were in salt water or other corrosive
materials, make sure to flush the affected equipment with
fresh water.
Operating in an extremely dusty or hot
Clean the air intake filters on a more frequent basis.
environment.
Clean the radiator and oil cooler fins to remove embedded
dirt and dust.
Clean the fuel system intake strainer and fuel filter more
frequently.
Inspect and clean as required the starter and alternator.
Operating in rocky terrain.
Check the undercarriage and track assemblies for damage
or excessive wear.
Inspect for loose or damaged fittings or bolts.
Relax track tension.
On a more frequent basis, inspect the front end
attachments for damage or excessive wear.
Install a top guard and front guard as required for
protection against falling rock.
Operating in extreme cold.
Use the proper fuel for the temperature conditions.
Using a hydrometer, check the antifreeze to make sure that
it is providing the proper cold weather freeze protection.
Verify the condition of the batteries. In extremely cold
weather remove the batteries at night and store them in a
warmer area.
Remove mud buildup as soon as possible to prevent it
from freezing to the undercarriage and causing damage.
Inspection, Maintenance and Adjustment
OP000484
4-86
OP000485
5Transportation
Obey all local, state or federal regulations for the transportation
of the excavator. If unsure of regulations check with local
authorities.
Check the intended route for road width, overhead clearances,
weight restrictions, and traffic control regulations. Special
approval or permits may be required.
LOADING AND UNLOADING
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 structure.
FG006999
Never rotate the upper structure once the counterweight or
Figure 1
front attachment has been removed.
OP000485
Transportation
5-1
WARNING!
When transporting the machine, know the width, height,
length and weight.
Loading or unloading the machine can be a dangerous
operation. Make sure to run the engine at the lowest speed
setting, and travel at the slowest speed possible.
Make sure that the ramp being used can handle the weight
of the machine. If required, add blocking under the ramp for
additional support.
Make sure that the ramp surface is free of grease or mud
that could cause the machine to slip or slide.
Make sure that the trailer is parked on firm, level ground
before attempting to load/unload the excavator.
If it is required to turn the machine while it is on the trailer,
make sure to do this at the slowest engine and travel
speeds possible.
Make sure to secure the excavator onto the trailer as
required by local transportation laws.
Total Height
Total Width
Total Length
Weight
Remarks
3,100 mm
3,200 mm
10,560 mm
24.6 metric tons
5.9 m Boom
(10' 2")
(10' 6")
(415.8 in)
(27.1 tons)
3.0 m Arm
600 G Shoe
1.
Make sure that the trailer is parked on firm, level ground.
See Figure 2.
2.
Make sure that the ramps that are being used are designed
to handle the weight of the excavator. If required, add
90 ~ 110
blocking under the ramp to provide additional support.
3.
The ramp angle should be less than or not exceeding a 15°
angle. Ramps steeper than this may cause a problem
when loading or unloading.
15
FG007000
Figure 2
Transportation
OP000485
5-2
4.
Set the travel speed selector switch to "O" (OFF) position.
See Figure 3.
O
I
II
FG000023
Figure 3
5.
Turn "OFF" auto idle selector button (1, Figure 4). The
indicator light (2) will not be lit.
2
1
6.
Set engine speed to "LOW IDLE."
POWER
AUTO
1
2
3
4
ESC
5
6
7
8
FG000164
Figure 4
7.
If the machine is equipped with work equipment, set the
work equipment at the front, and travel forward to load it.
90 ~ 110
15
FG007000
Figure 5
8.
The unit does not require disassembly for normal
over-the-road transportation. If the boom and arm need to
be removed, the counterweight will place more weight on
the rear of the machine. Make sure to back the excavator
onto the trailer so that the counterweight end of the
excavator is positioned on the ramp first. See Figure 6.
15
FG007002
Figure 6
OP000485
Transportation
5-3
9.
Extend bucket and arm cylinders to maximum length and
then lower the boom slowly.
FG007003
Figure 7
10. Set safety lever on "LOCK" position.
Unlock
lock
FG001091
Figure 8
11. Shut down engine by turning key to "O" (OFF) position
(Figure 9).
O I
12. Remove key from starter switch.
FG000175
Figure 9
13. Make sure to secure the excavator onto the trailer before
transporting. Place blocking (1, Figure 10) in front of
and behind each track. Use chains or cable tie-downs
(2) as required by local transportation laws.
14. Refer to the Dimensions for Transportation table and
1
drawing for overall machine height and width
1
measurements. Make sure to position the excavator as
shown. If not transported in this position, the height
measurements may be different.
2
FG007001
Figure 10
Transportation
OP000485
5-4
LIFTING WITH SLING
WARNING!
Improper lifting can allow load to shift and cause injury or
damage.
1.
Refer to “Specification” on page 7-1 of this manual for
information on weight and dimensions.
2.
Use properly rated cables and slings for lifting.
3.
Position machine for a level lift.
4.
Lifting cables should have a long enough length to prevent
contact with the machine. Spreader bars may be required.
NOTE:
If spreader bars are used, be sure that cables
are properly secured to them and that the angleFigure 11
of the cables is factored into the lift strength.
OP000485
Transportation
5-5
Transportation
OP000485
5-6
OP000013
6Troubleshooting
Anytime that a malfunction occurs, take immediate corrective
action. Check for and investigate the cause of the malfunction. A
schedule maintenance program can prevent malfunctions from
occurring by doing preventative maintenance. A systematic
approach should be taken to troubleshooting, since several
overlapping malfunctions may give the appearance of a problem
that does not exist. If cause for the malfunction cannot be
determined, contact your DOOSAN distributor. Never perform an
adjustment of or disassembly of, hydraulic components,
electrical and electronic components, without first consulting a
DOOSAN distributor.
ELECTRICAL SYSTEM
Problem
Cause
Remedy
Battery will not hold a
Low battery power.
Clean and retighten.
charge.
Alternator belt loose or bad.
Tighten or replace belt.
Loose or corroded terminals.
Tighten or replace as required.
Alternator faulty.
Repair or replace as required.
Low battery power.
Internal battery short.
Replace battery.
Short circuit in wiring.
Repair as required.
Engine speed is not
Speed control dial failed.
Replace control dial.
controllable.
Throttle controller failed.
Replace controller.
Speed control motor failed.
Repair or replace as required.
Blown fuse.
Replace fuse.
Wiring harness damaged.
Repair or replace as required.
Connector failed.
Repair or replace as required.
Power mode selector does
Blown fuse.
Replace fuse.
not work.
Power mode selector switch failed.
Replace switch.
Connector failed.
Replace connector.
Wiring harness damaged.
Repair or replace as required.
e-EPOS controller failed.
Repair or replace as required.
OP000013
Troubleshooting
6-1
Problem
Cause
Remedy
Working mode selector does
Blown fuse.
Replace fuse.
not work.
Working mode selector switch.
Replace switch failed.
Connector failed.
Replace connector.
Wiring harness damaged.
Repair or replace as required.
e-EPOS controller failed.
Repair or replace as required.
ENGINE
Problem
Cause
Remedy
Starter does not operate.
Low battery power.
Charge battery.
Poor terminal contact.
Clean and tighten connections.
Starter switch failed.
Replace switch.
Starter relay failed.
Replace relay.
Starter controller failed.
Replace controller.
Wiring harness faulty.
Replace harness.
Battery relay failed.
Replace relay.
Blown fuse.
Replace fuse.
Starter engages, engine
Fuel gelled in cold weather.
Replace fuel.
does not start.
Fuel filters plugged.
Replace filters.
Water or dirt in fuel system.
Clean system and add new fuel.
Air in fuel system.
Purge air from system.
Engine stop control failed.
Contact your DOOSAN dealer.
Engine stop relay failed.
Replace relay.
Blown fuse.
Replace fuse.
Engine starts, runs only at
Engine oil viscosity incorrect.
Change oil.
low speed or shuts down.
Clogged or dirty fuel injectors.
Clean injectors.
Fuel filters plugged.
Replace filters.
Troubleshooting
OP000013
6-2
Problem
Cause
Remedy
Engine knocks, runs
Low engine oil.
Refill.
unevenly or surges.
Plugged air intake system.
Clean system and replace filter.
Injection pump out of adjustment.
Contact your DOOSAN dealer.
Plugged fuel filter.
Replace fuel filter.
Water or dirt in fuel system.
Clean system and add new fuel.
Clogged or dirty fuel injectors.
Clean injectors.
Engine has poor power.
Plugged air intake system.
Clean system and replace filter.
Clogged or dirty fuel injectors.
Clean injectors.
Fuel filters plugged.
Replace filters.
Engine speed control cable out
Readjust.
of adjustment.
Injection pump out of adjustment.
Contact your DOOSAN dealer.
Valve backlash faulty.
Adjust backlash.
Engine runs hot.
Low coolant level.
Add coolant.
Thermostat faulty.
Replace thermostat.
Radiator cap faulty.
Replace radiator cap.
Radiator core plugged.
Clean radiator.
Oil cooler core plugged.
Clean oil cooler.
Fan belt loose or damaged.
Tighten or replace as required.
Temperature sensor faulty.
Replace sensor.
HYDRAULIC SYSTEM
Problem
Cause
Remedy
None of the controls
Hydraulic pump failed.
Contact your DOOSAN dealer.
function (loud noise from
pumps).
Low hydraulic oil level.
Add hydraulic oil as required.
Suction line plugged or damaged.
Clean or replace as required.
None of the controls
Pilot pump failure.
Contact your DOOSAN dealer.
function (no noise from
pumps).
Cut off solenoid valve failed.
Replace solenoid.
Pilot cutoff switch is ON.
Adjust pilot cutoff switch clearance.
OP000013
Troubleshooting
6-3
Problem
Cause
Remedy
All actuators have low
Low hydraulic oil level.
Add hydraulic oil as required.
power.
Suction filter clogged.
Clean filter.
Hydraulic pumps faulty.
Contact your DOOSAN dealer.
Main relief pressure too low.
Contact your DOOSAN dealer.
Hydraulic pumps excavating.
Bleed air from hydraulic pumps.
Only one or two actions
Overload relief pressure too low.
Reset pressure.
have little or no power.
Makeup check valve leaking.
Clean or replace as required.
Control valve spool faulty.
Replace valve spool.
Dirt in valve spool.
Clean or replace as required.
Actuator failed.
Repair or replace as required.
Cylinder seal failed.
Repair or replace as required.
Cylinder rod damaged.
Repair or replace as required.
Remote control valve failed.
Replace control valve.
Wrong pilot line connection.
Reconnect pilot lines.
Oil temperature too high.
Oil cooler faulty.
Contact your DOOSAN dealer.
Fan belt loose.
Tighten fan belting as required.
SWING SYSTEM
Problem
Cause
Remedy
No swinging motion.
Swing brake valve faulty.
Replace brake valve.
Hydraulic timer faulty.
Replace timer.
Low brake release pressure.
Adjust pressures.
Swing motor failed.
Replace swing motor.
Remote control valve failed.
Replace control valve.
Wrong pilot line connection.
Reconnect pilot lines.
Swing motion jerky.
Swing gear worn.
Replace swing gear.
Swing bearing damaged.
Replace bearing.
Improper lubrication.
Add grease.
Troubleshooting
OP000013
6-4
TRAVEL SYSTEM
Problem
Cause
Remedy
Travel motion does not
Center joint leaking.
Repair or replace as required.
function.
Parking brake will not release.
Repair parking brake.
Travel motor failed.
Repair or replace as required.
Remote control valve failed.
Repair or replace as required.
Wrong pilot line connection.
Reconnect pilot lines.
Travel speed is too low.
Track tension too high or too low.
Adjust tension.
Damaged rollers or idlers.
Repair or replace as required.
Track frame damaged.
Repair as required.
Parking brake will not release.
Repair parking brake.
OP000013
Troubleshooting
6-5
Troubleshooting
OP000013
6-6
OP000486
7Specification
STANDARD SPECIFICATION
SPECIFICATION
COMPONENT
METRIC
ENGLISH
Bucket
CECE
0.95 m3
1.24 yd3
capacity
PCSA
1.1 m3
1.44 yd3
Equipment weight
24.6 metric tons
27.1 tons
Engine
Model
DL06
Type
Water cooled - 6 cylinders
Rated output
175 ps @1,900 rpm
173 hp @1,900 rpm
Maximum torque
78 kg•m @ 1,400 rpm
564 ft lb @ 1,400 rpm
Fuel tank capacity
410 liters
108 U.S. gal.
Hydraulic
Type
Axial piston
pump
Discharging pressure
350 kg/cm2
5,000 psi
Maximum discharge quantity
2 x 219 liters/min
2 x 57.9 U.S. gpm
Hydraulic oil
Tank Level
150 liters
39.6 U.S. gal.
capacity
System
240 liters
63.4 U.S. gal.
Performance
Digging
Bucket
16.1 metric tons
17.5 tons
capability
Arm
12.1 metric tons
13.3 tons
Swing speed
10.0 rpm
High speed
5.2 km/h
3.2 MPH
Travel speed
Low speed
3.1 km/h
1.9 MPH
High speed
11 metric tons
12.2 tons
Traction force
Low speed
21.6 metric tons
23.8 tons
Gradeability
35˚ (70% slope)
Ground pressure
0.5 kg/cm2
7.1 psi
Ground clearance
450 mm
17.7 in
Track shoe width
600 mm
23.6 in
Upper roller qty.
2 per side
Bottom roller qty.
10 per side
Specification
OP000486
7-1
OVERALL DIMENSIONS
H
A
I
J
B
C
O
G
F
N
M
K
D
L
E
FG007004
Figure 1
5.3 m (17.3 ft) BOOM
5.9 m (19.4 ft) BOOM
DIMENSION
2.0 m (6.6 ft)
2.5 m (8.2 ft)
2.5 m (8.2 ft)
3.0 m (9.8 ft)
3.5 m (11.5 ft)
ARM
ARM
ARM
ARM
ARM
9,555 mm
9,470 mm
10,100 mm
10,055 mm
10,080 mm
A
(31' 4")
(31' 7")
(33' 3")
(33' 10")
(33' 8")
B
2,995 mm (9' 3")
6,560 mm
6,475 mm
7,105 mm
7,060 mm
7,085 mm
C
(21' 2")
(21' 5")
(23' 1")
(23' 7")
(23' 5")
D
3,835 mm (12' 10")
E
4,625 mm (15' 8")
F
1,110 mm (3' 5")
3,410 mm
3,180 mm
3,183 mm
3,100 mm
3,290 mm
G
(11' 10")
(10' 4")
(10' 5")
(10' 8")
(10' 10")
H
2,710 mm (8' 11")
I
1,400 mm (4' 11")
J
1,310 mm (4' 11")
K
2,600 mm (8' 3")
L
3,200 mm (10' 11")
M
600 mm (1' 8")
N
450 mm (1' 9")
O
2,970 mm (9' 5")
Specification
OP000486
7-2
WORKING RANGE
E
11
10
9
8
7
6
5
C
4
D
3
2
1
G.L
0
0
1
2
3
4
5
6
7
8
9
10
1
1
-1
-2
-3
B
-4
-5
-6
-7
-8
A
FG007005
Figure 2
5.3 m (17.3 ft) BOOM
5.9 m (19.4 ft) BOOM
DIM.
2.0 m (6.6 ft)
2.5 m (8.2 ft)
2.5 m (8.2 ft)
3.0 m (9.8 ft)
3.5 m (11.5 ft)
ARM
ARM
ARM
ARM
ARM
Max. digging
8,700 mm
9,070 mm
9,710 mm
10,195 mm
10,665 mm
A
radius
(28' 6")
(29' 9")
(31' 10")
(33' 5")
(35' 0")
Max. digging
5,380 mm
5,880 mm
6,315 mm
6,815 mm
7,315 mm
B
depth
(17' 8")
(19' 3")
(20' 9")
(22' 4")
(24' 0")
Max. digging
8,685 mm
8,610 mm
9,300 mm
9,605 mm
9,845 mm
C
height
(28' 6")
(28' 3")
(30' 6")
(31' 5")
(32' 4")
Max. dump
5,990 mm
6,010 mm
6,645 mm
6,925 mm
7,160 mm
D
height
(19' 8")
(19' 9")
(21' 10")
(22' 9")
(23' 6")
Min. digging
3,510 mm
3,580 mm
3,885 mm
3,845 mm
3,865 mm
E
radius
(11' 6")
(11' 9")
(12' 9")
(12' 6")
(12' 8")
Specification
OP000486
7-3
APPROXIMATE WEIGHT OF
WORKLOAD MATERIALS
IMPORTANT
Weights are approximations of estimated average
volume and mass. Exposure to rain, snow or ground
water; settling or compaction due to overhead weight
and chemical or industrial processing or changes due to
thermal or chemical transformations could all increase
value of weights listed in table.
LOW WEIGHT OR
MEDIUM WEIGHT OR
HIGH WEIGHT OR
DENSITY
DENSITY
DENSITY
MATERIAL
1,100 kg/m3
1,600 kg/m3
2,000 kg/m3
(1,850 lb/yd3), OR
(2,700 lb/yd3), OR
(3,370 lb/yd3), OR
LESS
LESS
LESS
401 kg/m3
Charcoal
---------------------
---------------------
(695 lb/yd3)
433 kg/m3
Coke, blast furnace size
---------------------
---------------------
(729 lb/yd3)
449 kg/m3
Coke, foundry size
---------------------
---------------------
(756 lb/yd3)
801 kg/m3
Coal, bituminous slack, piled
---------------------
---------------------
(1,350 lb/yd3)
881 kg/m3
Coal, bituminous r. of m., piled
---------------------
---------------------
(1,485 lb/yd3)
897 kg/m3
Coal, anthracite
---------------------
---------------------
(1,512 lb/yd3)
1,009 kg/m3
Clay, DRY, in broken lumps
---------------------
---------------------
(1,701 lb/yd3)
1,746 kg/m3
Clay, DAMP, natural bed
---------------------
---------------------
(2,943 lb/yd3)
1,506 kg/m3
Cement, Portland, DRY granular
---------------------
---------------------
(2,583 lb/yd3)
1,362 kg/m3
Cement, Portland, DRY clinkers
---------------------
---------------------
(2,295 lb/yd3)
1,522 kg/m3
Dolomite, crushed
---------------------
---------------------
(2,565 lb/yd3)
1,202 kg/m3
Earth, loamy, DRY, loose
---------------------
---------------------
(2,025 lb/yd3)
1,522 kg/m3
Earth, DRY, packed
---------------------
---------------------
(2,565 lb/yd3)
1,762 kg/m3
Earth, WET, muddy
---------------------
---------------------
(2,970 lb/yd3)
Specification
OP000486
7-4
LOW WEIGHT OR
MEDIUM WEIGHT OR
HIGH WEIGHT OR
DENSITY
DENSITY
DENSITY
MATERIAL
1,100 kg/m3
1,600 kg/m3
2,000 kg/m3
(1,850 lb/yd3), OR
(2,700 lb/yd3), OR
(3,370 lb/yd3), OR
LESS
LESS
LESS
3
961 kg/m
Gypsum, calcined, (heated, powder)
---------------------
---------------------
(1,620 lb/yd3)
3
1,522 kg/m
Gypsum, crushed to 3 inch size
---------------------
---------------------
(2,565 lb/yd3)
3
1,810 kg/m
Gravel, DRY, packed fragments
---------------------
---------------------
(3,051 lb/yd3)
3
1,922 kg/m
Gravel, WET, packed fragments
---------------------
---------------------
(3,240 lb/yd3)
3
1,282 kg/m
Limestone, graded above 2
---------------------
---------------------
(2,160 lb/yd3)
Limestone, graded
1,362 kg/m3
---------------------
---------------------
1-1/2 or 2
(2,295 lb/yd3)
3
1,522 kg/m
Limestone, crushed
---------------------
---------------------
(2,565 lb/yd3)
3
1,602 kg/m
Limestone, fine
---------------------
---------------------
(2,705 lb/yd3)
3
1,282 kg/m
Phosphate, rock
---------------------
---------------------
(2,160 lb/yd3)
3
929 kg/m
Salt
---------------------
---------------------
(1,566 lb/yd3)
3
529 kg/m
Snow, light density
---------------------
---------------------
(891 lb/yd3)
3
1,522 kg/m
Sand, DRY, loose
---------------------
---------------------
(2,565 lb/yd3)
3
1,922 kg/m
Sand, WET, packed
---------------------
---------------------
(3,240 lb/yd3)
3
1,362 kg/m
Shale, broken
---------------------
---------------------
(2,295 lb/yd3)
3
529 kg/m
Sulphur, broken
---------------------
---------------------
(1,620 lb/yd3)
Specification
OP000486
7-5
Specification
OP000486
7-6
1INDEX
Numerics
Cabin Work Light Switch 2-14
1,000 Hour / 6 Month Service 4-44
Ceiling Cover 2-63
10 Hour / Daily Service 4-14
Charge Warning Light 2-26
12,000 Hour / Six Year Service 4-58
Check and Confirmation After Stopping Engine
2,000 Hour / Yearly Service 4-51
3-12
250 Hour / Monthly Service 4-28
Cigarette Lighter 2-17
4,000 Hour / Biennial Service 4-57
Circuit Breaker 2-57
50 Hour / Weekly Service 4-25
Clock 2-25, 2-39
500 Hour / 3 Month Service 4-35
Cold Weather Hydraulic System Warm-up 3-10
Cold Weather Starting 3-6
Communication
A
Error Warning 2-30
Abnormal State Warning Symbols 2-31
Indicator 2-29
Adjust Valve Clearance 4-56
Component Locations 2-4
Air Intake System 4-22
Constant Speed Button 2-16
Outer Element of Air Cleaner 4-40
Coolant Temperature Warning Light 2-27
Replace Outer Air Cleaner Element 4-52
Cooling System
Alternator and Starter 4-56
Clean Radiator, Oil Cooler and Air Conditioner
Antifreeze Concentration Tables 4-76
Condenser Coil 4-39
Antivibration Shock Mounts 4-56
Engine 4-75
Ashtray 2-67
Engine Coolant Temperature Warning Light
Audio Control Panel 2-12
2-27
Auto Idle Mode 3-21
Oil Cooler Dust Net 4-20
Auto Idle Selector Button 2-35
Radiator Coolant 4-53
Auxiliary Mode Switch 2-11
Refill Cooling System 4-20
Cracks and Faulty Welds 4-23
B
Cup Holder 2-69
Batteries 4-34
Cycle Time Tests 4-56
Battery 4-71
Box Door 2-70
D
Electrolyte Level 4-72
Description of Lubrication and Service Chart 4-10
Terminals 4-72
Digital Clock 2-25
Voltage 2-30
Display Selection 2-38
Bolt and Nut Inspection 4-60
Display Selector Button 2-37
Boom, Arm and Front Attachment Pins 4-25, 4-29
Door Side Latch 2-66
Boost Mode 3-22
Door Window Holder 2-69
Booster Button 2-19
Down Arrow Button 2-37
Booster Cable 3-7
Breaker Selection 2-47
E
Bucket 4-68
O-ring 4-69
Electrical System 4-71, 6-1
Teeth and Side Cutters 4-21
Engine 6-2
Tooth 4-68
Adjust Valve Clearance 4-56
Check and Adjust Engine 4-50
Check Warning Light 2-27
C
Coolant Temperature Gauge 2-24
Cabin Light 2-57
Coolant Temperature Warning Light 2-27
Cabin Storage Compartments 2-67
Cover 2-70
K1016584E
Index
8-1
Emergency Stop Switch 2-11
Head Bolt Torques 4-56
Fan Belt 4-31
Headlight Switch 2-13
Head Bolt Torques 4-56
Heater and Air Conditioner 2-49
Oil and Filter 4-27, 4-36
Additional Operating Instruction 2-54
Oil Level 4-14
Control Panel 2-15, 2-50
Oil Pressure Warning Light 2-26
Filter 4-37, 4-48
Shutdown 3-11
Location of Controls and Vents 2-49
Speed 2-30
Memory Function of Used Mode 2-54
Speed Control Dial 2-10
Refrigerant 4-49
Start 3-4
System 4-59
Start and Stop 3-2
Horn Button 2-19
ESC Button 2-38
Hose Clamps 4-34
Excavator Rated Lift Capacity Tables 1-49
Hour Meter 2-26
Hydraulic System 6-3
Flow Control 2-45
F
Front Hydraulic Pump Pressure 2-31
Fan Belt 4-27
General Venting 4-84
Filter / Oil Info 2-40
Hydraulic Breaker 3-33
Filter State 2-31
Hydraulic Hoses and Tubing 3-33
Flow Control 2-45
Oil and Filter 3-37
Flow Control Button 2-35
Operation 3-33
Front
Selection 3-33
Bottom Window 2-65
Hydraulic Cylinders 4-83
End Attachments 4-34
Hydraulic Oil Exchange 4-54
Hydraulic Pump Pressure 2-31
Hydraulic Oil Return Filter 4-33, 4-45
Upper Windows 2-64
Hydraulic Oil Tank 4-15
Windows 2-64
Hydraulic Oil Temperature Gauge 2-25
Fuel
Leaks in the Hydraulic System 4-16
Filter 4-42
Main System Pump 4-83
Gauge 2-24
Oil Exchange 4-54
Heater Switch 2-18
Rear Hydraulic Pump Pressure 2-31
Level 4-16
Swing Motor 4-84
System 4-43
Warm-up 3-9
Transfer Pump 4-77
Tank Drain Valve 4-27
Transfer Pump 4-77
I
Fuse
Indicator
Boxes 2-58, 4-73
Communication Indicator 2-29
Fuses 4-72
Indicator Lights
Fusible Link 2-58
Charge Warning Light 2-26
Identification 4-74
Coolant Temperature Warning Light 2-27
Engine Check Warning 2-27
Engine Oil Pressure Warning Light 2-26
G
Preheating Indicator Light 2-28
Gauges
Work Light 2-28
Engine Coolant Temperature Gauge 2-24
Inspecting Engine Before Starting 3-2
Fuel Gauge 2-24
Inspection, Maintenance and Adjustment 4-1
Hour Meter 2-26
Instrument Panel 2-20, 2-22
Hydraulic Oil Temperature 2-25
Intermittent Speed Button 2-16
Multifunction Gauge 2-25, 2-29
General Venting 4-84
L
Language 2-39
H
Leaks in the Fuel System 4-17
Handling a New Excavator 3-1
Leaks in the Hydraulic System 4-16
Handling of Accumulator 4-80
Levers
Hanger 2-68, 2-69
K1016584E
Index
8-2
Adjusting Reclining 2-60
Overload Alarm Selection 2-48
Adjusting the Seat Forward 2-59
Overload Warning Switch (Optional) 2-18
Adjusting the Seat's Angle 2-59
Angle Adjustment of Armrest 2-60
P
Safety Lever 2-20
Panels
Lifting 3-41
Air Conditioner Control Panel 2-15
Lifting With Sling 5-5
Audio Control 2-12
Lights
Heater and Air Conditioner 2-49
Cabin 2-57
Heater and Air Conditioner Control Panel 2-50
Loading and Unloading 5-1
Instrument 2-20
Locations of Safety Labels 1-5
Instrument Panel 2-22
Long Term Storage 4-85
Wiper Switch 2-15
Lubrication and filters 3-2
Parking Excavator 3-31
Lubrication and Service Chart 4-8
Password
Activated 2-23
M
Set Password 2-43
Magnetic Clutch 4-59
Password Activated 2-23
Main Menu 2-36
Photo Sensor 2-21
Maintenance in Special Conditions 4-86
Pilot Cutoff Switch 2-57
Maintenance Intervals 4-12
Pilot Filter 4-33, 4-46
Miscellaneous Access Doors 2-70
Pins and Bushings 4-34
Mode Selection 3-20
Power Boost Selection 2-47
Mode Selector Buttons 2-34
Power Mode 3-20
Multifunction Gauge 2-25, 2-29
Power Mode Selector Button 2-34
Power Socket 2-17
Preheating Light 2-28
N
Preliminary Work Machine Setup for Maintenance
Nuts and Bolts 4-34
4-4
Preventive Maintenance 4-1
O
Pump Pressure
Oil Cooler Dust Net 4-20
Front Pump 2-31
Oil Level of Travel Reducer 4-32
Rear Pump 2-31
Opening the Window 2-64
Operating
Q
Controls 2-1
Quick Clamp Operation Selection 2-48
Instructions 3-20
Quick Clamp Switch (Optional) 2-11
Precautions 3-26
Techniques 3-41
Operation 3-1
R
Operation In
Radiator Coolant 4-53
Extreme Cold 3-43
Rear Hydraulic Pump Pressure 2-31
Extreme Heat 3-44
Refill Cooling System 4-20
High Altitudes 3-46
Rotating Buttons 2-19
Rainy or Humid Conditions 3-45
Salt Water Areas 3-46
S
Operation of All Switches 4-23
Safety 1-1
Operation Selection Display 2-47
Safety Lever 2-20, 3-13
Operation Under Unusual Conditions 3-43
Safety Precautions 4-3
Operational Checks Before Starting Engine 3-3
Seat 2-59
Operational Controls and Panels 2-8
Seat Adjustment
Operator's Area 2-6
Adjusting Reclining 2-60
Operator's Compartment Light 2-57
Adjusting the Seat Forward 2-59
Outer Air Cleaner Element 4-52
Adjusting the Seat's Angle 2-59
Outer Element of Air Cleaner 4-40
Adjustment of Lumbar Support 2-60
Overall Dimensions 7-2
K1016584E
Index
8-3
Air Suspension Seat 2-62
Cabin Work Light Switch 2-14
Angle Adjustment of Armrest 2-60
Cigar Lighter 2-17
Headrest 2-60
Constant Speed Button 2-16
Left ad Right Control Stand Location 2-61
Display Selector Button 2-37
Left and Right Control Stand Elevation Height
Down Arrow Button 2-37
2-61
Engine Emergency Stop 2-11
Seat Belt 2-60, 4-22
Engine Speed Control 3-20
Seat Warmer Switch (Optional) 2-18
Engine Speed Control Dial 2-10
Selection Button 2-37
ESC Button 2-38
Selection of
Flow Control Button 2-35
Breaker 2-47
Fuel Heater 2-18
Overload Alarm 2-48
Headlight Switch 2-13
Power Boost Selection 2-47
Horn Button 2-19
Quick Clamp Operation 2-48
Intermittent Speed Button 2-16
Shear 2-47
Overload Warning (Optional) 2-18
Serial Numbers 4-2
Pilot Cutoff Switch 2-57
Set Password 2-43
Power Mode Selector Button 2-34
Setting Clock 2-39
Power Socket 2-17
Shear Buttons 2-20
Quick Clamp (Optional) 2-11
Shear Selection 2-47
Rotating Buttons 2-19
Shutdown
Seat Warmer (Optional) 2-18
Check and Confirmation After Stopping Engine
Selection Button 2-37
3-12
Shear Buttons 2-20
Engine Shutdown 3-11
Starter Switch 2-10
Parking Excavator 3-31
Travel Speed Selector Switch 2-13
Side Door 2-70
Travel/Swing Alarm (Optional) 2-17
Specification 7-1
Trenching Mode Selector Button 2-35
Standard Specification 7-1
Up Arrow Button 2-36
Starter Switch 2-10
Warning Light 2-14
Starting Engine Using a Booster Battery 3-7
Washer Button 2-16
Start-up
Wiper Switch (Lower) 2-15
Cold Weather Hydraulic System Warm-up 3-10
Symbols
Cold Weather Starting 3-6
Air Cleaner Clogged Warning 2-33
Engine Start 3-4
Hydraulic Oil Overheat Warning 2-32
Hydraulic System Warm-up 3-9
Overload Warning (Optional) 2-34
Inspection Before Starting Engine 3-2
Pilot Filter Clogged Warning 2-32
Operational Checks Before Starting Engine 3-3
Return Filter Clogged Warning 2-33
Starting Engine Using a Booster Battery 3-7
Stereo 2-55
T
Audio Control Panel 2-12
Table of Recommended Lubricants 4-6
Structural Damage 4-56
Towing Procedure 3-32
Suction Strainer 4-54
Track Assemblies 4-27
Sun Visor 2-68
Track Tension 4-81
Swing
Transportation 5-1
Bearing 4-26
Travel 3-14
Gear and Pinion 4-35
Control Lever Operation 3-16
Motor 4-84
Instructions 3-17
Reduction Device 4-19, 4-28, 4-44, 4-51
Reduction Device 4-32, 4-33, 4-47
System 6-4
Speed Selector Switch 2-13
Switches
System 6-5
Auto Idle Selector Button 2-35
Travel/Swing Alarm Switch (Optional) 2-17
Automatic Travel Speed Control 3-14
Trenching Mode Selector Button 2-35
Auxiliary Mode 2-11
Troubleshooting 6-1
Booster Button 2-19
K1016584E
Index
8-4
U
Weight of Workload Materials 7-4
Unloading and Loading 5-1
Window Washer Liquid 4-21
Up Arrow Button 2-36
Windows
Door Window Holder 2-69
Front 2-64
V
Front Bottom 2-65
Venting and Priming Hydraulic System 4-83
Front Upper 2-64
General Venting 4-84
Opening 2-64
Hydraulic Cylinders 4-83
Sun Visor 2-68
Main System Pump 4-83
Wiper Switch (Lower) 2-15
Swing Motor 4-84
Wiper Switch Panel 2-15
Work Levers (Joysticks) (ISO Style) 3-23
W
Work Light Indicator Light 2-28
Warning Light Switch 2-14
Work Mode 3-21
Washer Button 2-16
Working Range 7-3
Water Separator 4-18
K1016584E
Index
8-5