Doosan DX300LCA. Operation and Maintenance Manual (2010)

Press "ESC" (

) button (3,Figure 72) for 1 more second, it

returns to main menu.

According to the selection of adoption (lock) or nonadoption

(unlock), the password function will be in working or nonworking.

SET PASSWORD

When you want to change a password, follow below procedure.

Lock

Move the cursor to "Change Password."

Unlock

Input desired 4 digits password using selector buttons (at

Change Password

the first column). Input the same password one more time

(at the second column)

Select adoption

(lock) or nonadoption

(unlock) at set

: UP

: DOWN

: SELECT

password menu.

FG000229

NOTE: Keep in mind never to forget password.

Figure 93

NOTE: Please contact a DOOSAN distributor, if you

forget your password.

Operating Controls

OP001003

2-43

FLOW CONTROL

02/05 [MO] 11:30

The flow control is used to set the proper flow rate for an

optional attachment (If equipped). The flow control screen is

accessed directly from the normal display screen without going

through the main menu or any submenus.

E/G SPEED 1700 RPM

FG000043

Figure 94

When the flow control button (Figure

70 and Figure 95) is

pressed at the normal display screen

(Figure

94), the flow

control screen (Figure 97) will be displayed.

FG000066

Figure 95

Select a tool by using the breaker / boost / shear selector switch.

The symbol in the upper left corner of the display screen will

change according to the position that the selector switch is in.

Compare the symbols shown in (Figure 97 and Figure 98).

FG000025

Figure 96

Operating Controls

OP001003

2-44

Adjusting Flow Rate

FLOW CONTROL

Use "UP" (

) or "DOWN" (

) buttons to adjust flow rate.

"UP" (

) button is used to increase a flow rate.

"DOWN" (

) button is used to decrease a flow rate.

Flow Control

Pump Flow Setting

Step

(l/min)

: APPLY

ESC: CANCEL

FG000254

Figure 97 Breaker

110

130

150

170

190

210

230

244

Pump flow setting is at rated engine speed, for only the output of

one pump.

FLOW CONTROL

Pump displacement will vary according to changes in engine

rpm.

: APPLY

ESC: CANCEL

FG000255

Figure 98 Shear

Escape

FLOW CONTROL

A. Press flow control button

(

, Figure

95) to return to

normal display screen and save the flow rate setting.

B. If there is no adjustment for twenty seconds, the flow

control screen will return to the normal display screen.

: APPLY

ESC: CANCEL

FG000254

Figure 99

Operating Controls

OP001003

2-45

Control Panel

A/C

OUTSIDE

AUTO

A/C

AUTO

MAX

TEMP

OFF

SEL

MODE

FG000086

Figure 106

Reference

Description

Number

Automatic Temperature Control

Air Inlet Selector Button

Button

Fan Speed Selector Button

Off Button

Air Conditioner Button

Temperature Control Button

Defroster Button

Temperature Unit Selector

LCD Display

Button

Air Outlet Selector Button

NOTE: When the light switch is turned to "I" or "II" position,

the LED for illuminating in the control panel will turn

"ON."

Automatic Temperature Control Button

This button is used to control the temperature level in the

cabin, according to the temperature setting of the operating

panel.

When the automatic temperature control function is

AUTO

activated, the word "AUTO" will be displayed in the upper

left of LCD display.

When the system is in "AUTO" mode, specifications can be

manually changed by pushing another button.

FG000088

If a function is manually changed, the word "AUTO" does

Figure 107

not appear in the LCD display, but the unchanged

functions will remain in "AUTO" mode.

Operating Controls

OP001003

2-49

Off Button

This button is used to stop the fan and air conditioner.

OFF

FG000089

Figure 108

Temperature Control Button

These buttons are used to control the cabin temperature.

Temperature is adjustable from 17°C (62°F) to 32°C (90°F)

by 0.5°C (1°F) increments.

Temperature setting is displayed on the LCD.

TEMP

When the system is turned "ON," the previously set

temperature is used as a starting point.

FG000090

Figure 109

Temperature Unit Selector Button

This button gives the choice to select either °C or °F.

SEL

FG000094

Figure 110

Operating Controls

OP001003

2-50

Mode Selector Button

This button is used to select which combination air outlets

will be used.

MODE

FG000096

Figure 111

A. Used to direct air flow to upper portion of operator's

cabin from both the front and rear.

FG015538

Figure 112

B. Used to direct air flow to upper portion of operator's

cabin from both the front and rear. It will also deliver

air to the lower portion of operator's cabin from under

the operator's seat.

FG015539

Figure 113

C. Used to direct air flow to lower portion of operator's

cabin and feet.

This mode is mainly used for heating.

FG015540

Figure 114

Operating Controls

OP001003

2-51

D. Used to direct air flow to the front window and to

operator's feet.

FG015541

Figure 115

Air Inlet Selector Button

This button is used to select fresh air from outside the

cabin, or recirculate air within the cabin.

Pressing this switch enables the choice between fresh air

and recirculating air within the operator's compartment.

The select mode is displayed on the LCD.

FG000101

Figure 116

A. "A" Symbol

- Draws fresh air into operator's

compartment. Used to exchange air within the

operator's compartment with fresh air. Used to

remove condensation or ice on window (Winter /

Rainy Season).

B. "B" Symbol - Recirculates air within the operator's

compartment. Used to quickly warm or cool the

operator's cabin.

FG000102

Figure 117

Fan Speed Selector Buttons

These buttons are used to control the speed of the blower

fan.

Momentarily, pressing a button, changes the speed one

stage.

Continuously pressing and holding a button, repeatedly

changes the speed.

FG000103

Figure 118

Operating Controls

OP001003

2-52

Air Conditioner Button

This button is used to turn the air conditioner "ON" or

"OFF."

When this function is activated, an "A/C" is displayed in the

upper left corner of the LCD.

A/C

FG000105

Figure 119

Defroster Button

Used to direct air flow to front window.

FG000106

Figure 120

10. LCD Display

This display shows the current setting.

A/C

OUTSIDE

AUTO

MAX

Memory Function

The air conditioner panel has a memory function. When the

starter switch is turned "OFF" the settings for the panel, will be

stored. When the excavator is started, the last stored setting will

be used.

FG000107

Figure 121

Additional Operating Instructions

A proper indoor temperature in summer is 5 - 6°C (10 - 12°F)

less than the outdoor temperature.

Operate the air conditioner for twenty - thirty minutes a week to

circulate the refrigerant in the system.

NOTE: The blower button should be on "Three Bars."

If operating the air conditioner or heater for a long time, operate

the air inlet selector button, and when smoking, vent the air to

the outside to prevent irritation to eyes.

Operating Controls

OP001003

2-53

STEREO

Before operating the stereo or CD player, read operation manual

enclosed with stereo.

Stereo

PROGRAM

AST

SOUND

AM/FM

SCAN

TUNE

FG000108

Figure 122

Reference

Description

Number

Power / Volume Control

Preset Station

Sound Mode Selector

Tape Ejection

Band Selection

Fast Forward / Rewind

Tuning Up / Down

Tape Loading Slot

Scan Function / Auto Store

LCD

CD Player (Optional)

AST/DIR

FG000109

Figure 123

Operating Controls

OP001003

2-54

MISCELLANEOUS ELECTRICAL

DEVICES

Cabin Light

A light is installed on the top of the operator's compartment.

The light will work despite starter switch position.

NOTE: If light is left "ON" for a long time while the engine is

not running, the battery will be discharged.

FG000417

Figure 124

Pilot Cutoff Switch

When the safety lever is put into the "LOCK" position, the switch

deactivates the work and travel levers. With the work and travel

levers deactivated, no digging/operational work can be done.

FG000211

Figure 125

Circuit Breaker

A main circuit breaker is in the battery box. It will automatically

cut off in case of an electrical short circuit or overload. This will

prevent the electric wiring and components from being burned or

damaged.

If the circuit breaker is cut off, check all related circuits, this

means something is wrong in the electric circuit.

After maintenance, press the red button for normal operation of

circuit breaker.

HAAE2110

Figure 126

Operating Controls

OP001003

2-55

Fusible Link

A fusible link is in the battery box.

If the engine does not crank, first check that the starter switch is

turned "ON" and that no power is available (No indicator lights

will light.). Check that the "A" portion (Figure 127) of the fusible

link is not broken or burned through. Replace the fusible link if

damage and investigate cause.

HAAE2120

WARNING

Figure 127

When changing the fusible link, replace the fusible link with

the same capacity part. Otherwise, a fire could break out in

the wiring harness and/or other components of the circuit.

Always use original DOOSAN parts.

Fuse Boxes

There are two fuse boxes (Figure 128) 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 access cover

indicates the function and amperage of each fuse.

NOTE: For a further explanation see

“Fuse Boxes” on

page 2-56.

Spare fuses are mounted on the inside of fuse box access

FG000110

cover.

Figure 128

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

fuse separates, check the circuit and repair the circuit.

CAUTION

Always replace fuses with the same type and capacity fuse

that was removed. Otherwise, electrical damage could

result.

Operating Controls

OP001003

2-56

SEAT ADJUSTMENT

WARNING

Adjust the seat position before starting operations or after

changing the operator.

Always fasten your seat belt while operating machine.

Adjust the seat so that the control levers and pedals can be

operated freely and easily with the operator back against

the backrest.

1. Forward / Backward Adjustment

Holding lever (1, Figure 129), raise it up, move the seat to

the desired position. Release lever to lock the seat in the

selected position. Adjustment range is 200 mm (7.9 in).

2. Seat Tilt and Height Adjustment

Forward Tilt

FG000183

Push lever (2, Figure 129) down to adjust the angle of the

Figure 129

front of the seat. There are four positions that it can be set

at.

Rear Tilt

Pull lever (2, Figure 129) up to adjust the angle of the rear

of the seat. There are four positions that it can be set at.

Seat Height

It is possible to move the seat up or down by combining

adjustments forward and rear tilt. Adjust the seat according

to operator's size and work conditions. Height adjustment

is 60 mm (2.4 in).

3. Suspension Adjustment

Turning knob

(3, Figure

129) to right makes the

suspension harder. Turning knob to left makes the

suspension softer. Adjust according to operator's weight by

checking the weight indicator dial. Adjustment range is

from 50 - 120 kg (110 - 265 lb).

Operating Controls

OP001003

2-57

4. Reclining Position Adjustment

Pulling up the right lever (4,Figure 129) allows the seat

backrest to be moved forward or backward.

Sit with your back against the seat back when adjusting it.

If your back is not touching the seat back, the seat back

may suddenly move forward.

5. Armrest Angle Adjustment

The angle of each armrest can be adjusted by turning a

dial (5, Figure 130) on bottom of armrest. When adjusting

the angle, manually raise the armrest before turning the

dial.

FG000778

Figure 130

6. Lumbar Support Adjustment

A lumbar support is located in the seat back.

Turn the dial (6, Figure 130) counterclockwise to increase

the force of the lumbar support

7. Headrest

The headrest (7, Figure 130) can be adjusted forward/

backward and up/down. Move it by holding both sides.

Operating Controls

OP001003

2-58

8. Seat Belt

WARNING

The seat belt is for the operator's safety and should

always be worn. Before driving the machine, adjust the

seat to the desired position for maximum comfort and

machine control, then fasten the seat belt. Seat belts

must be worn across the pelvic region and adjusted

snugly to lessen the chance and severity of injury in

case of an accident. Never fasten a seat belt across the

abdomen.

Under no circumstances should the operator be

standing in the cabin when operating the excavator.

Do not adjust the seat position while the vehicle is

moving because a loss of control may result. Stop the

machine, apply the parking brake, and then adjust the

seat.

Always, check the condition of seat belt and belt

bracket before fastening it. Do not use it with twists in

it. Replace belt or bracket if damaged or worn.

Seat Belt Locking and Unlocking

Insert belt end (1, Figure 131) into the buckle (2). Pull the

belt to check that belt end is locked into buckle.

Adjust belt length so that it comfortably tight against the

operator's pelvic region (hipbone).

HAOB140L

Figure 131

Press the button (3, Figure 132) in the center of buckle (2)

and pull out belt (1) to unlock.

HAOB150L

Figure 132

Operating Controls

OP001003

2-59

9. Seat Back-pocket

The seat has a seat back pocket. It is used for storing the

operation and maintenance manual.

10. Left and Right Control Stand

Adjustment

For operator's convenience, the right and left control

stands and seat can slide together, within a

160 mm

(6.3 in) forward or backward travel distance.

Holding lever (10, Figure 133), raise it up, set the seat to

desired position. Release lever to lock the seat in the

selected position.

FG000185

Figure 133

11. Left and Right Control Stand Height

Adjustment

The left and right dials (11, Figure 133) at the lower part of

the seat can be turned to adjust the elevation height of

each control stand.

It can be used to adjust the height of the control joystick.

12. Air Suspension Seat (Optional)

The operator seat is also available with air suspension for

even better comfort. The switch (12, Figure 134) in the

middle of the seat can be used to adjust the air cushion. If

the switch is pressed, the seat become harder, and pulling

it out makes the seat softer, when the air is bleed out.

FG000187

Figure 134

13. Heating the Operator's Seat (Optional)

The air suspension seat can be heated. The switch on the

left control stand is used to warm the seat. When heating is

not needed or seat is warmed, turn the switch to "OFF"

position.

FG000034

Figure 135

Operating Controls

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2-60

CEILING COVER

NOTE: If the machine is equipped with the optional

transparent ceiling cover never use any chemical

cleaners on its surface. Only use warm water to wash

dust and dirt from its surfaces, and after that, dry it

with a soft fabric towel.

FG000189

Figure 136

Opening the Ceiling Cover

Lower bucket to ground.

Set safety lever (Figure 136) on "LOCK."

Pull the lock (1, Figure 137) in front center of ceiling cover

and push it up with handle.

Closing the Ceiling Cover

Lower bucket to ground.

Set safety lever (Figure 136) on "LOCK."

Pull down cover with the handle (Figure 137) so that the

lock (1) can be locked in the bracket in the ceiling frame.

FG000190

Figure 137

Operating Controls

OP001003

2-61

FRONT WINDOWS

WARNING

When leaving operator's seat, set the safety lever to

"LOCK" position (Figure 138), if not a serious accident

could occur by accidentally moving the work levers.

FG000189

Figure 138

Front Upper Window

The front upper window can be housed in the cabin's ceiling.

Opening the Window

WARNING

When stowing front window in the cabin roof, make sure

both release levers (1, Figure 139) are latched.

Lower bucket to ground.

Set safety lever (Figure 138) on "LOCK."

FG000192

Set engine speed control dial to "LOW IDLE." Allow engine

Figure 139

to idle for three - five minutes.

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

Hold the window handles (1, Figure 139), then pull the lock

levers (2) to release the lock. The top of the front window

will come out.

Pull window up, and push it against lock pin at the rear of

the cabin. Make sure that it is securely latched.

Check that lock levers are securely latched in the lock

position.

NOTE: When the front upper window is open, never

extend your head or body through the window

frame.

NOTE: If the window happens to fall with a strong

impact against the machine, while some part of

your body is extended out of the cabin, it may

result in bodily injury.

Operating Controls

OP001003

2-62

Closing the Window

WARNING

Be careful that your hands are not caught in window frame.

Lower bucket to ground.

Set safety lever (Figure 138) on "LOCK," and shut down

engine.

FG000193

Holding upper handles (1, Figure 140) of front window with

Figure 140

left and right-hand, pull lock levers

(2, Figure

140) to

release the lock.

Push window forward, and lower it slowly.

When the bottom of the window, reaches the top of the

front bottom window, push the front window to engage the

lock (2, Figure 139).

Check that lock levers are securely latched in the lock

position.

Front Bottom Window

The front bottom window can be removed and stored in the rear

of the cabin.

After stowing the front upper window in the cabin ceiling,

remove bottom window (1, Figure

141) from cabin in

direction of the arrow.

FG000194

Figure 141

Set bottom window in rubber holders

(2, Figure

142)

behind operator's seat. Secure window with left and right

knobs (3) with push button (4).

WARNING

Never have wet hands when handling a window. Never

drop window or let it come into contact with other

parts of the machine.

FG001345

Figure 142

Operating Controls

OP001003

2-63

CABIN STORAGE

COMPARTMENTS

There are two storage compartments behind the operator's seat.

The large compartment

(1, Figure

145) is for storing

nonperishable items.

The covered other one (2, Figure 145) is interconnected with the

air conditioner. So, it can be supplied with either warm or cool air

when air conditioner is turned "ON."

FG000209

Figure 145

There is a separate small tray (3, Figure 146) on the right side of

operator's seat.

FG000675

Figure 146

ASHTRAY

An ashtray (1, Figure 147) is to the right side of the operator's

seat on the side of the cabin. Always close ashtray after putting

out a cigarette.

FG013855

Figure 147

Operating Controls

OP001003

2-65

SUN VISOR

The sun visor can be used to reduce the amount of sunlight

coming through the front window and ceiling.

When wanting to reduce the amount of sunlight coming in the

front window, pull bar (1, Figure 148) down.

When not wanting protection, hold the bar with left-hand and

push the release button (2, Figure 148) with right-hand. This will

allow the visor to retract.

FG000201

NOTE: Do not allow the visor to roll back up without holding

Figure 148

it. Not holding it may result in damage to the visor and

retract mechanism.

Ceiling sun visor

(3, Figure

149) slides forward and

backwards.Move it with handle (4) on each side.

FG000676

Figure 149

When opening the ceiling cover (if equipped), push the sun visor

into its compartment (Figure 150).

FG000204

Figure 150

HANGER

A hanger (1, Figure 151) is located on the upper left side of the

operator's compartment.

WARNING

Do not hang anything that will easily fall down, or will

impair your view out of the cabin.

FG000210

Figure 151

Operating Controls

OP001003

2-66

CUP HOLDER

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

Figure 152). Open the access cover and lower it to a horizontal

position.

FG000205

Figure 152

DOOR WINDOW HOLDER

When the machine is being operated with the cabin door window

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

Figure 153) against the window.

FG000206

Figure 153

EMERGENCY GLASS BREAKING

TOOL

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

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

an emergency situation which requires the breaking of glass to

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

point to break the glass.

FG000178

WARNING

Figure 154

Protect your eyes when breaking the glass.

Operating Controls

OP001003

2-67

MISCELLANEOUS ACCESS

COVERS AND DOORS

Side Door

Open the side access door and slide prop rod (1, Figure 155) in

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

FG000165

Figure 155

Battery Box Door

Opening

Open door until locking device (1, Figure 156) latches.

Closing

While holding door, press locking device to release lock and

close door.

FG000166

Figure 156

Engine Cover

Open the cover and slide prop rod (1, Figure 157) in the slot (2)

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

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

in slot.

FG000167

Figure 157

Operating Controls

OP001003

2-68

OP001004

3Operation

TO HANDLE A NEW

EXCAVATOR

All DOOSAN excavators are inspected and adjusted before

leaving the factory. However, it is required that the operator

follow these steps during the initial break-in period. Failure to

follow these steps may result in damage to the equipment or

reduced performance.

Hour

Load

Maintain about 80% load of

For first 50 hours of operation.

full capacity (Engine rpm:

80% of rated rpm)

After first 50 hours of operation.

Full load

If machine is used at full load before it is broken in, it may affect

the life cycle and safe running operations. This could lead to

problems later.

NOTE:

Check daily for leakage of coolant, fuel, engine

oil and hydraulic oil.

Inspect all lubricants daily, add appropriate

lubricants as required.

During operation, monitor all instruments and

gauges from time to time.

Avoid an extreme engine load.

Operate unit at 80% load until engine and all

other components are at operating temperature.

Check that work equipment is operating

normally during operation.

Check machine for loose parts or for damage

that may have occurred during shipping.

Check for loose wiring or terminals, check

gauge operation and battery electrolyte level.

Operation

OP001004

3-1

Lubrication and Filters

Change engine oil and replace oil filter after first 50 hours

of operation.

Change swing reduction device oil after first 250 hours of

operation.

Change hydraulic oil return filter after first 250 hours of

operation.

Replace travel and reduction gear oil after first 250 hours

of operation.

NOTE: For the replenishment of oil or grease, refer to

“Inspection, Maintenance and Adjustment” on

page 4-1 of this manual.

STARTING AND STOPPING THE

ENGINE

Inspection Before Starting Engine

WARNING

If a flammable materials such as leaves, paper, etc. are

allowed to accumulate on high temperature components,

such as the engine muffler and turbo, a fire may occur. Fuel,

lubricant and hydraulic oil leaks, may cause a fire. If there is

anything wrong, perform the appropriate corrective action.

Before starting engine, inspect the following items;

Electric system - Check for damaged electric cables, and

loose or missing connectors.

Fuel system - Drain water and sediment from fuel tank and

water separator.

Hydraulic system - Check for hydraulic oil leaks, damaged

tubing and hoses, and interference points of components.

Lubrication - Perform all daily and periodic maintenance

services. Perform services according to reading shown on

hour meter.

Safety - Perform a machine walk-around. Make sure that

no one is under the machine or performing any

maintenance on it, before starting engine.

After starting machine - Check that all operational controls

and components, are in proper operating condition, and

are functioning correctly. Stop operation and correct any

malfunction before continuing work.

Operation

OP001004

3-2

Operational Checks Before Starting

Engine

WARNING

When leaving operator's seat, set the safety lever to

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

occur by accidentally moving the travel or work levers.

FG000211

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

Figure 1

Fasten seat belt. Check for proper operation and condition.

Set all operation levers in "NEUTRAL."

NOTE: Be careful not to touch any switches when

starting engine.

Rotate the starter switch to the "I" (ON) position (Figure 2).

Check all indicator lights. A warning buzzer will sound for

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

following will turn "OFF."

•

Charging warning light

•

Engine oil pressure warning light

•

Engine coolant temperature gauge

•

Fuel gauge

•

Hydraulic oil temperature gauge

FG000084

Figure 2

•

Engine rpm (0 rpm) digital readout

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

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

Operation

OP001004

3-3

Engine Start

WARNING

Start the engine after sounding horn and making sure that

there are no people or obstacles in the area.

Perform all steps in “Operational Checks Before Starting

Engine” on page 3-3.

Set engine speed control dial slightly above "LOW IDLE"

(Figure 3).

Sound horn.

HAOB34L

Figure 3

Enter password.

DELETE FAIL LOG

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

password will be required to start the engine. If the

system is "UNLOCKED," no password will be

ENTER PASSWD

required and this display screen will not appear.

: Yes

ESC: No

FG000568

Figure 4

" "

Turn starter switch to

(START) position (Figure 5).

Engine should start in approximately five seconds.

WARNING

If the engine does not start after approximately fifteen

seconds of cranking, release the starter switch. Wait

about five minutes and repeat above step.

FG000085

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

"I" (ON) position (Figure 5).

Figure 5

Follow procedures in

“Hydraulic System Warm-up” on

page 3-9.

Operation

OP001004

3-4

After warming unit, check all operating indicators to make

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

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

shut down engine. Normal indicators are:

CHECK

02/05 [MO] 11:30

E/G SPEED

1700 RPM

FG000092

Figure 6

INDICATOR

No.

INSTRUMENT PANEL LIGHT OR GAUGE

READING

Engine Coolant Temperature Gauge

Blue Range

Fuel Gauge

Blue Range

Hydraulic Oil Temperature Gauge

Blue Range

Charging Warning Light

OFF

Engine Oil Pressure Warning Light

OFF

Engine Coolant Temperature Warning Light

OFF

Engine Check Warning Light

OFF

Check color of exhaust smoke.

•

No color or light blue - Engine is running in good

condition.

•

Black - Incomplete combustion. Check cause.

•

White or dark blue - Engine is burning engine oil.

Check cause.

10.

Check for usual engine vibration and noises. If any are

heard or felt, investigate cause.

NOTE: If engine coolant temperature gauge pointer

moves into the red zone, the engine coolant

temperature warning light will turn "ON," a

warning buzzer will sound, and the engine

speed will be automatically reduced. Allow the

engine to run at low idle speed until the

temperature gauge registers in the blue zone

again. When the blue zone is reached, allow the

engine to idle for an additional three

- five

minutes before shutting down the engine. If not

allowed to idle, heat surge may develop which

will damage the engine. Allowing the engine to

idle will dissipate heat. Check the coolant level,

look for a loose fan belt, inspect for debris

around radiator, and so on.

Operation

OP001004

3-5

Cold Weather Starting

WARNING

DO NOT USE STARTING FLUIDS. The preheat system could

cause the starting fluid to explode. Starting fluids should

never be used.

Perform all steps in "Operational Checks Before Starting

HAOB34L

Engine."

Figure 7

Set engine speed control dial slightly above "LOW IDLE"

(Figure 7).

Sound horn.

Turn starter switch to the "I" (ON) position (Figure 8). When

preheat cycle is completed, the preheat indicator light (1,

Figure 9) will turn "OFF."

FG000084

Figure 8

CHECK

FG000217

Figure 9

After the preheat completion, immediately turn starter

" "

switch to

(START) position

(Figure

10). Engine

should start in approximately five seconds.

WARNING

If the engine does not start after approximately fifteen

seconds of cranking, release the starter switch. Wait

FG000085

about five minutes and repeat above step.

Figure 10

Operation

OP001004

3-6

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

"I" (ON) position (Figure 10).

After the engine starts, check all operating indicators to

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

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

noticed, shut down engine.

Follow "Hydraulic System Warm-up" procedures in this

section. (See page 3-9)

Starting Engine With a Booster Cable

WARNING

An explosive gas is produced while batteries are in

use or being charged. Keep flames or sparks away

from the battery area.

Charge batteries in a well ventilated area.

HAOA440L

Always wear eye protection when starting a machine

Figure 11

with jumper cables.

Improper jump starting procedures can cause an

explosion resulting in personal injury.

Jump start vehicles on dry ground or concrete. Do not

jump start the machine on a steel floor, because the

floor is always grounded.

When starting from another machine, make sure the

machines do not touch.

Always connect the auxiliary battery positive

(+)

terminal too depleted battery positive (+) terminal first.

Then connect auxiliary battery negative (-) terminal to

the frame of the depleted battery machine second.

Connect positive cable first when installing cables and

disconnect the negative cable first when removing.

IMPORTANT

The machine has a

24V (-) negative ground electrical

system. Use the same capacity 24V booster batteries when

jump starting engine.

If the batteries are drained during starting procedures, jump start

engine using auxiliary or booster batteries according to the

following procedure;

Operation

OP001004

3-7

Connecting the Booster Batteries

Shut down engine of the machine on which booster

RED

batteries (3, Figure 12) are mounted.

Connect one end of red cable (1, Figure 12) to the positive

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

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

Connect one end of black cable (2, Figure 12) to the

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

BLACK

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

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

ARO0440L

(2, Figure 12). When making the last connection to upper

Figure 12

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

the machine batteries as possible. DO NOT CONNECT

DIRECTLY TO THE NEGATIVE BATTERY TERMINAL.

Start the engine.

Disconnecting the Booster Batteries

Disconnect black negative (-) cable (2, Figure 12) from the

machine frame (5) first.

Disconnect the other end of black negative (-) cable (2,

Figure 12) from the booster batteries (3).

Disconnect red positive (+) cable (1, Figure 12) from the

booster batteries (3).

Disconnect red positive (+) cable (1, Figure 12) from the

machine batteries (4).

Operation

OP001004

3-8

Hydraulic System Warm-up

WARNING

If a problem or abnormal operation occurs, immediately

shut down engine. Allow excavator to reach normal

operating temperature before starting work, especially in

cold weather.

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

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

here for hydraulic fluid warm-up.

Run engine for approximately five minutes set at the

middle of the speed range, without a load.

HAOB410L

Figure 13

Set safety lever (1, Figure 14) on "UNLOCK" position.

FG000093

Figure 14

Slowly cycle boom, arm and bucket cylinders about five

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

Do this for five minutes.

Check for clearance and fully raise the front attachment.

Swing clockwise 3 revolutions. Swing counterclockwise 3

revolutions.

Travel forward and reverse at low speed for two

revolutions of the drive sprocket.

FG000380

Figure 15

Operation

OP001004

3-9

Hydraulic System Warm-up - Cold Weather

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

(Figure 16).

HAOB290L

Figure 16

Run engine for approximately five minutes set at the

middle of the speed range, without a load (Figure 17).

HAOB410L

Figure 17

Set safety lever (1, Figure 18) on "UNLOCK" position.

FG000093

Figure 18

Slowly cycle boom, arm and bucket cylinders about five

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

Do this for five minutes.

FG000380

Figure 19

Operation

OP001004

3-10

Set engine speed control dial to "HIGH IDLE" (Figure 20).

Repeat Step 4 for five minutes. If working speeds continue

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

because the machine function may be erratic.

Check for clearance and fully raise the front attachment.

Slowly swing clockwise

3 revolutions. Slowly swing

counterclockwise 3 revolutions.

Travel forward and reverse at low speed for two

revolutions of the drive sprocket.

HAOB550L

Figure 20

Engine Shut Down

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

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

surge may develop which will damage the engine.

Allowing the engine to idle will dissipate heat.

Park excavator on level and firm ground.

Lower front end attachment to ground and make sure all

operating controls are in "NEUTRAL."

FG000111

Figure 21

Set safety lever on "LOCK" position (Figure 22).

Unlock

lock

FG001091

Figure 22

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

Allow engine to idle for three - five minutes.

HAOB290L

Figure 23

Operation

OP001004

3-11

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

(Figure 24).

Remove key from starter switch.

FG000175

Figure 24

Check and Confirmation After Stopping

Engine

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

Inspect front attachment and under carriage for abnormal

appearances. Correct any problems.

Fill fuel tank.

Get rid of any accumulated flammable materials such as

leaves and paper etc. in engine compartment.

Clean all mud, etc. from undercarriage and tracks. Make

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

operator's compartment is clean.

Operation

OP001004

3-12

SAFETY LEVER

WARNING

When stopping engine or leaving the operator's seat,

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

occur by accidental movement of travel and work levers.

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

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

Especially, when adjusting the seat, control stands, or

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

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

position.

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

safety lever.

Push safety lever (Figure 25) down into the "LOCKED"

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

the front attachment, swing and travel movement will be

disabled even though a lever is moved.

Unlock

NOTE: Lower bucket

(front attachment) to ground.

Place all control levers in "NEUTRAL" and shut

down engine, before using the safety lever.

Set safety lever

(Figure

25) on "RELEASE/UNLOCK"

position, by pulling it up before starting work.

lock

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

FG001091

lever is "RELEASED" and the starter key is

Figure 25

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

may result in movement. The charged

accumulators in the system will provide pilot

pressure for control valve spool movement.

Operation

OP001004

3-13

TRAVEL

WARNING

Before operating the travel levers, make sure that you

know in which direction the machine is pointing. Look at

the end of the track assemblies. If the drive motors are

visible while sitting in the operator's seat, you are

looking at the back end of the track assembly (therefore,

you are looking backwards). In this case, the response of

the travel levers will be the reverse of normal operation.

Before moving, make sure that there are no personnel

in the way or on the machine. Sound the horn to alert

workers that you are about to move the machine.

Be sure the path is clear during travel.

Use extreme caution when reversing travel. Be sure

there is a clear path behind the machine.

Make sure to operate the travel control levers

smoothly to avoid sudden starts or stops.

Before leaving the operator's seat, make sure to lock

out all control systems and shut down the engine to

avoid accidental activation.

Automatic Travel Speed Control

WARNING

Do not change the travel mode while traveling. Always use

speed mode "O" when traveling down a slope. It is very

dangerous to change to speed modes indicated "I" or "II"

while going down a slope. Only change travel mode after

coming to a complete stop.

Two travel speed ranges can be selected by using the travel

speed selector switch on the control panel (Figure 26).

"O" (LOW) - In this position low travel speed and a higher torque

are selected.

"I" (HIGH) - In this position high travel speed and a lower torque

are selected.

"II"

(AUTOMATIC) - Setting the control at the "II" position

enables the machine to change to a different speed range

automatically. This change happens automatically depending on

the hydraulic oil pressure in the travel circuit. When hydraulic oil

FG000023

pressure rises, the travel speed is automatically set to low. An

Figure 26

example is if the machine is traveling on a flat, solid surface, the

higher speed range would be used. When a slope is

encountered, the speed drops and the travel circuit hydraulic

pressure rises, causing the control circuit to shift to the higher

torque, lower speed range.

Operation

OP001004

3-14

Travel Control Lever Operation

To travel straight

(Figure

27), push both travel control

levers/pedals fully forward or backwards. The farther the

levers/pedals are pressed, the faster the travel speed.

NOTE: "X" is the sprocket end of the track.

"X"

FG000303

Figure 27

Pivot turns (Figure 28) are made by rotating only one track

forward or backward. The machine will pivot on the

nonmoving track.

NOTE: "X" is the sprocket end of the track.

"X"

FG000304

Figure 28

Spin turns (Figure 29) are made by rotating one track

forward and one track backward. The machine will spin

around its center point, thus counterrotating.

NOTE: "X" is the sprocket end of the track.

"X"

FG000305

Figure 29

Stopping travel (Figure 30) - Returning travel levers to

"NEUTRAL" position will automatically apply brakes and

stop excavator.

NOTE: "X" is the sprocket end of the track.

"X"

FG000306

Figure 30

Operation

OP001004

3-15

General Travel Instructions

Set engine speed control dial

(Figure

31) on desired

speed.

HAOB550L

Figure 31

Set safety lever on "UNLOCK" position, and folding the

front, raise it 40 - 50 cm (16 - 20 in) above ground. See

Figure 32.

40 ~ 50 cm

FG000123

Figure 32

When possible, travel on firm, level ground. Avoid sudden

movements and sharp turns.

When traveling on rough ground, travel at a slow speed

[1.0 - 1.5 km/h (0.62 - 0.93 MPH)]. Reduced engine speed,

to avoid shock loading the equipment. Be careful that an

excessive force is not added to equipment by touching or

climbing on rocks.

FG000423

Figure 33

Operation

OP001004

3-16

On rough, frozen or uneven terrain, travel slowly.

WARNING

When traveling, keep bucket from 20 - 30 cm (8 - 12 in)

above ground.

Do not travel backward on a slope.

Never turn or travel crosswise on a slope.

Choose a safe alternate route before climbing a slope.

FG000212

If excavator starts to slip or becomes unstable, lower

Figure 34

the bucket immediately into the ground, using it as a

brake.

Avoid working on slopes, because there is a danger of

overturning by becoming unbalance while swinging

and performing front attachment operations.

It is very dangerous to swing towards bottom of slope

with a loaded bucket.

In unavoidable cases level the slope with fill soil, to

make the vehicle as horizontal as possible. See Figure

34.

Do not travel on slopes more than 30° due to turnover

FG000126

danger.

Figure 35

Travel straight up or down slopes, never diagonally across

the slope. See Figure 35 and Figure 36. Extend the arm

and lower the boom to keep the bucket about 20 - 30 cm (8

12 in) off the ground. If the machine starts to slide or

becomes unstable, lower the bucket to regain control. If the

engine stalls, lower the bucket, make sure that all controls

are in the neutral position and restart the engine.

NOTE: Even though engine stops on a slope, do not

operate swing control. The hydraulic

accumulators may cause the unit to swing.

FG000128

NOTE: Do not open or close operator's door on a slope.

Figure 36

Make sure door is latched.

If dirt or mud builds up in the track frame, raise each track

and rotate and clean that track.

CAUTION

When using the boom and arm to lift any portion of the

machine, roll the bucket until the round base is against

the ground. The angle of the arm to the boom should

be at 90°.

FG000376

Figure 37

Operation

OP001004

3-17

Make sure that the material buildup has been cleared. See

Figure 37 and Figure 38.

The excavator can travel in water that comes up to center

of upper carriage rollers. Make sure that footing is solid so

that the machine will not sink. See “Working in Water” on

90 ~ 110

page 3-29.

NOTE: If the machine is submerged to the point that

water or mud gets into the swing bearing or

center joint, stop machine operation. Remove

the machine from the submerged location to

FG000345

firm, dry ground. Do not operate until proper

Figure 38

inspection and maintenance have been

completed. Refer to the Shop Manual or contact

your distributor.

Operation

OP001004

3-18

OPERATING INSTRUCTIONS

Engine Speed Control

Engine speed can be manually adjusted using the engine speed

control dial, Increase engine speed by rotating the control knob

clockwise. Decrease engine speed by rotating the control knob

counterclockwise.

IMPORTANT

The engine speed control system has been set at the

HAOA690L

factory and should not require adjustment as part of routine

Figure 39

maintenance.

Mode Selection

More efficient work can be done by choosing a proper power

and work mode combination, suitable to type of work and

conditions. Use the mode selection according to following guide.

Power Mode

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

automatically defaulted to the standard setting.

POWER

Select a proper power mode using button (1, Figure 40)

AUTO

before starting work.

When the power mode button (1, Figure 40) is pressed, a

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

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

indicates on the screen.

FG015474

Deactivate the power mode by pressing it a second time.

Figure 40

When the power mode is turned "OFF," the symbol of

standard mode indicates on the screen and the power

mode returns to the standard mode.

Mode

Selection Point

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

POWER MODE

• Fast speed loading.

• Fast speed travel.

• General work.

STANDARD MODE

• Minimize fuel consumption.

• Light work.

ECONOMY MODE

• Minimize fuel consumption.

• Reduce noise.

Operation

OP001004

3-19

Economy Mode

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

automatically defaulted to the digging mode.

POWER

Select the work mode using button (2, Figure 41) before

AUTO

starting work.

When the economy mode button (2, Figure 41) is pressed,

a signal sounds, changing the economy mode to either

"ON" or "OFF". When the economy mode is turned "ON"

the symbol appears on the screen.

FG015475

Deactivate the economy mode by pressing it a second

Figure 41

time. When the economy mode is turned "OFF". the

symbol of standard mode indicates on the screen and the

economy mode returns to the standard mode.

Auto Idle Mode

The system will automatically reduce engine speed to idle

speed approximately four seconds after all of the control

POWER

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

AUTO

activated, engine speed is automatically returned to the

preselected range.

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

automatically defaulted to "AUTO IDLE".

When the symbol is turned "ON", the auto idle function is

activated. Deactivate the auto idle function by again

FG015518

pressing the auto idle selector button (3, Figure 42). At this

Figure 42

time the LED indicator will be turned "OFF".

WARNING

Turn "OFF' auto idle function when performing work in

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

loading / unloading on or off a trailer.

Operation

OP001004

3-20

Work Levers (Joysticks) (ISO Style)

WARNING

Check surrounding area before swinging. When operating a

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

speed will increase rapidly.

NOTE: When starting work, move work levers (joysticks) slowly

FG013842

and check movement of swing and front attachment.

Figure 44

This equipment is manufactured using the lever configuration

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

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

and swing direction of work levers (joysticks) are as follows:

Left-hand Work Lever (Joystick) (Figure 44 and Figure 45)

Arm dump

Arm crowd

Left swing

Right swing

NOTE: The swing brake is spring applied and

hydraulically released. It is always engaged

when the work lever (joystick) is in "NEUTRAL"

or the engine is shut down.

FG000119

Figure 45

NOTE: The following is not a mechanical malfunction

but a proper phenomenon of the excavator.

When operating the arm, it may stop

momentarily. When the arm is operated, the

weight of the arm may cause it to move faster

than the amount of oil being supplied.

FG000120

Figure 46

Right-hand Work Lever (Joystick) (Figure 44 and Figure 47)

Boom down

Boom up

Bucket crowd

Bucket dump

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

lowered to the ground by operating work lever

(joystick), by setting safety lever on "UNLOCK"

position and turning starter switch "ON."

FG000121

Figure 47

Operation

OP001004

3-22

Change Machine Control Pattern by Select

Valve (If Equipped)

WARNING

Check surrounding area before swinging. When operating a

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

speed will increase rapidly.

FG013842

Figure 48

NOTE: When starting work, move work levers (joysticks)

slowly and check movement of swing and front

attachment.

The machine control pattern can easily be changed to the ISO

standard or to the BHL standard by changing the position of the

select valve

(if equipped). Use the following procedure to

change the position of the select valve.

The select valve is located in the rear of the cabin.

Rotating spool to the ISO position or to the BHL position.

(Figure 49)

FG004954

Figure 49

Operation

OP001004

3-23

Work Levers (Joysticks) (BHL Style)

Left-hand Work Lever (Joystick) (Figure 48 and Figure 50)

Boom down

Boom up

Left swing

Right swing

NOTE: The swing brake is spring applied and

hydraulically released. It is always engaged

when the work lever (joystick) is in "NEUTRAL"

or the engine is shut down.

FG004951

Figure 50

Right-hand Work Lever (Joystick) (Figure 48 and Figure 51)

Arm dump

Arm crowd

Bucket crowd

Bucket dump

NOTE: The following is not a mechanical malfunction

but a proper phenomenon of the excavator.

When operating the arm, it may stop

momentarily. When the arm is operated, the

FG004952

weight of the arm may cause it to move faster

Figure 51

than the amount of oil being supplied.

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

lowered to the ground by operating work lever

(joystick), by setting safety lever on "UNLOCK"

position and turning starter switch "ON."

FG000120

Figure 52

Operation

OP001004

3-24

OPERATING PRECAUTIONS

WARNING

Do not rest your feet on the travel pedals during normal

machine operation. Unexpected machine travel may occur

in this situation.

Before starting work, investigate terrain and soil condition.

Level ground and drain area if necessary.

Install window guards when working where there is a

possibility of falling rocks or other objects.

FG000374

Figure 53

Check strength of supported structures in advance before

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

exists about structural strength, refuse to operate unit.

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

contact with the upper or lower structure of the machine.

There are digging conditions which could allow this to

happen.

FG000375

Figure 54

Do not continually "bottom out" the hydraulic cylinders.

Machine damage may occur if the cylinders are fully

extended or retracted, example: arm cylinder fully retracted

and the bucket cylinder is extended to rotate the bucket

into the ground.

FG000132

Figure 55

Operation

OP001004

3-25

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

the ground to provide additional breakout force. See Figure

56.

FG000134

Figure 56

Do not use machine weight to provide additional breakout

force. See Figure 57.

When working on soft or muddy ground, make sure that

the machine is not sinking.

FG000137

Figure 57

When working close to the excavated edge, make sure

that the ground the machine is sitting on is solid. Keep the

travel motors (1, Figure 58) to the rear. See Figure 58.

FG000677

Figure 58

10. Do not excavate underneath the machine. See Figure 59.

FG000170

Figure 59

Operation

OP001004

3-26

11. Make sure that there is adequate clearance from overhead

electrical supply lines. See Figure 60.

FG000171

Figure 60

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

building, make sure that there is adequate overhead

clearance and that there is adequate ventilation. See

Figure 61.

FG000172

Figure 61

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

This is dangerous and causes damage to the front

attachment. See Figure 62.

FG000173

Figure 62

14. Do not dig with the excavator tracks raised. This can result

in structural and mechanical failures.

FG000174

Figure 63

Operation

OP001004

3-27

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

range.

•

Avoid sudden starts.

•

When traveling in one direction come to a complete

stop before reversing directions. Do not rock

excavator back and forth with levers.

•

Avoid sudden stops. Return levers to neutral by

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

own.

FG000213

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

Figure 64

front end attachments are used, the machine balance will

be altered. Follow these additional operating precautions.

WARNING

Do not travel downhill with the front end attachments

raised.

Do not travel across slopes; travel straight up or down

slope.

Use extreme caution when swinging the upper frame

when positioned on a slope.

Allow extra swing stopping room. The additional

momentum generated by the longer or heavier front

end equipment will increase the amount of time

needed to stop the swing motion.

Make sure that all optional equipment has been

authorized and installed properly.

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

them. This can result in structural and mechanical failures.

Operation

OP001004

3-28

Working in Water

IMPORTANT

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

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

structure will be immersed in water, resulting in radiator fan

and engine ECU damage.

FG000179

Figure 65

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

upper roller (1, Figure 66).

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

grease is purged from bearing.

If water gets into swing gear housing, drain water immediately

by removing lower inspection cover. Apply new grease.

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

FG000181

Figure 66

Operation

OP001004

3-29

PARKING EXCAVATOR

WARNING

120

Park excavator on firm, level ground. Avoid parking on

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

and place bucket teeth in ground. See Figure 67.

FG000214

Figure 67

Park excavator on firm, level ground. Lower bucket to

ground as shown in Figure 68.

FG000111

Figure 68

Set engine speed control dial on "LOW IDLE."

HAOB290L

Figure 69

If you touch the operation lever unintentionally, it may

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

set safety lever on "LOCK" position.

Unlock

lock

FG001091

Figure 70

Operation

OP001004

3-30

TOWING PROCEDURE

Cloth

WARNING

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

and cause a serious accident.

Towing Wire

Always wear gloves when handling a chain or wire rope.

When towing excavator use a wire rope or chain capable of

handling the load.

Attach chain or wire rope to track frame as shown in Figure

Insert protective material such as thick cloths between

track frame and wire rope to prevent the wire rope from

being damage.

Towing Wire

FG014871

IMPORTANT

Figure 71

Use shackle hook on track frame to only haul objects that

weigh less than 5 metric tons (5.51 U.S. Tons). Never use it

to haul objects over 5 metric tons (5.51 U.S. Tons).

Operation

OP001004

3-31

HYDRAULIC BREAKER

IMPORTANT

If a hydraulic breaker and piping is installed without

DOOSAN's authorization, it may create a serious

malfunction which will not be covered under the excavator

warranty.

Selection of Hydraulic Breaker

If a hydraulic breaker is installed, consider equipment's stability

and suitability for such modification. Also, consider hydraulic oil

pressure and quantity. When selecting a hydraulic breaker

consult with a DOOSAN distributor or sales agency.

Hydraulic Hoses and Tubing for Breaker

When installing hydraulic breaker, assemble according to

drawings provided with kit.

If breaker is taken off excavator, be sure to plug and cap all

hoses and tubing to prevent contamination from entering

hydraulic system.

Plug and cap all connectors and fittings on breaker to

prevent contamination.

Check all hydraulic connections for signs of leaks or loose

components before starting operation.

Operation

OP001004

3-32

Hydraulic Breaker Operation

NOTE: Hydraulic pressure and flow settings may need to be

changed. Refer to the Maintenance Section of this

manual for further information.

Make sure to read and understand the breaker user's

manual.

Inspect all mechanical and hydraulic connections.

Do not use the breaker as a hammer. See Figure 72.

Do not drop breaker from extreme heights.

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

breaker from extreme heights or damage to upper

structure may result.

FG000188

Figure 72

Do not operate the breaker with the boom or arm cylinders

fully extended (bottomed out). See Figure 73.

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

cylinder and cylinder head. This will help prevent damage

to cylinders during breaker operation.

FG000191

Figure 73

Do not use the breaker if the hydraulic hoses vibrate

excessively. See Figure 74. Check the breaker's hydraulic

accumulator (1) for damage and repair as required. If

excavator is operated under this condition, structural and

hydraulic components can be damaged.

FG000215

Figure 74

Operation

OP001004

3-33

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

equipped for underwater operation. The breaker seal can

be damaged and allow rust, foreign material or water to

enter the hydraulic system and cause damage. Only insert

the breaker tool into water. See Figure 75.

HAOB970L

Figure 75

Do not any lifting or towing with a breaker. See Figure 76.

FG000207

Figure 76

Operate the breaker only to the front and rear of the

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

excavator. Do not swing the breaker from side to side

when operating it. See Figure 77.

WARNING

Operating a breaker with the upper body turned 90° to

the tracks can result in tipping over the machine or

reduction in service life.

HAOB990L

Figure 77

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

traveling or parking the excavator. See Figure 78.

FG000216

Figure 78

Operation

OP001004

3-34

To activate breaker

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

Press lower button on top of right-hand work lever

(joystick) to activate hydraulic breaker.

Release lower button on top of right-hand work lever

(joystick) to deactivate hydraulic breaker.

FG000117

Figure 79 RIGHT-HAND WORK LEVER

(JOYSTICK)

Relief Valve Adjustment

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

350.0 kg/cm²

(5,000 psi) under the condition of

disconnecting hose to hydraulic breaker.

Adjust pump pressure using activating the breaker, and

watching the pressure displayed on the instrument panel.

Press the display selector button to show digital pressure

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

Adjust the relief valve pressure by turning the adjustment

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

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

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

valve for the breaker relief valve.)

FG000777

Figure 80

WARNING

If the relief valve pressure is adjusted while the

hydraulic breaker is connected, there is possibility

that a high-pressure spike or setting could break a

hose or pipe. Personal injury or death could result

from a hydraulic hose or pipe failure.

Operation

OP001004

3-35

Hydraulic Oil and Filter Service Intervals

When using a hydraulic breaker, the viscosity breakdown and

contamination of hydraulic oil is faster because the work

condition is more severe than during normal digging work. To

prevent the hydraulic components

(especially pump) from

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

hydraulic oil return filter using the following schedule.

Attachment

Operation Rate

Hydraulic Oil

Filter

250 Hours (First Replacement)

Bucket Work

100%

2,000 Hours

1,000 Hours (After First Replacement)

Hydraulic Breaker

100%

500 Hours

100 Hours

Work

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

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

100

105

116

551

106

144

614

FILTER

692

112

171

(First Replacement)

119

214

782

128

275

893

HYDRAULIC OIL

137

335

1028

FILTER

156

412

(After First Replacement)

1196

175

500

1400

206

635

1658

500

1000

1500

2000

MACHINE OPERATING HOURS

FG000767

Figure 81

NOTE: The replacement intervals of hydraulic oil and filter

depend upon the amount of time the hydraulic

breaker is being used. These intervals should be

followed as opposed to regularly scheduled

maintenance.

Operation

OP001004

3-36

ADJUSTING THE PUMP FLOW

NOTE: For further information, see

“Flow Control” on

page 2-44.

On the instrument panel, press the flow control button

, the flow control screen (Figure 82) will be displayed.

Use "UP" (

) or "DOWN" (

) buttons to adjust flow rate.

Press "SELECT" (

) button, to return to normal display

screen and save the flow rate setting.

02/05 [MO] 11:30

FLOW CONTROL

: APPLY

ESC: CANCEL

E/G SPEED 1700 RPM

FG001090

Figure 82

Setting

Flow Rate (l/min)

110

130

150

170

190

210

230

244

Operation

OP001004

3-37

Shear Pedal Valve (Optional)

Activating Shear with Pedal Valve

Select "SHEAR" with selector switch on right panel.

Make sure that stopper (Figure 85) is in "SHEAR" position.

NOTE: When stopper is in "SHEAR" position, pedal

valve can be moved/rocked in both directions.

Two-way operation is possible by rocking pedal back and

forth between positions (1 and 2, Figure 83). When pedal is

in its center (at rest) position, valve is in "NEUTRAL" and

hydraulic oil flow is stopped.

FG000402

Before operating attachment, be sure to check function

Figure 83

controlled by direction of pedal movement.

Activating Breaker with Pedal Valve

Select "BREAKER" with selector switch on right panel.

Make sure that stopper

(Figure

85) is in "BREAKER"

position.

NOTE: When stopper is in "BREAKER" position, pedal

valve can be only moved in one direction.

With the stopper in "BREAKER" position, pedal can only

be pressed in direction (1, Figure 83). When pedal is in its

center

(at rest) position, valve is in "NEUTRAL" and

FG000403

hydraulic oil flow is stopped.

Figure 84

Stopper Positions

The stopper has three positions;

Shear

Breaker

Locked

Rotate knob (3, Figure 84) clockwise in direction of arrow.

The stopper (4) then engages or disengages the pedal

Breaker

bracket

(5). The pedal can then function according to

displayed symbol shown by knob rotation.

Lock

Shear

FG014607

CAUTION

Figure 85

When only operating breaker or shear using joystick

button(s), and it is not being controlled by pedal, make

sure stopper is in "LOCKED" position to prevent pedal

from being activated.

Operation

OP001004

3-38

Rotating Pedal Valve (Optional)

Attachment Rotating by Using the Pedal Valve

Pressing end (1, Figure 86) is used to turn clockwise.

Pressing end

(2, Figure

86) is used to turn

counterclockwise.

NOTE: Before activating the pedal, be sure to check

the function of the attachment.

FG000405

Figure 86

Locking the Pedal

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

the prop rod (3) locking device.

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

positioned into pedal hole.

FG000406

Figure 87

A. Location for "UNLOCKING."

B, Location for "LOCKING."

FG000407

Figure 88

Attachment Rotation Using the Left-hand Work Lever

(Joystick)

For a machine equipped with an attachment that rotates,

rotation is activated while one of the control buttons is being

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

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

left and right ones are for controlling rotation.

NOTE: The middle button is for the horn.

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

FG000035

for clockwise rotation.

Figure 89 LEFT-HAND WORK LEVER

(JOYSTICK)

Operation

OP001004

3-39

OPERATING TECHNIQUES

Lifting

IMPORTANT

There may be local or government regulations, about the

use of excavators for the lifting of heavy loads. Always

contact your local and government agencies in regards to

these regulations.

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

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

will vary.

Short slings will prevent excessive load swing.

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

Always try to maintain the lifting eye (Figure 90) straight below

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

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

by the bucket cylinder, link, and link pins.

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

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

loose.

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

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

machine as possible.

HAAD3830

Lift capacity decreases as the distance from the machine swing

Figure 90

center line is increased.

Lifting Unknown Weight

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

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

FRONT LIFT

does not exceed the machine LOAD RATING CHART at the

ZONE

radius at which it is to be lifted.

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

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

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

SIDE LIFT

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

ZONE

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

become more stable. DO NOT INCREASE SWING RADIUS

AFTER THE LOAD IS LIFTED.

REAR LIFT

ZONE

DANGER

HAAD3842

If a load is picked up from the front zone and swung into the

Figure 91

side zone, a tip-over could result causing a deadly or fatal

injury.

Operation

OP001004

3-40

Lifting Known Weight

The load chart is the governing factor when lifting known

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

a precaution against tip-over. Whenever possible, lift and swing

payloads between the front idler area.

Pick and Carry

The machine has the ability to pick and carry payloads without

added labor. We recommend when traveling with a suspended

payload, you evaluate the prevailing conditions and determine

the safety precautions required in each case. The following

factors must be considered before attempting to pick and carry a

load.

Align the boom with the forward direction of machine travel.

Maintain this boom position when turning the machine. Turn only

when necessary, at the slowest speed, and at a wide turning

radius.

Use the shortest lifting radius distance possible.

Keep the load as close to the ground as conditions will

permit.

Provide tag lines to prevent load from pendulating.

Pendulating can cause a change in radius. A change in

radius could exceed the load chart rating or cause a

tip-over condition.

Govern travel speed to suit conditions.

Avoid sudden starts and stops.

Operation

OP001004

3-41

OPERATION UNDER UNUSUAL

CONDITIONS

NOTE: See

“Maintenance in Special Conditions” on

page 4-87 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.

A. 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.

B. Operate hydraulic units with care until they have

reached a temperature to enable them to operate

normally.

C. 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.

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

OP001004

3-42

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.

A. 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.

B. 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.

A. Cover inactive machine with tarpaulin if no suitable

shelter is available. Protect engine compartment,

transmission and hydraulics from entrance of dust.

B. 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.

C. 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

OP001004

3-43

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.

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

OP001004

3-44

OP001005

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 2-39.

02/05 [MO] 11:30

E/G SPEED

1700

RPM

POWER

AUTO

ESC

FG015471

Figure 2

Inspection, Maintenance and Adjustment

OP001005

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

file, incase the machine is stolen.

FG001447

Figure 3

Doosan Infracore Co., Ltd.

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

Incheon, Korea

FG012987

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.

FG000418

Figure 5

Inspection, Maintenance and Adjustment

OP001005

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.

Inspection, Maintenance and Adjustment

OP001005

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.

FG000111

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

OP001005

4-4

TABLE OF RECOMMENDED

LUBRICANTS

IMPORTANT

It is highly recommend to use the Doosan Genuine

Products, or products which meet the specification below.

Using other products may damage the equipment.

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

SAE 90 and API GL5

Drive 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

Inspection, Maintenance and Adjustment

OP001005

4-6

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. Note that the mixing ratio is for reference purpose

only, and is not an absolute standard.

API: American Petroleum Institute.

ACEA: Association des Constructeurs Europens d’Automobiles.

ASTM: American Society of Testing and Material.

ISO: International Standardization Organization.

NLGI: National Lubricating Grease Institute.

SAE: Society of Automotive Engineers.

CAUTION

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.

IMPORTANT

Fluctuating daily or weekly extremes of temperature, or

operation in subzero freezing weather may make it

impractical to use straight weight lubricants. Use good

judgement in selecting lubricant types that are appropriate

for climate conditions.

Inspection, Maintenance and Adjustment

OP001005

4-7

FLUID CAPACITIES

Component

Capacity

36 liters

Oil Pan with Filter

(9.5 U.S. gal.)

Engine

35 liters

Cooling System

(9.2 U.S. gal.)

500 liters

Fuel Tank

(132 U.S. gal.)

160 liters

Tank Level

(42 U.S. gal.)

Hydraulic Oil

280 liters

System

(74 U.S. gal.)

7 liters

Travel Reduction Device (Each)

(1.8 U.S. gal.)

6 liters

Swing Device

(1.6 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

Hydraulic Oil Tank Breather

Gear Oil (Swing Device, Travel Device)

Coolant

Engine Oil

Air Cleaner Element

Engine Oil Filter

Fuel Filter

Hydraulic Oil

Air Conditioner Filter

Hydraulic Oil Return Filter

Drain Water

Inspection, Maintenance and Adjustment

OP001005

4-8

SERVICE DATA

Service Interval

No.

Items to Check

Service

Qty.

250

500

1000

2000

Arm, Bucket Joint Pin

Grease

F100

W10

Boom, Arm Joint Pin

Grease

F100

W10

Swing Bearing

Grease

W10

Swing Gear

Grease

Swing Reduction Gear

Grease

W10

Gear Oil

Swing Device

6 L

(80W90)

Track Spring

Grease

W10

Travel Reduction

Gear Oil

2X7 L

F, V

Device

(80W90)

Engine Oil

31.5 L

(10W40)

Hydraulic Oil Tank

Hydraulic Oil

280 L

Fuel Tank

Diesel

500 L

Fuel Prefilter

Cartridge

Coolant

Radiator

35 L

(Antifreeze)

Hydraulic Oil Return

Element

Filter

Pilot Filter

Element

Hydraulic Oil Suction

Strainer

Engine Oil Filter

Cartridge

Fuel Filter

Cartridge

Air Cleaner (Outer)

Element

Air Cleaner (Inner)

Element

Air Conditioner Filter

Cartridge

(Outer)

Air Conditioner Filter

Cartridge

(Inner)

Air Breather Filter

Cartridge

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.

EG: Ethylene Glycol - Doosan Genuine Antifreeze Solution (Drain and replace using this interval.) See

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

PG: Propylene Glycol - Doosan Genuine Antifreeze Solution (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.

Inspection, Maintenance and Adjustment

OP001005

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

4-17

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 Engine Fan Blade

4-21

Check Air Intake System

4-22

Inspect Seat Belt for Proper Operation

4-22

Inspect the Structure for Cracks and Faulty Welds

4-22

Check the Operation of All Switches

4-22

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

4-23

Lights

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

4-23

Operating Temperature. Listen for Any Abnormal Sounds

Check Operation of All Controls

4-23

50 Hour / Weekly Service

Perform All Daily Service Checks

4-24

Grease Arm and Bucket Joint Pins

4-24

Grease Swing Bearing

4-25

Drain Water and Sediment from Fuel Tank

4-26

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

4-26

Change Engine Oil and Filter (After First 50 Hours)

4-26

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

4-26

(Links, Shoes, Rollers, Idlers)

250 Hour / Monthly Service

Perform All Daily and 50 Hour Service Checks

4-27

Grease Boom and Arm Joint Pins

4-27

Check Engine Fan Belt Tension

4-29

Check Engine Fan Belt Wear

4-30

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

4-31

Change Breaker Filter Element (Optional)

4-32

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

4-32

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

4-32

Change Engine Oil and Filter

4-33

Replace Hydraulic Oil Return Filter (After First 250 Hours)

4-34

Inspection, Maintenance and Adjustment

OP001005

4-12

SERVICE ITEM

PAGE

Change Pilot Filter (After First 250 Hours)

4-34

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

Clean Air-Conditioning Outer Filter

4-36

Check and Clean Air-Conditioning Inner Filter

4-37

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

4-38

Clean Outer Filter of Air Cleaner

4-39

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

4-43

Grease Swing Reduction Device

4-43

Replace Hydraulic Oil Return Filter

4-44

Change Pilot Filter

4-45

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

4-46

Change Air Breather Filter

4-46

Change Air-Conditioning Outer Filter

4-47

Check Air Conditioner Refrigerant

4-48

Check and Adjust Engine **

4-48

2,000 Hour / Yearly Service

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

4-49

Change Swing Reduction Device Oil

4-49

Replace Outer and Inner Air Cleaner Elements

4-50

Change Radiator Coolant

4-51

Hydraulic Oil Exchange and Suction Strainer Cleaning

4-53

Check Alternator and Starter**

4-55

Check All Rubber Antivibration Shock Mounts

4-55

Perform and Record the Results of the Cycle Time Tests

4-55

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

4-55

Check, Adjust Valve Clearance **

4-55

Check Head Bolt Torques

4-55

4,000 Hour / Biennial Service

Major Parts - Periodic Replacement

4-56

12,000 Hour / 6 Year Service

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

4-57

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

Inspection, Maintenance and Adjustment

OP001005

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.

Let anybody never be in the blowing direction.

FG000500

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 4-24).

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.

FG000330

Shut down engine and wait for fifteen minutes. This will

Figure 13

allow all oil to drain back to oil pan.

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

clean cloth.

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

again.

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

marks on dipstick.

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

must be drained to return oil to proper level.

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

level is below the "LOW" mark.

FG000616

Figure 14

Inspection, Maintenance and Adjustment

OP001005

4-14

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. Lift the breather cap

slowly to allow the pressurized air to vent. After the

ARO1760L

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

Figure 15

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."

FG000012

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

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

A. Shut down engine.

B. The hydraulic tank is pressurized. Lift the breather

cap slowly to allow the pressurized air to vent.

C. Remove the upper cover of the hydraulic tank and

add oil.

IMPORTANT

FG000127

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

Figure 18

can result in damage to equipment and oil leaking

from hydraulic tank due to expansion.

Inspection, Maintenance and Adjustment

OP001005

4-15

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

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

cool down.

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

bottom of the tank into a suitable container, using a

hose at the point (plug).

NOTE: Dispose of drained fluids according to local

regulations.

FG014339

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.

Inspection, Maintenance and Adjustment

OP001005

4-16

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 through fuel

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

Figure 20

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

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

equivalent.

Make sure that the fuel fill hose is grounded to the

excavator before fueling begins.

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

tank sight gauge (2, Figure 20).

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

(Optional)” on

page 4-78, 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.

Inspection, Maintenance and Adjustment

OP001005

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.

FG002080

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

OP001005

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

FG000133

level check.

Figure 24

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

dipstick with a cloth.

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

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, release

the drain plug (3, Figure 26). Drain the excessive oil into a

suitable container.

NOTE: Dispose of drained fluids according to local

regulations.

FG014340

Figure 26

Inspection, Maintenance and Adjustment

OP001005

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.

FG000151

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

FULL

Allow the engine to cool before releasing the radiator cap.

LOW

Make sure to loosen the cap slowly to release any

remaining pressure.

Radiator cleaning is performed while the engine is running.

FG000136

Take extreme caution when working on or near a running

Figure 28

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.

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 4-77)

Check to make sure that the coolant transfer line from the

coolant recovery tank to the radiator is free and clear of

obstructions, or not pinched.

Observe the level of coolant in the coolant recovery tank.

The normal cold engine fluid level should be between

"FULL" and "LOW" marks on tank.

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

tank.

Inspection, Maintenance and Adjustment

OP001005

4-20

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.

FG000295

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.

Inspect Engine 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.

NOTE: Manually rotate the crankshaft by using a wrench on

the accessory drive pulley nut.

Figure 31

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

cracks, loose bolts, bent or loose blades, 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.

Inspection, Maintenance and Adjustment

OP001005

4-21

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" position, and shut

HAOA050L

down engine.

Figure 32

Check the engine intake hose, and hose bands for damage

and tightness.

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

contact your nearest DOOSAN dealer.

IMPORTANT

Severe engine damage will result from running with

unfiltered air.

Do not operate engine if any leaks or defects are found

FG000421

on air intake system.

Figure 33

Inspect Seat Belt for Proper Operation

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.

Inspection, Maintenance and Adjustment

OP001005

4-22

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

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

OP001005

4-23

50 HOUR / WEEKLY SERVICE

Perform All Daily Service Checks

Grease Arm and Bucket Joint Pins

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

thereafter.

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

front attachment should be greased on a 10 hour /

daily basis.

•

Position machine as shown below and lower the front

attachment to the ground and shut down engine

•

Press the grease fitting and inject grease with the

grease gun on the marked point

•

After injection, clean off the old grease that has been

purged.

D B,E

FG001437

Figure 34

Reference

Description

Number

Arm Link Joint Pin (1 Point)

Bucket Link Joint Pin (1 Point)

Link Joint Pin (2 Points)

Bucket Cylinder Rod Pin (1 Point)

Arm Bucket Joint Pin (1 Point)

Inspection, Maintenance and Adjustment

OP001005

4-24

A. Arm link joint pin (1 point)

B. Link joint pin (2 points)

C. Arm bucket joint pin (1 point)

D. Bucket link joint pin (1 point)

FG001438

Figure 35

E. 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.

FG000143

Figure 37

Inspection, Maintenance and Adjustment

OP001005

4-25

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 4-29.

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 4-33.

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.

Inspection, Maintenance and Adjustment

OP001005

4-26

250 HOUR / MONTHLY SERVICE

Perform All Daily and 50 Hour Service

Checks

Grease Boom and Arm Joint 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

FG001440

Figure 39

Reference

Description

Number

Boom Cylinder Head Pin (2 Points)

Boom Arm Joint Pin (2 Points)

Boom Foot Pin (2 Points)

Arm Cylinder Rod Pin (1 Point)

Boom Cylinder Rod Pin (2 Points)

Bucket Cylinder Head Pin (1 Point)

Arm Cylinder Head Pin (1 Point)

Inspection, Maintenance and Adjustment

OP001005

4-27

Doosan DX300LCA. Operation and Maintenance Manual (2010) - page 2